Plate and Frame Heat Exchanger

PLATE AND FRAME HEAT EXCHANGER
engineering-resource.com
PRESENTED BY
HAFEERA SHABBIR MUBASHRA LATIF PAKEEZA TARIQ MEER MAHPARA MUGHAL 06-CHEM-19 06-CHEM-23 06-CHEM-65 06-CHEM-69
OUTLINE
Introduction Construction Principle of Operation Applications Advantages Limitations of Operation Comparison of with STH Design steps with Solved example
Introduction
It is a type of compact heat exchanger A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer heat between two fluids
CONSTRUCTION
Based on their construction plate and frame heat exchangers are classified into (a) Gasketedplate (b) Welded-plate
GASKETED-PLATE HEAT EXCHANGER(GPHE)

Parallel corrugated plates clamped in a frame with each plate sealed by gaskets and with four corners ports, one pair for each of the two fluids. The fluids are at all times separated by 2 gaskets, each open to the atmosphere. Gasket failure cannot result in fluid intermixing but merely in leakage to atmosphere, hence a protective cover is there.
Construction of GPHE
Plates Gaskets Plate frame
PLATES
Plate thickness is 0.4 to 0.8 mm Channel lengths are 2-3 meters Plates are available in: Stainless Steel, Titanium, Titanium-Palladium, Nickel
PLATES
PATTERNS
1)Induce turbulence for high HT coefficient 2)Reinforcement and plate support points that maintains inter-plate separation.
TYPES OF PATTERNS
Mainly 2 types of patterns (corrugations) are used 1)Intermating or washboard corrugations 2)Chevron or herringbone corrugations
CHEVRON OR HERRINGBONE
Most common type Corrugations are pressed to same depth as plate spacing Operate at High pressure Corrugation depth 3mm to 5mm Velocity 0.1 to 1 m/s
CHEVRON CORRUGATIONS
INTERMATING TROUGH PATTERNS

Pressed deeper than spacing Fewer connection points Operate at Lower pressure Max channel gap 3mm to 5mm Min channel gap 1.5 mm to 3 mm Velocity range in turbulent region is 0.2 to 3 m/s
DIMPLE CORRUGATIONS
GASKETS
They limit the maximum operating temperature for a plate heat exchanger. Material selection depends upon 1)Chemical resistance 2)Temperature resistance 3)Sealing properties 4)Shape over an acceptable period of time
GASKET MATERIALS
Typical gasket materials are Natural rubber styrene Resin cured butyl Compressed asbestos fiber gaskets
FRAMES
Materials 1)Carbon steel with a synthetic resin finish 2)stainless steel
WELDED PLATE HEAT EXCHAGERS(WPHE)

Developed to overcome the limitations of the gasket in GPHE Inabilty of heat transfer area inspection and mechanical cleaning of that surface
OPERATION
Channels are formed between the plates and corner ports are arranged so that the two media flow through alternate channels. The heat is transferred through the thin plate between the channels, and complete counter current flow is created for highest possible efficiency. No intermixing of the media or leakage to the surroundings will take place as gaskets around the edges of the plates seal the unit.
APPLICATIONS
3 major applications (1)liquid-liquid services (2)condensing and evaporative (3)Central cooling
LIQUID-LIQUID SERVICES
It is well-suited to liquid/liquid duties in turbulent flow, i.e. a fluid sufficiently viscous to produce laminar flow in a smooth surface heat exchanger may well be in turbulent flow in PHE. It has major applications in the food industry.
CONDENSATION AND VAPORIZATION

Condensation of vapor (including steam) at moderate pressure, say 6 to 60 Psi, is also economically handled by PHEs, but duties involving large volumes of very low pressure gas or vapor are better suited to other forms of heat exchangers
CENTRAL COOLING
It is the cooling of a closed circuit of fresh non-corrosive and non-fouling water for use inside a plant, by means of brackish water. Central coolers are made of titanium, to withstand the brackish water
ADVANTAGES
Compactness Flexibility Very high heat transfer coefficients on both sides of the exchanger Close approach temperatures and fully counter-current flow Ease of maintenance. Heat transfer area can be added or subtracted with out complete dismantling the equipment
CONTD..
Ease of inspection on both sides Ease of cleaning Savings in required flow area Low hold-up volume Low cost No Local over heating and possibility of stagnant zones is also reduced Fouling tendency is less
LIMITATIONS
Low Pressure
upto 300 psi
Low temperature
upto 300 F
Limited capacity Limited plate size

