Basic Modes Heat Exchangers

 heat exchangers are designed to maximize the surface area of the wall between the two fluids, while minimizing resistance to fluid flow through the exchanger. The exchanger’s performance can also be affected by the addition of fins or corrugations in one or both directions, which increase surface area and may channel fluid flow or...

There are three primary classifications of heat exchangers according to their flow arrangement. In parallel-flow heat exchangers, the two fluids enter the exchanger at the same end, and travel in parallel to one another to the other side. In counter-flow heat exchangers the fluids enter the exchanger from opposite ends. The counter current...

A heat exchanger is a system used to transfer heat between a source and a working fluid. Heat exchangers are used in both cooling and heating processes.[1] The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact.[2] They are widely used in space heating, refrigeration, air conditioning, power...

A plate heat exchanger functions as a specialized device for transferring thermal energy between two fluid streams using a series of metal plates. One of its primary advantages over traditional heat exchangers lies in the substantial increase in surface area for heat exchange, achieved by spreading the fluids across these plates. This...

Cooling System Design Requirements The primary purpose of the engine cooling system is to reject heat from the jacket water coolant and auxiliary circuit if equipped, at greatest engine load, highest ambient temperature, and altitude. This section will outline the proper methods to be used for cooling system sizing. Heat Rejection Before a cooling...

Compressor Oil Coolers A compressor oil cooler (or other external heat load) should be connected into the after cooler circuit after the water has left the after cooler. The return line back into the circuit should be placed before the thermostat. If full flow is not needed to the compressor oil cooler, a bypass line […]

Two-Stage After cooler Cooling Systems The two-stage after cooler, currently offered for some gas engines, is intended to provide high temperature heat recovery for Electric Power Generation (EPG) applications and Reduce overall radiator sizing for Gas Compression applications. There are two coolant stages on the two-stage after cooler; the first...

Types of Cooling Systems • Radiator • Heat Exchanger • Submerged Pipe • Cooling Tower • Keel & Box Coolers • Seawater Systems • Electrochemical Series

All internal combustion engines produce heat as a byproduct of combustion andfriction. This heat can reach temperatures up to 1925°C (3500°F) and can havecatastrophic effects on engine components. Pistons, valves and cylinder headsmust be cooled to reduce the risk of detonation. Cylinder temperatures need to becontrolled so lubricating oil can...

Working Principles of Heat Exchanger Heat exchanger functions by transferring heat from higher to lower temperatures. Heat can thus be transferred from the hot fluid to the cold fluid if a hot fluid and a cold fluid are separated by a heat-conducting surface. The operation of a heat exchanger is governed by thermodynamics. Heat can […]

Common materials used in heat exchangers Selecting the materials used in a heat exchanger is a pivotal part of the design. They need to be heat conductive whilst withstanding any corrosive properties of the mediums involved. Some materials will wear or get dirty faster than others, so upkeep and durability is another consideration. Conductive...

Other types of tubular exchanger include: Air Cooled Heat Exchangers consist of bundle of tubes, a fan system and supporting structure. The tubes can have various type of fins in order to provide additional surface area on the air side. Air is either sucked up through the tubes by a fan mounted above the bundle (induced […]

A Shell and Tube Exchanger consists of a number of tubes mounted inside acylindrical shell.  typical unit that may be found in a petrochemicalplant. Two fluids can exchange heat, one fluid flows over the outside of thetubes while the second fluid flows through the tubes. The fluids can be singleor two phase and can flow in […]

Heat Exchanger Types   This section briefly describes some of the more common types of heat exchanger and is arranged according to the classification Indirect heat exchangers   In this type, the steams are separated by a wall, usually metal. Examples of these are tubular exchangers, plate exchangers, Tubular heat exchangers are very...

Recuperative heat exchangers   There are many types of recuperative exchangers, which can broadly be grouped into indirect contact, direct contact and specials. Indirect contact heat exchangers keep the fluids exchanging heat separate by the use of tubes or plates etc. Direct contact exchangers do not separate the fluids exchanging heat and in...

Regenerative heat exchangers In a regenerative heat exchanger, the flow path normally consists of a matrix, which is heated when the hot fluid passes through it (this is known as the “hot blow”). This heat is then released to the cold fluid when this flows through the matrix (the “cold blow”). Regenerative Heat Exchangers...

Classification of Heat Exchangers by Construction heat exchangers are classified mainly by their construction, The first level of classification is to divide heat exchanger types into recuperative or regenerative. A Recuperative Heat Exchanger has separate flow paths for each fluid and fluids flow simultaneously through the exchanger...

Cross flow heat exchangers are intermediate in efficiency between counter current flow and parallel flow exchangers. In these units, the streams flow at right angles to each other

In co current flow heat exchangers, the streams flow parallel to each other and in the same direction This is less efficient than counter current flow but does provide more uniform wall temperatures. Process 1. Process fluid assignments to shell side or tube side. 2. Selection of stream temperature specifications. 3. Setting shell side and...

Counter flow exchanger in which the two fluids flow parallel to each other but in opposite directions. This type of flow arrangement allows the largest change in temperature of both fluids and is therefore most efficient (where efficiency is the amount of actual heat transferred compared with the theoretical maximum amount of heat that can...

A heat exchanger is a device used to transfer heat between two or more fluids. The fluids can be single or two phase and, depending on the exchanger type, may be separated or in direct contact. Devices involving energy sources such as nuclear fuel pins or fired heaters are not normally regarded as heat exchangers […]

Tube metal is usually: Low carbon steel Low alloy steel Stainless steel Copper Admiralty Cupronickel Inconel Aluminum (in the form of alloys), or titanium. Tube diameters (8–15 mm) are preferred for greater area/volume density but are limited, for purposes of in-tube cleaning larger tube diameters are often required for condensers and boilers....

