Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
automobile radiators
Condensers
evaporators
air preheaters
oil coolers.
Applications of heat
exchangers
Process liquid or gas cooling.
Process or refrigerant vapor or steam
condensing.
Process liquid, steam or refrigerant
evaporation.
Process heat removal and preheating of
feedwater.
Thermal energy conservation efforts and heat
recovery.
Heat Transfer in heat
exchangers
Heat Transfer In Heat
Exchangers
Modes of Heat Transfer
Conduction
Convection
Radiation
Heat Transfer In Heat
Exchangers
Conduction
Parameters affecting the rate of conductive
heat transfer
1- Temperature difference
2- Surface area
3- Thermal conductivity of material
Thermal Conductivities
Material k (Btu/hr. ft. F)
Fiber Insulating Board 0.028
Maple or Oak Wood 0.096
Building Brick 0.4
Window Glass 0.45
Concrete 0.79
1% Carbon Steel 25
1% Chrome Steel 35
Aluminum 118
Copper 223
Silver 235
Sat Steam ( 600 E F) 0.030
Liquid Water (at 600 E F) 0.3
Heat Transfer In Heat
Exchangers
Convection
Natural Convection
Forced Convection
Boiling
Condensation
Heat Transfer In Heat
Exchangers
Radiation heat transfer
Factors affecting the radiative heat
transfer
1- Temperature.
2- Surface area.
3- Emissivity
4- Configuration
Overall Heat Transfer Coefficient
Fluid U [Btu/ft2.hr.F]
Organics to Organics 10-60
Steam to:
Aqueous Solutions 100-600
Fuel Oil, Heavy 10-30
Light 30-60
Gases 5-50
Water 175-600
Water to:
Alcohol 50-150
Brine 100-200
Compressed Air 10-30
Overall Heat Transfer Coefficient
Fluid U [Btu/ft2.hr.F]
Condensing Alcohol 45-120
Condensing Ammonia 150-250
Condensing Freon-12 80-150
Condensing Oil 40-100
Gasoline 60-90
Lubricating Oil 20-60
Organic Solvents 50-150
Water 150-300
Classification of heat
exchangers
Classification of heat
exchangers
industrial heat exchangers have been
classified according to
(1) Construction
(2) transfer processes
(3) degrees of surface compactness
(4) flow arrangements
(5) pass arrangements
(6) phase of the process fluids
(7) heat-transfer mechanisms.
Classification
According
to Construction
Extended surface
Tubular heat Plate heat
heat
exchangers exchangers
exchangers
Tubular Heat Exchanger
Double Pipe Exchangers
Shell and Tube Heat Exchanger
Coiled Tube Heat Exchanger
Plate Heat Exchanger
Plate Heat Exchanger
Plate Heat Exchanger
spiral plate heat exchanger
Extended Surface Exchangers
(a) continuous plain; (b) cut and twisted;
(c) perforated; (d) internal and external longitudinal fins.
Classification
According
to Transfer
Process
Compact Non-compact
Classification
According
to Flow
Arrangement
two-phase
single phase Combined
convection
convection convection
(condensation or
forced or free and radiation
evaporation)
SELECTION OF HEAT
EXCHANGERS
Selection Criteria
1.Materials of construction
2. Operating pressure and temperature,
temperature program, and temperature driving
force
3.Flow rates
4. Flow arrangements
5.Performance parameters-thermal effectiveness
and pressure drops
6. Fouling tendencies
7. Types and phases of fluids
Selection Criteria
8. Maintenance, inspection, cleaning,
extension, and repair possibilities
9. Overall economy
10. Fabrication techniques
11. Intended applications
REQUIREMENTS OF
HEAT EXCHANGERS
1. High thermal effectiveness
2. Pressure drop as low as possible
3. Reliability and life expectancy
4. High-quality product and safe operation
5. Material compatibility with the process fluids
6. Convenient size, easy for installation, reliable in use
7. Easy for maintenance and servicing
8. Light in weight but strong in construction to withstand the
operational pressures
9. Simplicity of manufacture
10.Low cost
11. Possibility of effecting repair to maintenance problems
Shell and tube heat
exchangers
Types and Standards of Shell and Tube Heat Exchangers
Association) are Small design : is the design from 2 in. to
around 24 in. in shell diameter. Shell is made of pipe of low cost
welded steel, brazed pipe, cast end bonnets and copper tubing
rolled or brazed to the tube sheet.