0.02 sq.m to 1.5 sq.m
Large difference b/w flow rates cant be handled High pressure drop Potential for leakage
COMPARISON BETWEEN PHE AND STHE

PHE Possible Multiple duty Hold up volume Low On each plate Gaskets
FEATURES
STHE Impossible High On flanged joints impossible
modifications
Easy by adding or removing plates
FEATURES
Repair
PHE
STHE
Detection of leakage Access for inspection Time reqd. for opening Fouling
Easy to replace Requires tube plates and plugging gaskets Easy to detect Difficult to detect Limited On each side of plate 60 to 90 min 15 min 15 to 20 % of STHE
FEATURES
Sensitivity to vibrations
PHE Not sensitive
STHE sensitive
DESIGN STEPS WITH SOLVED EXAMPLE

STATEMENT OF PROBLEM
A plate heat exchanger was use to preheat 4 kg/s of dowtherm from 10 to 70C with a hot water condensate that was cooled from 95 to 60C.Determine the number of plates required for a single-pass counter flow plate and frame exchanger. Assume that each mild stainlesssteel plate [kw=45j/s.m.K]has a length of 1.0m and a width of 0.25m with a spacing between the plates of 0.005m.Also,estimate the pressure drop of the hot water stream as it flows through the exchanger.
DATA REQUIRED
The performance characteristics for the chevron configuration selected for the plates are shown . For Re > 100,Nu and f can be represented by the following relationships: Nu = 0.4 Re0.64Pr0.4 f = 2.78Re-0.18 :
ASSUMPTIONS
The plate heat exchanger operates under steady state conditions. No phase change occurs: both fluids are single phase and are unmixed. Heat losses are negligible; the exchanger shell is adiabatic. The temperature in the fluid streams is uniform over the flow cross section. There is no thermal energy source or sink in the heat exchanger. The fluids have constant specific heats. The fouling resistance is negligible.
Properties of each fluid at the mean temperature in the exchanger are

property Heat capacity CP Thermal conductivity k Viscosity Density Dowtherm at 40C 1.622*103 J/kg.K 0.138 J/.m.K 2.70*10-3Pa.s 1.044*102kg/m3 Water at 77C 4.198*103J/kg.K 0.668J/s.m.K 3.72*10-4Pa.s 9.74*102kg/m3
SOLUTION
APPROACH TO THE PROBLEM: To avoid an iterative calculation because of the interdependency between the heat transfer area and the total flow area, use the NTU approach to determine the NTUmin required, noting that NTUmin=UA/(mCp)min.the area of the plate and frame exchanger can be calculated once the overall heat transfer coefficient has been evaluated.
CALCULATION OF HT AREA
For a single pass configuration with Np plates and NP+1 flow passages ,solution of the problem can be simplified mathematically by assuming n flow passages and n-1 plates ,since flow velocities involve flow passages and not plates. with this modification, the heat transfer surface area of the exchanger in terms of n is A=(n-1)LW=(n-1)(1)(0.25)=0.25(n-1)m2
CALCULATION OF FLOW AREA

The flow area for each stream with n/2flow passages is given by: S=n/2(W)(b) =n/2(0.25)(0.005) =(6.25*10-4)n.
CALCULATION OF HEAT DUTY AND FLOW RATES

TOTAL RATE OF HEAT TRANSFER: FOR DOWTHERM q= (mCpT)c =4(1.622*103)(70-10) =3.89*105W THE MASS FLOW RATE OF WATER : mh=q/(CPT)h =3.89*105/(4.198*103)(95-60) =2.65 Kg/s VELOCITY OF WATER: Vh =mh /hS =2.65/(9.74*102)(6.25*10-4)n =(4.35/n)m/s
EQUIVALENT DIAMETER: De=2b =0.01m
CALCULATION OF HOT SIDE HT COEFFICIENT

