Aninterchangeableplateheat

exchanger
Tubularheatexchanger.
FromWikipedia,thefreeencyclopedia
Aheatexchangerisapieceofequipmentbuiltforefficientheat
transferfromonemediumtoanother.Themediamaybe
separatedbyasolidwalltopreventmixingortheymaybein
directcontact.
[1]
Theyarewidelyusedinspaceheating,
refrigeration,airconditioning,powerplants,chemicalplants,
petrochemicalplants,petroleumrefineries,naturalgas
processing,andsewagetreatment.Theclassicexampleofaheat
exchangerisfoundinaninternalcombustionengineinwhicha
circulatingfluidknownasenginecoolantflowsthroughradiator
coilsandairflowspastthecoils,whichcoolsthecoolantand
heatstheincomingair.
1Flowarrangement
2Typesofheatexchangers
2.1Electricheating
2.2Doublepipeheatexchanger
2.3Shellandtubeheatexchanger
2.4Plateheatexchanger
2.5Plateandshellheatexchanger
2.6Adiabaticwheelheatexchanger
2.7Platefinheatexchanger
2.8Pillowplateheatexchanger
2.9Fluidheatexchangers
2.10Optimization
2.11WasteHeatRecoveryUnits
2.12Dynamicscrapedsurfaceheatexchanger
2.13Phasechangeheatexchangers
3Directcontactheatexchangers
4HVACaircoils
5Spiralheatexchangers
5.1Construction
5.2Selfcleaning
5.3Flowarrangements
5.4Applications
6Selection
7Monitoringandmaintenance
7.1Fouling
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Countercurrent(A)and
parallel(B)flows
Fig.1:Shellandtube
heatexchanger,single
pass(11parallel
flow)

Fig.2:Shellandtube
heatexchanger,
2passtubeside(12
crossflow)

Fig.3:Shellandtube
heatexchanger,
2passshellside,
2passtubeside(22
countercurrent)
7.2Maintenance
8Innature
8.1Humans
8.2Birds,fish,marinemammals
8.3Carotidrete
9Inindustry
10Inaircraft
11Currentmarketandforecast
12Amodelofasimpleheatexchanger
13Seealso
14References
15Externallinks
Therearethreeprimary
classificationsofheat
exchangersaccordingtotheir
flowarrangement.In
parallelflowheatexchangers,thetwofluidsentertheexchangeratthesameend,andtravelinparallel
tooneanothertotheotherside.Incounterflowheatexchangersthefluidsentertheexchangerfrom
oppositeends.Thecountercurrentdesignisthemostefficient,inthatitcantransferthemostheat
fromtheheat(transfer)mediumduetothefactthattheaveragetemperaturedifferencealonganyunit
lengthisgreater.Seecountercurrentexchange.Inacrossflowheatexchanger,thefluidstravelroughly
perpendiculartooneanotherthroughtheexchanger.
Forefficiency,heatexchangersaredesignedtomaximizethesurfaceareaofthewallbetweenthetwo
fluids,whileminimizingresistancetofluidflowthroughtheexchanger.Theexchanger'sperformance
canalsobeaffectedbytheadditionoffinsorcorrugationsinoneorbothdirections,whichincrease
surfaceareaandmaychannelfluidfloworinduceturbulence.
Thedrivingtemperatureacrosstheheattransfersurfacevarieswithposition,butanappropriate
meantemperaturecanbedefined.Inmostsimplesystemsthisisthe"logmeantemperature
difference"(LMTD).SometimesdirectknowledgeoftheLMTDisnotavailableandtheNTUmethodis
used.
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AShellandTubeheatexchanger
Electricheating
ElectricHeatingisanyprocessinwhichelectricalenergyisconvertedtoheat.
