Heat Transfer

Equipment
Heat Exchangers
Boilers
Process Fired Heaters
Evaporators, condensers,
crystallizers

Thermal unit operations

Heat Exchangers
A heat exchanger is a device that is used to transfer

thermal energy (enthalpy) between two or more

fluids, between a solid surface and a fluid, or
between solid particulates and a fluid, at different
temperatures and in thermal contact.
CLASSIFICATION ACCORDING TO CONSTRUCTION FEATURES
Tubular heat exchanger
shell and tube heat exchanger
double pipe heat exchanger
Spiral tube heat exchanger
Plate heat exchanger
Gasketed plate heat exchanger
Spiral plate and lamella heat exchanger
Extended surface heat exchanger
Plate fin and tubular fin heat exchanger.

Shell and Tube Heat Exchanger

This exchanger, generally built of a bundle

of round tubes mounted in a cylindrical
shell with the tube axis parallel to that of
the shell. One fluid flows inside the tubes,
the other flows across and along the tubes.
The major components of this exchanger
are tubes (or tube bundle), shell, frontend head, rear-end head, baffles, and tube
sheets, and are described briefly later in
this subsection

Parts of Shell and tube HXE

Shell and Tube Heat Exchanger

Details

Shellside Flow
In

Tubeside Flow
Out
Shell

Tube Bundle

Shellside Flow
Out
Tubeside Flow
In

Shell and Tube Heat Exchanger

Shell Outlet
Channel Inlet

Channel
Outlet

Shell Outlet
SINGLE SEGMENTAL TRANVERSE BAFFLES

Shell and Tube Heat Exchanger

Shell Inlet

Shell Outlet

Double Segmental Transverse Baffles

Shell and Tube Heat Exchanger

Doughnut and Disc Type Baffles

Double Pipe Heat Exchanger

Shell Cover Gasket

Vent

External Fin Pipe

Shell

Shell
Cover

Return Bend
(welded)
Drain

Sliding
Support

Twin Flange

Fixed
Support
Shell End Piece

This exchanger usually consists of two con- centric pipes with

the inner pipe plain or finned One fluid flows in the inner pipe
and the other fluid flows in the annulus between pipes in a
Counter flow direction for the ideal highest performance for
the given surface area. Double-pipe exchangers are generally used for
small-capacity applications where the total heat transfer surface area required
is 50m2(500ft2) or less because it is expensive on a cost per unit surface area
basis.

Spiral Tube Heat Exchangers.

These consist of one or more spirally

wound
coils fitted in a shell.
Heat transfer rate associated with a
spiral tube is higher than that for a
straight tube.
In addition, a considerable amount of
surface can be accommodated in a
given space by spiraling.
Thermal expansion is no problem, but
cleaning is almost impossible
Spiral tube heat exchanger consists of number of
spirals attached to the header. One fluid
flows from periphery to center of the casing
while the other is moving from center to
periphery

Plate and Frame Heat Exchanger

Gasketed Plate Heat Exchangers
8

5
3

10
6

Plate-type heat exchangers are usually

built of thin plates (all prime surface). The
plates are either smooth or have some
form of corrugation, and they are either flat
or wound in an exchanger. Generally, these
exchangers cannot accommodate very
high pressures temperatures, or pressure
and temperature differences.
Gasketed Plate Heat Exchangers

Spiral Plate Heat Exchangers

lamella Heat Exchangers

7
1

Spiral Plate Heat Exchangers

Spiral plate heat exchangers are built by

rolling two parallel long sheets around a
central bar to make a spiral shape. The
free final edges of channels then will weld
together to seal the end of channels.
The distance between metal sheets is kept
using studs that are welded to the sheets.
The length of studs can vary from 5 to 25
mm. hence, with respect to the mass flow
rate, different distances between the
sheets can be chosen during the design
period.
In each channel, hot or cold fluid path,
secondary flows are developed that lead to
better mixing and therefore heat transfer
rate is increased and fouling is decreased

lamella Heat Exchangers

A lamella heat exchanger consists of an
outer tubular shell surrounding an
inside bundle of heat transfer elements.
These elements, referred to as lamellas
are flat tubes (pairs of thin dimpled
plates, edge welded, resulting in highaspect-ratio rectangular channels),.
The inside opening of the lamella
ranges from 3 to 10 mm (0.1 to 0.4 in.)
and the wall thickness from 1.5 to
2mm(0.06 to 0.08in.).
This exchanger is a modified floatinghead shell-and-tube exchanger.
One fluid (tube fluid) flows inside the
lamellas and the other fluid (shell fluid)
flows longitudinally in the spaces
between them, with no baffles on the
shell side.
The exchanger thus has a single pass,
and the flow arrangement is generally
counter flow

