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Course objectives
What are exchangers for?
Exchanger types
How are they specified?
The design task
© Hyprotech 2002
Objectives
By the end of the course you will
• be familiar with the main exchanger types
• know which is likely to be the best type for a given
application
• understand what are the key factors in exchanger
design
• be able to estimate the size and cost of key exchanger
types
• have the background necessary to start using
commercial exchanger design software
• be an informed purchaser of heat exchangers
© Hyprotech 2002
Lecture series
• Introduction to heat
exchangers Q = U A T
• Selection of the best
type for a given
application
• Selection of right
shell and tube
• Design of shell and
tube
© Hyprotech 2002
Contents
• Why we need heat exchangers
• The basics of their design
• Some general features of exchangers
• Different types of exchanger
• The design process
© Hyprotech 2002
Example of an exchanger
© Hyprotech 2002
Feed-effluent exchanger
Feed-effluent
Exothermic reaction
exchanger
Heat recovery
© Hyprotech 2002
Distillation
Reflux condenser
Top product
Feed Column
Reboiler
Bottom product
© Hyprotech 2002
Naphtha
Typical crude oil distillation and gases
Top pump
Kerosene
around
E2
Distillation tower
Desalter
Light
Top pump gas oil
around Heavy gas oil Bottom
pump
around
E2 E3 Heavy
E5 gas oil
Light gas oil
Kerosene
E4
E1 Bottom pump
Furnace
around
Reduced
E5 E6 crude
Steam turbine
Boiler Condenser
Feedwater
heater
© Hyprotech 2002
Q = U A T
yw
Thot
Tcold
© Hyprotech 2002
Thermal integration
or process integration
© Hyprotech 2002
Local and mean values
• “Overall” means from the hot side to the
cold side including all resistances
• However it is still at a particular point in the
exchanger: i.e. it is local
• Hence you can have a local, overall
coefficient
LOCALLY q UT
© Hyprotech 2002
Definitions of mean values
From previous slides
Q T
U m AT
Tm
dQ
Q T A UdA
Comparing the two sides T T
1 1 dQ
Tm Q T Q T Um
1
UdA
AT AT
© Hyprotech 2002
Special case where Ts are linear with Q
• Eqn. integrates to
give log. mean
temperature
Temperature
difference - LMTD Ta
Ta Tb Q
Tm TLM Tb
ln( Ta / Tb )
© Hyprotech 2002
Multipass exchangers
T1
• For single-phase duties, T2
Temp.
theoretical correction t2
factors, FT, have been t1
derived
• FT values are less than 1 Q
Tm FT TLM
© Hyprotech 2002
Typical FT correction factor curves
For shell and tube with 2 or more tube-side passes
T1,in T1,out
T2,out T2,in
© Hyprotech 2002
Compactness
• Can be measured by the heat-transfer area
per unit volume or by channel size
• Conventional exchangers (shell and tube)
have channel size of 10 to 30 mm giving
about 100m2/m3
• Plate-type exchangers have typically 5mm
channel size with more than 200m2/m3
• More compact types available
© Hyprotech 2002
Compactness
Hydraulic diameter, mm
60 10 1 0.1
Human lungs
Special
Car radiator
Plate fin
Plate
Shell-&-tube
Recuperators Regenerators
Recuperative
Has separate flow paths for each
fluid which flow simultaneously
through the exchanger
Rotating wheel
transferring heat between the
streams
Regenerative
Has a single flow path which the hot
and cold fluids alternately pass
through.
© Hyprotech 2002
Double Pipe
Simplest type has one tube inside another - inner
tube may have longitudinal fins on the outside
© Hyprotech 2002
Shell and Tube
Typical shell and tube exchanger as used in the
process industry
© Hyprotech 2002
Shell-side flow
© Hyprotech 2002
Complete shell-and-tube
© Hyprotech 2002
Plate and frame
• Plates hung vertically and
clamped in a press or frame.
• Gaskets direct the streams
between alternate plates and
prevent external leakage
• Plates made of stainless steel or
higher quality material
• Plates corrugated to give points
of support and increase heat
transfer
© Hyprotech 2002
Plate types
Corrugations on plate
improve heart transfer
give rigidity
Many points of
contact and a
tortuous flow path
Chevron Washboard
© Hyprotech 2002
General view of
plate exchanger
“Plate exchanger”
normally refers to
a gasketted plate-
and-frame
exchanger
© Hyprotech 2002
Flow Arrangement within a PHE
Gaskets
arranged for
each stream to
flow between
alternate plates
Finned tubes
© Hyprotech 2002
ACHE bundle
© Hyprotech 2002
Plate-fin exchanger
© Hyprotech 2002
Typical plate-fin
© Hyprotech 2002
Spiral (plate)
© Hyprotech 2002
• Used for batch Agitated Vessel
heating or cooling
of fluids
• An agitator and
baffles promote
mixing
• A range of agitators
are used
• Often used for
batch chemical
reaction
© Hyprotech 2002
Proprietary types
• Types described so far are generic types
• These can be made by any company with
necessary skills (no real patent protection)
• There are now many special, proprietary
exchangers made by one company or a
small number of companies under licence
• One example is the “printed circuit
exchanger” by Heatric
© Hyprotech 2002
Printed circuit heat exchanger
• Plates are etched to
give flow channels
• Stacked to form
exchanger block
• Block diffusion welded
under high pressure
and temperature
• Bond formed is as
strong as the metal
itself
© Hyprotech 2002
Printed circuit exchanger
Waste Heat
Boilers Other Heat
Cooling Towers Recovery
5%
9% 10%
Air Coolers
10%
Other Proprietary
2%
Other Plate
4%
Other Tubular
5%
© Hyprotech 2002
Preliminary points on selection
• Tubes and cylinders can withstand higher
pressures than plates
• If exchangers can be built with a variety of
materials, then it is more likely that you can
find a metal which will cope with extreme
temperatures or corrosive fluids
• More specialist exchangers have fewer
suppliers, longer delivery times and must be
repaired by experts
• S&Ts cannot normally give high thermal
effectiveness,
© Hyprotech 2002
Design sequence
• Design the process flow flow-sheet
• Specify the heat exchanger requirements
• Select the best exchanger type for the job
• Thermal design of exchanger
• Mechanical design of exchanger
Looping back may be necessary at any
stage but can be difficult because of the
project timetable
© Hyprotech 2002
Who does what?
• Design the process flow flow- Processor/
sheet end user
• Specify the heat exchanger
requirements
• Select the best exchanger type Contractor
for the job
• Thermal design of exchanger
• Mechanical design of exchanger
Manufacturer
© Hyprotech 2002
Exchanger specification
• Heat load (duty) along with the terminal
temperatures of the streams
• Maximum pressure drop each streams
– liquids - 0.5 bar
– gases/vapours below 2bar - 10% of inlet pressure
• Design pressures and temperatures
• Size/weight constraints
• Standards to apply
– General standards like ISO, TEMA, ASME etc
– Companies own standards
• Other requirements
© Hyprotech 2002
The designer must supply an
exchanger which
• Meets the stated specification
• Has reasonable initial costs and operating
costs (most exchangers are bought on the
basis of the cheapest tender)
• Has a reasonable lifetime
– no damaging vibration
– no thermal fatigue
– no unexpected fouling or corrosion
© Hyprotech 2002