Doublepipeheatexchanger
Doublepipeheatexchangersarethesimplestexchangersusedinindustries.Ononehand,theseheat
exchangersarecheapforbothdesignandmaintenance,makingthemagoodchoiceforsmall
industries.Butontheotherhand,lowefficiencyofthembesidehighspaceoccupiedforsuch
exchangersinlargescales,hasledmodernindustriestousemoreefficientheatexchangerlikeshell
andtubeorotherones.Butyet,sincedoublepipeheatexchangersaresimple,theyareusedtoteach
heatexchangerdesignbasictostudentsandasthebasicrulesformodernandnormalheatexchangers
arethesame,studentscanunderstandthedesigntechniquesmucheasier.Tostartthedesignofa
doublepipeheatexchanger,thefirststepistocalculatetheheatdutyoftheheatexchanger.Itmustbe
notedthatforeasierdesign,itsbettertoignoreheatlossinheatexchangerforprimarydesign.The
heatdutycanbedefinedastheheatgainedbycoldfluidwhichisequaltotheheatlossofthehot
fluid.
[2]
Shellandtubeheatexchanger
Shellandtubeheatexchangersconsistofseriesoftubes.Oneset
ofthesetubescontainsthefluidthatmustbeeitherheatedor
cooled.Thesecondfluidrunsoverthetubesthatarebeing
heatedorcooledsothatitcaneitherprovidetheheatorabsorb
theheatrequired.Asetoftubesiscalledthetubebundleandcan
bemadeupofseveraltypesoftubes:plain,longitudinallyfinned,
etc.Shellandtubeheatexchangersaretypicallyusedfor
highpressureapplications(withpressuresgreaterthan30bar
andtemperaturesgreaterthan260C).
[3]
Thisisbecausethe
shellandtubeheatexchangersarerobustduetotheirshape.
Severalthermaldesignfeaturesmustbeconsideredwhen
designingthetubesintheshellandtubeheatexchangers:There
canbemanyvariationsontheshellandtubedesign.Typically,theendsofeachtubeareconnectedto
plenums(sometimescalledwaterboxes)throughholesintubesheets.Thetubesmaybestraightor
bentintheshapeofaU,calledUtubes.
Tubediameter:Usingasmalltubediametermakestheheatexchangerbotheconomicaland
compact.However,itismorelikelyfortheheatexchangertofoulupfasterandthesmallsize
makesmechanicalcleaningofthefoulingdifficult.Toprevailoverthefoulingandcleaning
problems,largertubediameterscanbeused.Thustodeterminethetubediameter,theavailable
space,costandfoulingnatureofthefluidsmustbeconsidered.
Tubethickness:Thethicknessofthewallofthetubesisusuallydeterminedtoensure:
Thereisenoughroomforcorrosion
Thatflowinducedvibrationhasresistance
Axialstrength
Availabilityofspareparts
Hoopstrength(towithstandinternaltubepressure)
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Bucklingstrength(towithstandoverpressureintheshell)
Tubelength:heatexchangersareusuallycheaperwhentheyhaveasmallershelldiameteranda
longtubelength.Thus,typicallythereisanaimtomaketheheatexchangeraslongasphysically
possiblewhilstnotexceedingproductioncapabilities.However,therearemanylimitationsfor
this,includingspaceavailableattheinstallationsiteandtheneedtoensuretubesareavailable
inlengthsthataretwicetherequiredlength(sotheycanbewithdrawnandreplaced).Also,
long,thintubesaredifficulttotakeoutandreplace.
Tubepitch:whendesigningthetubes,itispracticaltoensurethatthetubepitch(i.e.,thecentre
centredistanceofadjoiningtubes)isnotlessthan1.25timesthetubes'outsidediameter.A
largertubepitchleadstoalargeroverallshelldiameter,whichleadstoamoreexpensiveheat
exchanger.
Tubecorrugation:thistypeoftubes,mainlyusedfortheinnertubes,increasestheturbulenceof
thefluidsandtheeffectisveryimportantintheheattransfergivingabetterperformance.
