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Natural Convection
Stampings
Extrusions
Heat Pipe Assemblies
Single & Two Phase Liquid Cooling, Refrigeration
Folded Fin Assemblies
Loop Heat Pipes & Pulsating Heat Pipes Assemblies
Advanced & Emerging
Technologies
Mature Technologies
37
Recuperators
Transfer across a barrier wall
Single or bank of tubes to transfer heat
Pressure drop along tubes is low so particulate
matter does not collect in pipes
Some system incorporate a continuous
mechanical scraper to remove deposits /
oxidation scale
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Simple Recuperator
39
Compact-plate heat exchangers
Large surface area for transfer
High heat transfer efficiency
Suitable for small temperature differences
Hot and cold fluids pass between alternate
plates
Ribs on plates provide mechanical strength
and also fluid turbulence to improve transfer
40
Compact-plate heat exchangers
Design allows easy addition of extra plates,
external lagging
41
Compact-plate heat exchangers
42
Compact-plate heat exchangers
Plate materials often stainless steel pressings
Since 1990s polymer film plates
eg. PEEK (polyether ether ketone) thermoplastic
Plates can be down to 100um thick
Operate up to 250 Deg C. (Mpt. 343 Deg C.)
Corrosion resistant
Fouling resistant hydrophobic / smooth
finish mouldings
43
Compact-plate design
44
Compact-Plate heat Exchangers
Applications :
air conditioners, portable systems (cars,
cooled containers)
design allows easy capacity adjustment
45
Compact-Plate heat exchangers
Pros :
good temperature control
compact and lighter weight
easy to strip for cleaning / repair
Cons :
seals can leak
higher pumping P required
solutions should be silt free
46
Shell & Tube Heat Exchangers
Large exchangers used industrially
Heat transfer across barrier wall using conduction and
convection processes
Simplest for is a tube inside a tube / shell
Three main types :
Fixed tube plates cheap / simple
hard to clean tube o/d
U bend form hard to clean tube i/d
Floating head expensive but easy to clean
47
CME 8056 Shell & Tube Heat Exchanger Types
48
Types of Shell & Tube Exchanger
Fixed tube
49
Types of Shell & Tube Exchanger
U tube
50
Types of Shell & Tube Exchanger
Floating head
51
Flow in the exchanger
Tube end plate / or tube sheet Tube support plates / baffles
52
Shell & Tube Exchangers
Flow may be parallel
counter
cross-flow
Cross-flow often achieved using baffle plates
Applications : liquid/liquid heat exchange,
gas/liquid heat exchange
53
Shell & Tube Exchangers
Aim for thin-walled barrier
Aim for large surface area of interface
Limit stagnant layer on tube wall by controlled
pumping cost / maintenance versus
efficiency
Control fouling of surfaces
54
Shell & Tube Exchangers
Shell is often a pressure vessel
Tubes also have to withstand pressure
differential
Hot fluid pressurised to prevent boiling
Cold fluid often at lower pressure
55
Applications of recuperators
Special cases :
Automotive Radiators where air cools hot
water
condensers where a cold fluid causes
condensation from a gas
steam generators where hot fluid is used to
convert water to steam
56
Automotive Radiators
Design improvements / savings
57
Tube Materials Selection
Properties required :
Good mechanical strength
Ease of fabrication /ductility
Reasonable heat transfer
Good creep resistance
Resistance to corrosion
Resistance to fouling
Acceptable cost
58
Materials Used
Many carbon steel shells with alloy steel tubes
this can lead to galvanic issues
In hostile environments shell is also alloy
Corrosion problems from impurities in fluids
Today also specialist polymers and ceramics
applications
59
Carbon steel / alloy applications
60
Materials Selection
61
Alloy materials for tube bundles
In order of usage :
300 stainless steels
nickel
monel
copper
aluminium alloys
inconel alloys
400 series alloys
62
Corrosion Risks
Drawn / stressed tubing may fail by stress
corrosion cracking
Deposition of impurities causes sludge piles
under which low oxygen, occluded cell
corrosion
General surface oxidation due to heat or fluid
attack
63
Steam Generators
Specific type of shell and tube exchanger used
in power stations to convert water to steam to
drive turbine operation
Provides isolation between primary and
secondary water circuits - safety
Operating temperature ~ 300 Deg. C.
64
Steam Generators in Nuclear Power
Plant
Pressurised Water Reactors, PWR, common US
and EU designs
Older boiling water reactors, BWR, less safe
65
PWR Layout
66
Nuclear Power Factoids
Over 440 plants worldwide
Producing over 360,000 MW
US has most plants
France has highest % nuclear power provision
67
Nuclear Power in the UK
Last PWR plant commissioned 1995 at
Sizewell, East Anglia
PWR output >1000 MW
Over 1000 heat exchangers on site !
Four steam generators
68
Steam Generators
Has same features as other heat exchangers
tube bundle, tube-sheet, tube support plates
At Sizewell : each has 5,600 alloy tubes giving
a heat transfer area of 5000 m
2
69
Steam Generators
The vertical tube steam generators run two
turbines each
The primary circuit input is ~ 315 Deg C. at
16 MPa
The secondary side steam is ~ 270 Deg C. at
6 MPa
Theoretical transfer efficiency is 99 %
70
Development of Steam Generators
Initially tube bundles made from 316 stainless
steel
Failures led to selection of a more corrosion
resistant alloy : Inconel 600
Eventually (17 years later) Inconel 690
purpose designed alloy developed
71
PWR Failures in the US
72
BWR Failures in the US
73
Steam Generator Plant
74
Steam Generator Operation
75
Steam Generator Failure Modes
76
Why use seamless tubing ?
Risk of cracking at welds :
77
Heat-affected zone, HAZ
78
How do you make seamless tube ?
79
U bend tube failures
80
Tube support-plate denting
81
Sludge
pile build
-up
Force of
Oxide
growth
Sludge Piles in many systems
82
Cross-section
of domestic
radiator
Showing
sludge pile and
localised
pitting
corrosion
Dealing with leaking tubes in SG
Plug during shut-down -> efficiency loss
Monitor losses :
Failure rate = Number Plugged
Total No. tubes x Operating time
Replace bundle when performance
unacceptable
83
Design Solutions to TSP denting
84
Tube-sheet expansions
85
Partial expansion
Full expansion
Roller expansion or explosive
welding
86
In many shell and tube exchangers tubes are
brazed or welled to the tube sheet
In SG the tubes are either roller expanded or
explosively welded
Minimise diffusion / micro-structural changes
Explosive Welding
87
Conclusions
Heat exchangers essential to all modern
industry
Designs / material selection still improving
Life-cycle costing and pay-back economics
important
Monday 3pm student presentations
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