Major design : is of shell diameter from 24 in. to over 100 in.
Above 24 in., manufactures There are different designs of shell
and tube heat exchangers, based on shell diameter.
use rolled and welded steel plates for shells, which is more
costly and not rounded well.
The tube hole pattern or pitch varies the distance from one tube to
the other and angle of the tubes relative to each other and to the
direction of flow.
TEMA G and H shell designs are most suitable for phase change
applications where the bypass around the longitudinal plate and counter-
current flow is 1ess important than even flow distribution.
TEMA J Shells are typically specified for phase change duties where
significantly reduced shell side pressure drops are required
The TEMA K shell, also termed a kettle reboiler is specified when the
shell side stream will undergo vaporization. The liquid level of a K shell
design should just cover the tube bundle, which fills the smaller diameter
end of the shell.
The TEMA X shell, or cross flow shell is most commonly used in vapor
TEMA Shell Types and Standards
TEMA Shell and tube heat exchanger
Shell and tube heat exchanger
.
Vertical cut segmental baffles.
Fluid Stream Allocations
1. The higher-pressure fluid normally flows through the
tube side.
2. If it is necessary to put the higher-pressure stream in
the shell, it should be placed in a smaller diameter
and longer shell.
3. Place corrosive fluids in the tubes. Epoxy coated
tube side can resist corrosion.
4. Flow the higher fouling fluids through the tubes.
Tubes are easier to clean using mechanical
methods.
5. It is best to place fluids requiring low pressure drops
in the shell circuit.
6. The fluid with the lower heat transfer coefficient
normally goes in the shell circuit. This allows the
use of externally finned tubes to enhance the heat
transfer rate.
TEMA classes
1) Flow considerations
For liquids, the Reynolds number should probably be in the
range 300-50,000. If the velocity head is high (pV2/9,266 >0.5
psi), the force in the streamwise direction may be sufficient to
cause damage.
4- Increased Viscosity.
Heat Exchanger
Troubleshooting
High Fluid Losses/Make-Up Rate.
1- Leaks from Fittings and Connections.
2- Vibration
3- thermal stress
Heat Exchanger
Troubleshooting
Short Fluid Life.
1- Oxidation.
2- Thermal Degradation.
3- Contamination.
Heat Exchanger
Troubleshooting
Frequent Filter Plugging.
1-Polymerization.
2-Fouling After Cleaning.
3- Unsaturated Components
4- Increased Pressure Drop in the System.
GUIDE TO FREE
TROUBLESHOOTING
Avoiding leakage
Forced Draft
Requiring smaller volumes of air
and less horsepower
They generally offer better
arrangements for maintenance and
they are easily accessible.
Forced draft fans afford a higher
heat-transfer coefficient relative to
induced draft
Forced Draft Versus Induced Draft
Induced Draft
1. Easier to shop assemble, ship, and install.
2. The hoods offer protection from weather and hailstone
protection.
3. Easier to clean the underside when covered with lint,
bugs, and debris.
4. Better air distribution over the tube bundle.
5. Less likely to be affected by hot air recirculation.
The disadvantages of induced draft design are:
1. More difficult to remove bundles for maintenance.
2. High-temperature service limited due to effect of hot
air on the fans.
3. More difficult to work on the fan assembly, due to heat
from the bundle and due to their location.
Air Velocity
.
Flow Patterns and Pass
Arrangement
.
Z-arrangement
U-arrangement
Plate
Plate thickness as low as 0.6 mm (0.024
in) can therefore be used for working
pressures as high as 230 psig
PLATE HEAT EXCHANGER-DETAILED
CONSTRUCTION FEATURES
.
PLATE HEAT EXCHANGER-DETAILED
CONSTRUCTION FEATURES
.
Fired Heaters
Fired Heaters Applications
Common applications of indirect heaters
1- Heating the gas from the well to prevent hydrocarbon
hydrate formation.
2- Crude oil preheat between head and pipeline.
3- Crude oil preheat to Separators or Desalters.
5- Fuel gas dew-point control systems associated with
gas turbine power plants.