TubeLayout:referstohowtubesarepositionedwithintheshell.Therearefourmaintypesof
tubelayout,whichare,triangular(30),rotatedtriangular(60),square(90)androtated
square(45).Thetriangularpatternsareemployedtogivegreaterheattransferastheyforcethe
fluidtoflowinamoreturbulentfashionaroundthepiping.Squarepatternsareemployedwhere
highfoulingisexperiencedandcleaningismoreregular.
BaffleDesign:bafflesareusedinshellandtubeheatexchangerstodirectfluidacrossthetube
bundle.Theyrunperpendicularlytotheshellandholdthebundle,preventingthetubesfrom
saggingoveralonglength.Theycanalsopreventthetubesfromvibrating.Themostcommon
typeofbaffleisthesegmentalbaffle.Thesemicircularsegmentalbafflesareorientedat180
degreestotheadjacentbafflesforcingthefluidtoflowupwardanddownwardsbetweenthe
tubebundle.Bafflespacingisoflargethermodynamicconcernwhendesigningshellandtube
heatexchangers.Bafflesmustbespacedwithconsiderationfortheconversionofpressuredrop
andheattransfer.Forthermoeconomicoptimizationitissuggestedthatthebafflesbespacedno
closerthan20%oftheshellsinnerdiameter.Havingbafflesspacedtoocloselycausesagreater
pressuredropbecauseofflowredirection.Consequentlyhavingthebafflesspacedtoofarapart
meansthattheremaybecoolerspotsinthecornersbetweenbaffles.Itisalsoimportantto
ensurethebafflesarespacedcloseenoughthatthetubesdonotsag.Theothermaintypeof
baffleisthediscanddonutbaffle,whichconsistsoftwoconcentricbaffles.Anouter,widerbaffle
lookslikeadonut,whilsttheinnerbaffleisshapedlikeadisk.Thistypeofbaffleforcesthefluid
topassaroundeachsideofthediskthenthroughthedonutbafflegeneratingadifferenttypeof
fluidflow.
Fixedtubeliquidcooledheatexchangersespeciallysuitableformarineandharshapplicationscanbe
assembledwithbrassshells,coppertubes,brassbaffles,andforgedbrassintegralendhubs.
[4]
(See:
Copperinheatexchangers).
Plateheatexchanger
Anothertypeofheatexchangeristheplateheatexchanger.Oneiscomposedofmultiple,thin,slightly
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Conceptualdiagramofaplateand
frameheatexchanger.
Asingleplateheatexchanger
Aninterchangeableplateheat
exchangerappliedtothesystemof
aswimmingpool
separatedplatesthathaveverylargesurfaceareasandfluidflow
passagesforheattransfer.Thisstackedplatearrangementcanbe
moreeffective,inagivenspace,thantheshellandtubeheat
exchanger.Advancesingasketandbrazingtechnologyhavemade
theplatetypeheatexchangerincreasinglypractical.InHVAC
applications,largeheatexchangersofthistypearecalledplate
andframe;whenusedinopenloops,theseheatexchangersare
normallyofthegaskettypetoallowperiodicdisassembly,
cleaning,andinspection.Therearemanytypesofpermanently
bondedplateheatexchangers,suchasdipbrazed,vacuum
brazed,andweldedplatevarieties,andtheyareoftenspecified
forclosedloopapplicationssuchasrefrigeration.Plateheat
exchangersalsodifferinthetypesofplatesthatareused,andin
theconfigurationsofthoseplates.Someplatesmaybestamped
with"chevron",dimpled,orotherpatterns,whereothersmay
havemachinedfinsand/orgrooves.
Plateandshellheatexchanger
Athirdtypeofheatexchangerisaplateandshellheatexchanger,
whichcombinesplateheatexchangerwithshellandtubeheat
exchangertechnologies.Theheartoftheheatexchangercontains
afullyweldedcircularplatepackmadebypressingandcutting
roundplatesandweldingthemtogether.Nozzlescarryflowin
andoutoftheplatepack(the'Plateside'flowpath).Thefully
weldedplatepackisassembledintoanoutershellthatcreatesa
secondflowpath(the'Shellside').Plateandshelltechnology
offershighheattransfer,highpressure,highoperating
temperature,compactsize,lowfoulingandcloseapproach
temperature.Inparticular,itdoescompletelywithoutgaskets,
whichprovidessecurityagainstleakageathighpressuresand
temperatures.