Extended surface heat exchanger

Tube-Fin Heat Exchangers

Heat transfer between the two fluids takes

place by conduction through the tube wall.
However, in a heat pipe exchanger (a
specialized type of tube-fin exchanger),
tubes with both ends closed act as a
separating wall, and heat transfer between
the two fluids takes place through this
separating wall (heat pipe) by conduction,
and evaporation and condensation of the
heat pipe fluid. Let us first describe
conventional tube-fin exchangers and then
heat pipe exchangers

In a tube-fin exchanger, round and

rectangular tubes are most common,
although elliptical tubes are also used. Fins
are generally used on the outside, but they
may be used on the inside of the tubes in
some applications.

Plate-Fin Heat Exchangers

This type of exchanger has corrugated fins
(most commonly having triangular and
rectangular cross sections) or spacers
sandwiched between parallel plates .
Sometimes fins are incorporated in a flat
tube with rounded corners, thus eliminating
the need for side bars. If liquid or phasechange fluid flows on the other side, the
parting sheet is usually replaced by a flat
tube with or without inserts or webs
The plates or flat tubes separate the two fluid
streams, and the fins form the individual flow
passages. Alternate fluid passages are
connected in parallel by suitable headers to form
the two or more fluid sides of the
exchanger.

Limitations of Shell and

tube HX

Tube Failure Shell and Tube Heat

Exchanger

Fouling in Shell and Tube Heat

Exchanger

Boilers

Fired Tube Boiler

Industrial Boiler

Packaged Boiler

Steam
Drum

Burners

Mud
Drum

To Exhaust Stack

Heat Recovery Steam

Generator

10

2
3
4

1.

Gas Turbine

6.

Superheater

2.

Dump Stack

7.

Boiler Section

3.

Bypass Damper

8.

Downcomers

4.

Boiler Shut-Off Damper

9.

Economizer

5.

Supplemental Burner

10.

Steam Drum

With permission from Henry Vogt Machine Company

Utility Boiler
Steam Drum

Boiler
Superheater
Mud Drum
Economizer

Air
Air Heater
Burners

Steam Coil
Air Heater
To Stack
Gas Outlet

Gas

Induced
Draft Fan
With Permission from Babcock and Wilcox

Air
Forced
Draft Fan

Process Fired Heaters

Different Process Heater Designs

C. Cabin Furnace with Horizontal

Tube Coil

A. Box Furnace with Arbor Coil

B. Vertical Cylindrical Furnace with
Helical Coil

D. Box Furnace with Vertical Tube Coil

E. Vertical Cylindrical Furnace with

Vertical Coil

F. Box Furnace with Horizontal

Tube Coil

Convection
Coil
Radiant
Coil

Burners

Burners

Cabin with
Convection
Section

Cabin with
Dividing
Bridgewall

Process Fired Heater

Serrated
Fins

Studs

Solid Fins

Extended Surface Area

18 psig

D-124

52

D-103

Offgas
To Refinery
Collection
System
To Whole
Naphtha
Stabilizer

41
Steam

No. 1 S/C

32
C-100
Atmospheric Column

D-102
Flash Drum

Steam

24

F-100 A/B
Crude Atmospheric
Preheat
Furnaces Steam
Exchangers

Desalter
Water

Steam

No. 3 S/C

Steam

No. 4 S/C

17
10
6

Crude

No. 2 S/C

5
1

To Vacuum
Overheat
System

C-200
Vacuum
Column

26 psig

No. 6 S/C
12
8
6

No. 7 S/C
No. 8 S/C

F-200 A/B
Vacuum Furnaces
Crude
Desalter
Preheat
Exchangers Water
Injection
Steam to
Radiant Coils

5
Steam

2 psia

1
Vacuum
Residuum

Crude Unit - Ras Tanura Refinery

Thanks