Shell & tube heat exchangers are the most versatile type of heat exchangers. stations, steam generators, etc

The most common type of heat exchanger in industrial applications is shell-and-tube heat exchangers. The exchangers exhibit more than 65% of the market share with a variety of design experiences of about 100 years. Shell-and tube heat exchangers provide typically the surface area density ranging from 50 to 500 m2/m3 and are easily cleaned. The...

TEMA DESIGNATIONS BEM: Bonnet (Integral Cover), One Pass Shell, Fixed Tube sheet Bonnet Fixed tube sheet heat exchanger. Is a version with one shell pass and two tube passes and a very popular version as the heads can be removed to clean the inside of the tubes. The front head piping must be unbolted to […]

TYPES OF SHELL CONSTRUCTIONS TEMA-E: This shell is the most common shell type, as it is most suitable for most industrial process cooling applications. TEMA-F: This shell design provides for a longitudinal flow plate to be installed inside the tube bundle assembly. This plate causes the shell fluid to travel down one half of the […]

In intercoolers, boilers, pre-heaters and condensers inside power plants as well as other engineering processes, heat exchangers are utilized for controlling heat energy. Heat exchangers are devices that regulate efficient heat transfer from one fluid to another. There are two main types of heat exchangers. The first type of a heat exchanger is...

Shell and Tube Heat Exchangers Tube size: Length is standard, commonly 8, 12 or 16 ft. Diameter: most common 3/4 or 1 in OD Tube pitch and clearance: Pitch is the shortest center-to-center distance between adjacent tubes. Commonly 1.25 to 1.5 times the tube diameter. Clearance is the distance between tubes. It should be larger […]

Shell and Tube Heat Exchangers is the Most commonly used heat exchangers. Advantages • Large surface area in a small volume. • Good mechanical layout. • Uses well established fabrication methods. • Can be constructed from a wide variety of materials. • Easily cleaned and maintained. • Well established design procedures

Heat Exchangers – Typical Old Fashion design 1) Define duty: heat transfer rate, flows, temperatures. 2) Collect required physical properties (ρ, μ, k). 3) Decide on the type of exchanger. 4) Select a trial value for U. 5) Calculate the mean temperature difference, ΔTm 6) Calculate area required. 7) Decide on the exchanger layout. 8)...

Heat exchangers are typically classified according to flow arrangement and type of construction. In the first classification, flow can be countercurrent or co current (also called parallel). Heat exchangers can also be classified based on their configuration as tubular, plate and shell & tube heat exchangers. The tubular heat exchanger,...

Radiation Thermal radiation describes the electromagnetic radiation that is emitted at the surface of a body which has been thermally excited. This electromagnetic radiation is emitted in all directions; and when it strikes another body, part may be reflected, part may be transmitted, and part may be absorbed. Thus, heat may pass from one body...

Conduction Heat conduction is the transfer of heat from one part of a body to another part of the same body, or from one body to another body in physical contact with it, without appreciable displacement of the particles of the body. Energy transfer by conduction is accomplished in two ways. The first mechanism is […]

The process of heat exchange between two fluids that are at different temperatures and separated by a solid wall occurs in many engineering applications. The device used to implement this exchange is called a heat exchanger, and specific applications may be found in space heating and air-conditioning, power production, waste heat recovery and...

There are some criteria for a successful heat exchanger design.  These principles are given below The process requirements which are accomplishing the thermal change on the streams within the allowable pressure drops, and retaining the capability to do this in the presence of fouling until the next scheduled maintenance period must be...

The thermal design of heat exchangers is directed to calculate an adequate surface area to handle the thermal duty for the given specifications whereas the hydraulic analysis determines the pressure drop of the fluids flowing in the system, and consequently the pumping power or fan work input necessary to maintain the flow.  The most common...

COMPONENTS OF SHELL AND TUBE HEAT EXCHANGER 1.Shell 2. Fin Tube 3. Stationary Head 4. Lap Jointed Flange 5. Channel Cover 6. Stationary Tube sheet 7. Floating Tube sheet 8. Nozzle 9. Front Backing Device 10. Rear Backing Device 11. Saddle Support 12. Gasket

In a shell and tube heat exchanger two fluids circulate in a different temperature conditions exchange heat through the walls of the tubes without direct contact between the fluids. The fluid flowing inside the heat transfer tubes that belongs to the tube bundle they finds the tube side of a shell and tube heat exchanger. […]

Gravitational separation of liquid and vapor also plays an important part in the functioning of condensers, of which many designs exist, their nature determined largely by the ratio of the condensed to the uncondensed components in the fluid stream being cooled. Even when the cooled stream is nominally wholly condensable, as is true of stream...

Evaporators, boilers, and reboilers   When the function of the heat exchanger is to cause one of the fluid streams to change from the liquid to the vapor phase, it is common for a modified shell-and-tube construction to be employed. Compared with the no-phase-change equipment discussed in Sec. B, vapor producing heat exchangers are usually...

The designs differ in the following ways, among others:

Most unfired heat exchangers, operating with fluids that do not change phase, are of baffled shell-and-tube design, by which is meant that one of the fluids flows within straight or hairpin-bent tubes, whereas the other flow between and around those tubes, within an ah-confining shell, being guided in its path by baffles. These baffles serve...

Plain tubes The most common arrangement is for one fluid to flow within straight or curved tubes of circular cross section, while a second fluid washes the outside of these tubes in a longitudinal, perpendicular, or oblique direction. The interface is thus represented by a tube wall, and contact is indirect. The tubes may, of […]