Adiabaticwheelheatexchanger
Afourthtypeofheatexchangerusesanintermediatefluidor
solidstoretoholdheat,whichisthenmovedtotheothersideof
theheatexchangertobereleased.Twoexamplesofthisare
adiabaticwheels,whichconsistofalargewheelwithfine
threadsrotatingthroughthehotandcoldfluids,andfluidheat
exchangers.
Platefinheatexchanger
Thistypeofheatexchangeruses"sandwiched"passages
containingfinstoincreasetheeffectivenessoftheunit.The
designsincludecrossflowandcounterflowcoupledwithvarious
finconfigurationssuchasstraightfins,offsetfinsandwavyfins.
Plateandfinheatexchangersareusuallymadeofaluminium
alloys,whichprovidehighheattransferefficiency.Thematerialenablesthesystemtooperateata
lowertemperatureandreducetheweightoftheequipment.Plateandfinheatexchangersaremostly
usedforlowtemperatureservicessuchasnaturalgas,heliumandoxygenliquefactionplants,air
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separationplantsandtransportindustriessuchasmotorandaircraftengines.
Advantagesofplateandfinheatexchangers:
Highheattransferefficiencyespeciallyingastreatment
Largerheattransferarea
Approximately5timeslighterinweightthanthatofshellandtubeheatexchanger.
Abletowithstandhighpressure
Disadvantagesofplateandfinheatexchangers:
Mightcausecloggingasthepathwaysareverynarrow
Difficulttocleanthepathways
AluminumalloysaresusceptibletoMercuryLiquidEmbrittlementFailure
Pillowplateheatexchanger
Apillowplateexchangeriscommonlyusedinthedairyindustryforcoolingmilkinlargedirect
expansionstainlesssteelbulktanks.Thepillowplateallowsforcoolingacrossnearlytheentire
surfaceareaofthetank,withoutgapsthatwouldoccurbetweenpipesweldedtotheexteriorofthe
tank.
Thepillowplateisconstructedusingathinsheetofmetalspotweldedtothesurfaceofanother
thickersheetofmetal.Thethinplateisweldedinaregularpatternofdotsorwithaserpentine
patternofweldlines.Afterweldingtheenclosedspaceispressurizedwithsufficientforcetocausethe
thinmetaltobulgeoutaroundthewelds,providingaspaceforheatexchangerliquidstoflow,and
creatingacharacteristicappearanceofaswelledpillowformedoutofmetal.
Fluidheatexchangers
Thisisaheatexchangerwithagaspassingupwardsthroughashoweroffluid(oftenwater),andthe
fluidisthentakenelsewherebeforebeingcooled.Thisiscommonlyusedforcoolinggaseswhilstalso
removingcertainimpurities,thussolvingtwoproblemsatonce.Itiswidelyusedinespressomachines
asanenergysavingmethodofcoolingsuperheatedwatertouseintheextractionofespresso.
Optimization
Therearethreegoalsthatarenormallyconsideredintheoptimaldesignofheatexchangers:(1)
Minimizingthepressuredrop(pumpingpower),(2)Maximizingthethermalperformanceand(3)
Minimizingtheentropygeneration(thermodynamicirreversibility).Seeforexample:
[5]
WasteHeatRecoveryUnits
AWasteHeatRecoveryUnit(WHRU)isaheatexchangerthatrecoversheatfromahotgasstream
whiletransferringittoaworkingmedium,typicallywateroroils.Thehotgasstreamcanbethe
exhaustgasfromagasturbineoradieselengineorawastegasfromindustryorrefinery.