REYNOLD NUMBER: Reh=DeVhh /h =0.01(4.35/n)(9.74*102)/(3.72*10-4) =1.139*105/n This indicates that Reynold number is greater than 100 and correlation for Nu can be used. Pr NUMBER: Prh = Cp/k = (4.198*103)(3.72*10-4)/0.668 =2.34 hh = (0.4)(kh/De)Re0.64Pr0.4 =[0.668/0.01][1.139*105/n]0.64(2.34)0.4 =6.467*104/n0.64W/m2.K
CALCULATION OF COLD SIDE HT COEFFICIENT

The same calculations are repeated for cold stream. V=mc/c S =4.0/(1.044*103)(6.25*10-4)n =6.13/n Re=DeVcc/c =0.01(6.13/n)(1.044*103)/(2.70*10-3) =2.37*104/n Prc=(1.622*103)(2.70*10-3)/(0.138) =31.73 This also indicates that Re>100 hc=(0.4)(kc/De)Re0.64Pr0.4 =(0.4)(0.138/0.01)(237*104/n)0.64 (31.73)0.4 =1.388*104 /n0.64 W/m2.K
CALCULATION OF OVERALL HT COEFFICIENT

The overall heat transfer coefficient can now be determined in terms of n. Since the surface areas on either side of the plate are the same, no correction for area is required. Assume a thickness of the plate xw of 0.0032m 1/U=1/hh+xw/kw+1/hc =n0.64/(6.467*104)+(0.0032)/(45)+n0.64/(1.388*104) =8.751*10-5n0.647+7.11*10-5 m. K/W
USING THE NTU METHOD

A NTUmin for cold stream with a minimum mcp is defined NTUmin=UA/(Mcp)min =Tc,outTc,in/ fT,log mean LOG MEAN TEMPERATURE DIFF: T,log mean: =(Th,in-Tc,out)-(Th,outTc,in)/ln[(Th,inTc,out)/Th,out-Tc,in)] =(95-70)-(60-10)/ln[(95-70)/(60-10)] =36.067 K. For a single pass counter flow plate and frame heat exchanger ,F=1. engineering-resource.com
NTU =70-10/36.067 =1.664 To satisfy the other NTU definition of UA/ (Mc) in terms of results in the relation 1 0.25(n-1) 1.664 = ( )( )
8.751*105n0.64+7.11*10-5 4.0(1.622*103)
ITERATIVE METHOD
This equation can be solved with itreration to indicate that n=51.Thus 50 plates are required to meet to the heat transfer needs to preheat 4kg/s of dowtherm from 10 to 70C.
HYDRAULIC DESIGN
PRESSURE DROP IN WATER STREAM: Vh =4.35/51=0.0853m/s Reh=1.139*105/51=2233 Since Re>100 f =2.78Re-0.18 =2.78(2233)-0.18 =0.694
CONTD..
Neglecting friction due to entrance and exit losses as well as temperature effects on the viscosity between the wall and the bulk fluids. So pressure drop is calculated from the following equation: P=4f(L/De)h Vh2 /2 =4(0.694)(1/0.01) (9.74*102)(0.0853)2/2 =984N/m2 =984Pa
CONCLUSION
Since the entrance and exit losses will be small, the pressure drop per plate is small, and a new configuration with modified dimensions should be considered.

Plate and Frame Heat Exchanger

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Plate and Frame Heat Exchanger

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PLATE AND FRAME HEAT EXCHANGER

GASKETED-PLATE HEAT EXCHANGER(GPHE)

INTERMATING TROUGH PATTERNS

WELDED PLATE HEAT EXCHAGERS(WPHE)

CONDENSATION AND VAPORIZATION

Limited capacity Limited plate size

COMPARISON BETWEEN PHE AND STHE

STHE Impossible High On flanged joints impossible

Easy by adding or removing plates

PHE Not sensitive

DESIGN STEPS WITH SOLVED EXAMPLE

Properties of each fluid at the mean temperature in the exchanger are

CALCULATION OF FLOW AREA

CALCULATION OF HEAT DUTY AND FLOW RATES

EQUIVALENT DIAMETER: De=2b =0.01m

CALCULATION OF HOT SIDE HT COEFFICIENT

CALCULATION OF COLD SIDE HT COEFFICIENT

CALCULATION OF OVERALL HT COEFFICIENT

USING THE NTU METHOD

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