Module 3-2

Heat exchanger types & selection

(Reading in Ulrich: p187 p210)

Which heat exchanger to use?

Watch out for information in footnotes!

Preliminary design

(T + T1 ) 3t Watch out for typo in footnote c: t 2 t1 = 0.0009 U 2 1 2

Double pipe HEX

U-tube HEX

Which flow path? I.e. which stream is tube side flow, which is shell side flow?
5

Fixed tube sheet HEX

Expansion joints to allow for thermal expansion

(From Perrys Handbook: for explanation of numbers see there)
7

Kettle boiler HEX

Pool boiling: only driven by convection Vapour-liquid separation in shell space

Floating head HEX

Different versions available (see TEMA)

10

Bayonet-tube HEX

Useful for vessel, tank or suction heaters (then mounted without or partial shell)

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Bayonet-tube HEX

12

TEMA classification
Tubular Exchanger Manufacturers Association Coding: e.g. BEU
13

TEMA safety classes

Class R: for refinery and related service Class B: for chemical process service Class C: for commercial and general process applications Watch out for tube-bundle vibrations, can be catastrophic!
14

Tube pitch
Triangular pitch Square pitch

60

90

Staggered or Aligned (relative to flow direction)

15

Boiling in tubes

16

Reboiler configurations

Kettle reboiler

Vert. thermosyphon
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Reboiler configurations (2)

Horiz. thermosyphon

Internal

18

Condensation inside or outside tubes

19

Disadvantage of shell flow

(Thermal) Leakage Dead zones

20

Enhancement of Heat transfer

Shell side Helixchanger Statiflow BrownFintube Tube side Inserts (tape, wire) Static mixer Fins/porous

Any many more (often proprietary designs)

21

Helixchanger (ABB)

Higher heat transfer rate Lower pressure drop Reduced fouling Less prone to vibrations
22

Helixchanger bundle (partial tubing)

www.abb.com /Products & Services /Industries & Utilities /Oil & Gas /ABB Lummus Global, www.lummusonline.com/global/tools/helixchanger/index.htm 23 See website for video animation

Statiflo

For high-viscous flow on shell-side (laminar) Good radial mixing, no hot/cold spots

www.statiflo.net

24

Koch HT: Brown Fintube

Increased heat transfer Less fouling No vibration: good for gas

http://www.brownfintube.com 25

Turbulator: tape

Improve heat transfer 3 to 5 times Can convert laminar to turbulent flow Good radial mixing
(Ref: http://www.alcotwin.com/turbulators.html )
26

Static mixer inserts

Sulzer, Koch, Kenics, Primix

27

Tube insert: CalGavin Hitran

Wire mesh Re<50000

www.calgavin.co.uk

28

Low fin tubes

Fins of 1.5mm, 10 to 40 fpi Larger area Higher heat transfer
Fins for low k fluid

Better for fouling Watch out with condensation Inside: longitudinal fins possible
29

Porous tubes: Boiling

Enhances boiling through cavities

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Spiral tube HEX

31

Flat-Plate (& Frame) HEX

32

Plate & frame HEX

With elastic gaskets: up to 25bar, 160C (can be opened) Welded or brazed: up to 40bar, 350C (not to open) HTC 1.5 to 4 times higher than S&T Close temperature approach Easy to increase size (debottlenecking) For same duty smaller and lighter
33

Same duty!

34

Compabloc (-laval)

Higher temperatures (350C) and pressures (35barg) than gasketed PFE Both sides open for cleaning Also as boiler or condenser

35

 Higher U, smaller size 3-5 times higher U than S&T (Tapproach=3C) Small footprint area, e.g. 320m2 heat transfer area has 1m2 footprint; flow up to 4000m3/h36

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Spiral plate HEX

True counter- or co-current flow Identical flow in both channels Even flow in whole equipment

38

 Two streams separated by walls rather than gaskets Self-cleaning Both sides easy access For slurries Also for condensation and evaporation

39

40

Printed circuit HEX: Heatric

4 to 6 times smaller than S&T Similar pressure drop to S&T Up to 400bar Clean streams (dP<300m) No vibrations: good for gas

42

Heatric
Etched channels Diameter 3mm Multi-stream possible For: Gas duty Off-shore
www.heatric.com
43

Scraped-wall HEX
For high viscosity fluids (>1 Pa s) For extreme fouling fluids For crystallisation

44

Reactor HEX: Sulzer SMR

Combining mixing and heat transfer (process intensification)

for polymerisation and highly exothermic reactions

www.sulzerchemtech.com
45

Air coolers or Fin-Fan HEX

46

High-finned tube

47

Air cooler design

Ganapathy, 1978; Ulrich, 1982

Design for worst case - summer air temperatures of 30-35 C For winter operation internal recirculation Typical approach temperature is 50 C Maximum process fluid temperature ca. 260 C Typical inlet process fluid temperature < 150 C
48

Cooling tower
Work on the evaporation of water Utilise latent heat of water Installed in moderate climates Source of water necessary for make-up Mechanical draft type predominant: forced-draft (fan at the bottom) induced-draft (fan at the top)
49

Mechanical-draft cooling tower

Induced-draft type
50

Elements

51

Furnaces
Fired heaters: - Process heaters - Steam generators - (Steam-) Superheaters

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