Bigsystemswithhighvolumeandtemperaturegasstream,typicalonindustry,canbenefitfromSteam
RankineCycle(SRC)inaWHRU,butsmallsystemsbecometooexpensivetouseit.Therecoverofheat
fromlowtemperaturesystemsrequiresmoreefficientworkingfluidsthansteam.
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Typicalkettlereboilerusedfor
industrialdistillationtowers
Typicalwatercooledsurfacecondenser
AnOrganicRankineCycle(ORC)WHRUcanbemoreefficientatlowtemperaturerangeusing
Refrigerantthatboilatlowertemperaturesthanwater.TypicalorganicrefrigerantsareAmmonia,
Pentafluoropropane(R245faandR245ca),andToluene.
TherefrigerantisboiledbytheheatsourceintheEvaporatortoproducesuperheatedvapor.This
fluidisexpandedintheturbinetoconvertthermalenergytokineticenergy,thatisconvertedto
electricityintheelectricalgenerator.Thisenergytransferprocessdecreasesthetemperatureofthe
refrigerantthat,inturn,condenses.Thecycleisclosedandcompletedusingapumptosendthefluid
backtotheevaporator.
Dynamicscrapedsurfaceheatexchanger
Anothertypeofheatexchangeriscalled"(dynamic)scrapedsurfaceheatexchanger".Thisismainly
usedforheatingorcoolingwithhighviscosityproducts,crystallizationprocesses,evaporationand
highfoulingapplications.Longrunningtimesareachievedduetothecontinuousscrapingofthe
surface,thusavoidingfoulingandachievingasustainableheattransferrateduringtheprocess.
Phasechangeheatexchangers
Inadditiontoheatinguporcoolingdownfluidsinjusta
singlephase,heatexchangerscanbeusedeithertoheata
liquidtoevaporate(orboil)itorusedascondenserstocool
avaporandcondenseittoaliquid.Inchemicalplantsand
refineries,reboilersusedtoheatincomingfeedfor
distillationtowersareoftenheatexchangers.
[6][7]
Distillationsetupstypicallyusecondenserstocondense
distillatevaporsbackintoliquid.
Powerplantsthatusesteamdriventurbinescommonlyuse
heatexchangerstoboilwaterintosteam.Heatexchangersor
similarunitsforproducingsteamfromwaterareoften
calledboilersorsteamgenerators.
Inthenuclearpowerplantscalledpressurizedwater
reactors,speciallargeheatexchangerspassheatfromthe
primary(reactorplant)systemtothesecondary(steam
plant)system,producingsteamfromwaterintheprocess.
Thesearecalledsteamgenerators.Allfossilfueledand
nuclearpowerplantsusingsteamdriventurbineshave
surfacecondenserstoconverttheexhauststeamfromthe
turbinesintocondensate(water)forreuse.
[8][9]
Toconserveenergyandcoolingcapacityinchemicaland
otherplants,regenerativeheatexchangerscantransferheat
fromastreamthatmustbecooledtoanotherstreamthat
mustbeheated,suchasdistillatecoolingandreboilerfeedpreheating.
Thistermcanalsorefertoheatexchangersthatcontainamaterialwithintheirstructurethathasa
changeofphase.Thisisusuallyasolidtoliquidphaseduetothesmallvolumedifferencebetween
thesestates.Thischangeofphaseeffectivelyactsasabufferbecauseitoccursataconstant
temperaturebutstillallowsfortheheatexchangertoacceptadditionalheat.Oneexamplewherethis
hasbeeninvestigatedisforuseinhighpoweraircraftelectronics.
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HeatexchangersfunctioninginmultiphaseflowregimesmaybesubjecttotheLedinegginstability.
Directcontactheatexchangersinvolveheattransferbetweenhotandcoldstreamsoftwophasesin
theabsenceofaseparatingwall.