6-Heating high-pressure hydrocarbon gas streams at
pressure reduction stations.
7- Liquid-gas vaporization. The Indirect Heater operates
as a vaporizer/superheated.
8- Reboiler and stabilizer medium fluid heater.
Fired Heaters
Types of Fired Heaters
1) Premix inspirating.
and
Corrective Actions
Controlling air supply
Energy saving ideas
Expanding heat capacity
Fired Heaters
Insufficient draft
This may be due to:
Draft gauge plugging
Excess CO2 in flue gas
Fouled convection section
Leaks in furnace skin
Stuck stack diameter
Damage to furnace structure
Smoke leaks out of convection
Fired Heaters
Excessive draft
Excessive draft :
Wastes energy from the system.
Sucks cold air into convection section
Causes secondary combustion in the
convection section tubes
Fired Heaters
Insufficient combustion air
This may be due to:
Fire box looks hazy
Heater makes a thumping sound
Temperature drops with the increase in
the fuel
Fin-tubing damage
Sample fire box effluent not stack gas
Fired Heaters
Incomplete Oil burning
Oil pressure too high
Oil temperature too low
Plugged burner tips
Enlarged holes
Wet atomizing steam
Fired Heaters
Existence of hot spots in tubes
Cool tubes are dark to cherry red
Silver streaks are hot spots
Low flow cause coke lay down
Steam jet cools hot spot
Maximize flow through hot coil
Fired Heaters
Corrective Actions:
1) Controlling air supply
Maximize Primary air
Flame lifts off burner
Open secondary dampers to control yellow
flame
Cool box with excess air
Seal convection section doors
Burner flashback
Fired Heaters
Energy saving ideas
Onstream blasting of radiant tubes
Steam air decoking tubes
Onstream washing convection section tubes
Infrared thermograph survey
SO3 dew point limit
Minimize atomizing steam
Install soot blowers
Fired Heaters
Expanding heat capacity
Drill out burner tips
Draft limits
Pressure survey on flue gas side
Add convection tubes
Replace raw gas burners
Increase tube side mass velocity.
CORRECT DRAFT
CORRECT DRAFT
The stack draft pulls and when correctly balanced
the pressure at the bridgewall should be close to
zero or very slightly negative.
A process heater operating properly will have a
zero, or slightly negative draft, at the shield section
of zero to -0.5" wc (water column).
The firebox will be slightly positive (+0.5 to +2.0 "
wc) and the stack will have a range of -0.5 to -1.0"
wc.
EXCESSIVE DRAFT - POSITIVE
PRESSURE CREATED
The pressure is always greatest at the
firewall. In Figure, the air registers are wide
open and the damper mostly closed. This
generates a positive pressure which forces
flue gases outward through leaks in the
convection section leading to serious
structure damage, as well as heat loss.
EXCESSIVE DRAFT - NEGATIVE
PRESSURE CREATED
The air registers are mostly closed and the
stack damper is wide open (Figure) leading to
a high negative pressure in the convection
section. Cold ambient air is sucked in through
leaks in the convection section leading to
erroneous oxygen readings, as well as heat
loss; excessive draft causes tall flames that
can reach the tubes resulting in serious
damage.
USING OXYGEN AND PPM
COMBUSTIBLES
SUGGESTED MANUAL TRIM
OF A FIRED HEATER
1. Adjust primary air on the burner for proper flame
height and color at the operating fuel gas pressure.
2. Adjust the stack damper to the recommended -
0.1" wc draft at the entrance to the convection
section, with secondary air registers open.
3. Trim the secondary air registers to the lowest
excess oxygen level up to, but not exceeding, the
PPM combustibles operational limit as dictated by
plant personnel or experience.
SUGGESTED MANUAL TRIM
OF A FIRED HEATER
.4Readjust stack damper and secondary air
registers as necessary to maintain convection
section draft and minimal radiant section oxygen
with a safe level of combustibles.
.5Set up the heater using oxygen and
combustibles. The heater is now controlled on
oxygen, and the combustibles detector is used to
watch for process upsets and burner performance
over time. This is the window into the process.
.6A 100 ppm combustibles level can achieve
maximum fuel efficiency as well as minimizing
emissions, without sacrificing safety.