[10]
Thussuchheatexchangerscanbeclassifiedas:
Gasliquid
Immiscibleliquidliquid
Solidliquidorsolidgas
MostdirectcontactheatexchangersfallundertheGasLiquidcategory,whereheatistransferred
betweenagasandliquidintheformofdrops,filmsorsprays.[2]
Suchtypesofheatexchangersareusedpredominantlyinairconditioning,humidification,industrial
hotwaterheating,watercoolingandcondensingplants.
[11]
Phases
[12]
Continuous
phase
Driving
force
Changeof
phase
Examples
Gas
Liquid
Gas Gravity No Spraycolumns,packedcolumns
Yes
Coolingtowers,fallingdroplet
evaporators
Forced No Spraycoolers/quenchers
Liquidflow Yes
Spraycondensers/evaporation,jet
condensers
Liquid Gravity No Bubblecolumns,perforatedtraycolumns
Yes Bubblecolumncondensers
Forced No Gasspargers
Gasflow Yes
Directcontactevaporators,submerged
combustion
Oneofthewidestusesofheatexchangersisforairconditioningofbuildingsandvehicles.Thisclassof
heatexchangersiscommonlycalledaircoils,orjustcoilsduetotheiroftenserpentineinternaltubing.
Liquidtoair,orairtoliquidHVACcoilsaretypicallyofmodifiedcrossflowarrangement.Invehicles,
heatcoilsareoftencalledheatercores.
Ontheliquidsideoftheseheatexchangers,thecommonfluidsarewater,awaterglycolsolution,
steam,orarefrigerant.Forheatingcoils,hotwaterandsteamarethemostcommon,andthisheated
fluidissuppliedbyboilers,forexample.Forcoolingcoils,chilledwaterandrefrigerantaremost
common.Chilledwaterissuppliedfromachillerthatispotentiallylocatedveryfaraway,but
refrigerantmustcomefromanearbycondensingunit.Whenarefrigerantisused,thecoolingcoilis
theevaporatorinthevaporcompressionrefrigerationcycle.HVACcoilsthatusethisdirectexpansion
ofrefrigerantsarecommonlycalledDXcoils.SomeDXcoilsare"microchannel"type.
[13]
OntheairsideofHVACcoilsasignificantdifferenceexistsbetweenthoseusedforheating,andthose
forcooling.Duetopsychrometrics,airthatiscooledoftenhasmoisturecondensingoutofit,except
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Schematicdrawingofaspiralheat
exchanger.
withextremelydryairflows.Heatingsomeairincreasesthatairflow'scapacitytoholdwater.So
heatingcoilsneednotconsidermoisturecondensationontheirairside,butcoolingcoilsmustbe
adequatelydesignedandselectedtohandletheirparticularlatent(moisture)aswellasthesensible
(cooling)loads.Thewaterthatisremovediscalledcondensate.
Formanyclimates,waterorsteamHVACcoilscanbeexposedtofreezingconditions.Becausewater
expandsuponfreezing,thesesomewhatexpensiveanddifficulttoreplacethinwalledheatexchangers
caneasilybedamagedordestroyedbyjustonefreeze.Assuch,freezeprotectionofcoilsisamajor
concernofHVACdesigners,installers,andoperators.
Theintroductionofindentationsplacedwithintheheatexchangefinscontrolledcondensation,
allowingwatermoleculestoremaininthecooledair.Thisinventionallowedforrefrigerationwithout
icingofthecoolingmechanism.
[14]
Theheatexchangersindirectcombustionfurnaces,typicalinmanyresidences,arenot'coils'.They
are,instead,gastoairheatexchangersthataretypicallymadeofstampedsteelsheetmetal.The
combustionproductspassononesideoftheseheatexchangers,andairtoheatontheother.Acracked
heatexchangeristhereforeadangeroussituationthatrequiresimmediateattentionbecause
combustionproductsmayenterlivingspace.
Aspiralheatexchanger(SHE),mayrefertoahelical(coiled)
tubeconfiguration,moregenerally,thetermreferstoapair
offlatsurfacesthatarecoiledtoformthetwochannelsina
counterflowarrangement.Eachofthetwochannelshasone
longcurvedpath.Apairoffluidportsareconnected
tangentiallytotheouterarmsofthespiral,andaxialports
arecommon,butoptional.
[15]
ThemainadvantageoftheSHEisitshighlyefficientuseof
space.Thisattributeisoftenleveragedandpartially
reallocatedtogainotherimprovementsinperformance,
accordingtowellknowntradeoffsinheatexchangerdesign.
(Anotabletradeoffiscapitalcostvsoperatingcost.)A
compactSHEmaybeusedtohaveasmallerfootprintand
thuslowerallaroundcapitalcosts,oranoversizedSHE
maybeusedtohavelesspressuredrop,lesspumpingenergy,higherthermalefficiency,andlower
energycosts.
Construction
Thedistancebetweenthesheetsinthespiralchannelsaremaintainedbyusingspacerstudsthatwere
weldedpriortorolling.Oncethemainspiralpackhasbeenrolled,alternatetopandbottomedgesare
weldedandeachendclosedbyagasketedflatorconicalcoverboltedtothebody.Thisensuresno
mixingofthetwofluidsoccurs.Anyleakageisfromtheperipherycovertotheatmosphere,ortoa
passagethatcontainsthesamefluid.
[16]
Selfcleaning
SHEsareoftenusedintheheatingoffluidsthatcontainsolidsandthustendtofoultheinsideofthe
heatexchanger.ThelowpressuredropletstheSHEhandlefoulingmoreeasily.TheSHEusesaself
cleaningmechanism,wherebyfouledsurfacescausealocalizedincreaseinfluidvelocity,thus
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Concurrentandcountercurrentflow.
increasingthedrag(orfluidfriction)onthefouledsurface,thushelpingtodislodgetheblockageand
keeptheheatexchangerclean."Theinternalwallsthatmakeuptheheattransfersurfaceareoften
ratherthick,whichmakestheSHEveryrobust,andabletolastalongtimeindemanding
environments."Theyarealsoeasilycleaned,openingoutlikeanovenwhereanybuildupoffoulantcan
beremovedbypressurewashing.
SelfCleaningWaterfiltersareusedtokeepthesystemcleanandrunningwithouttheneedtoshut
downorreplacecartridgesandbags.
Flowarrangements
Therearethreemaintypesofflowsin
aspiralheatexchanger:
CountercurrentFlow:Fluids
flowinoppositedirections.
Theseareusedforliquidliquid,
condensingandgascooling
applications.Unitsareusually
mountedverticallywhen
condensingvapourandmounted
horizontallywhenhandlinghigh
concentrationsofsolids.
1.
SpiralFlow/CrossFlow:One
fluidisinspiralflowandthe
otherinacrossflow.Spiralflowpassagesareweldedateachsideforthistypeofspiralheat
exchanger.Thistypeofflowissuitableforhandlinglowdensitygas,whichpassesthroughthe
crossflow,avoidingpressureloss.Itcanbeusedforliquidliquidapplicationsifoneliquidhasa
considerablygreaterflowratethantheother.
2.
DistributedVapour/Spiralflow:Thisdesignisthatofacondenser,andisusuallymounted
vertically.Itisdesignedtocaterforthesubcoolingofbothcondensateandnoncondensables.
Thecoolantmovesinaspiralandleavesviathetop.Hotgasesthatenterleaveascondensatevia
thebottomoutlet.
3.
Applications
TheSHEisgoodforapplicationssuchaspasteurization,digesterheating,heatrecovery,preheating
(see:recuperator),andeffluentcooling.Forsludgetreatment,SHEsaregenerallysmallerthanother
typesofheatexchangers.
Duetothemanyvariablesinvolved,selectingoptimalheatexchangersischallenging.Hand
calculationsarepossible,butmanyiterationsaretypicallyneeded.Assuch,heatexchangersaremost
oftenselectedviacomputerprograms,eitherbysystemdesigners,whoaretypicallyengineers,orby
equipmentvendors.
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Toselectanappropriateheatexchanger,thesystemdesigners(orequipmentvendors)wouldfirstly
considerthedesignlimitationsforeachheatexchangertype.Thoughcostisoftentheprimary
criterion,severalotherselectioncriteriaareimportant:
High/lowpressurelimits
Thermalperformance
Temperatureranges
Productmix(liquid/liquid,particulatesorhighsolidsliquid)
Pressuredropsacrosstheexchanger
Fluidflowcapacity
Cleanability,maintenanceandrepair
Materialsrequiredforconstruction
Abilityandeaseoffutureexpansion
Materialselection,suchascopper,aluminum,carbonsteel,stainlesssteel,nickelalloys,and
titanium.
Smalldiametercoiltechnologiesarebecomingmorepopularinmodernairconditioningand
refrigerationsystemsbecausetheyhavebetterratesofheattransferthanconventionalsized
condenserandevaporatorcoilswithroundcoppertubesandaluminiumorcopperfinthathavebeen
thestandardintheHVACindustry.Smalldiametercoilscanwithstandthehigherpressuresrequired
bythenewgenerationofenvironmentallyfriendlierrefrigerants.Twosmalldiametercoil
technologiesarecurrentlyavailableforairconditioningandrefrigerationproducts:copper
microgroove
[17]
andbrazedaluminiummicrochannel.
[18]
Choosingtherightheatexchanger(HX)requiressomeknowledgeofthedifferentheatexchanger
types,aswellastheenvironmentwheretheunitmustoperate.Typicallyinthemanufacturing
industry,severaldifferingtypesofheatexchangersareusedforjusttheoneprocessorsystemto
derivethefinalproduct.Forexample,akettleHXforpreheating,adoublepipeHXforthecarrier
fluidandaplateandframeHXforfinalcooling.Withsufficientknowledgeofheatexchangertypesand
operatingrequirements,anappropriateselectioncanbemadetooptimisetheprocess.
[19]
Onlinemonitoringofcommercialheatexchangersisdonebytrackingtheoverallheattransfer
coefficient.Theoverallheattransfercoefficienttendstodeclineovertimeduetofouling.
U=Q/AT
lm
Byperiodicallycalculatingtheoverallheattransfercoefficientfromexchangerflowratesand
temperatures,theowneroftheheatexchangercanestimatewhencleaningtheheatexchangeris
economicallyattractive.
Integrityinspectionofplateandtubularheatexchangercanbetestedinsitubytheconductivityor
heliumgasmethods.Thesemethodsconfirmtheintegrityoftheplatesortubestopreventanycross
contaminationandtheconditionofthegaskets.
MechanicalintegritymonitoringofheatexchangertubesmaybeconductedthroughNondestructive
methodssuchaseddycurrenttesting.
Fouling
HeatexchangerWikipedia,thefreeencyclopedia http://en.wikipedia.org/wiki/Heat_exchanger
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Aheatexchangerinasteampower
stationcontaminatedwithmacrofouling.
Foulingoccurswhenimpuritiesdepositontheheat
exchangesurface.Depositionoftheseimpuritiescan
decreaseheattransfereffectivenesssignificantlyovertime
andarecausedby:
Lowwallshearstress
Lowfluidvelocities
Highfluidvelocities
Reactionproductsolidprecipitation
Precipitationofdissolvedimpuritiesduetoelevated
walltemperatures
Therateofheatexchangerfoulingisdeterminedbytherate
ofparticledepositionlessreentrainment/suppression.This
modelwasoriginallyproposedin1959byKernandSeaton.
CrudeOilExchangerFouling.Incommercialcrudeoilrefining,crudeoilisheatedfrom21Cto
343Cpriortoenteringthedistillationcolumn.Aseriesofshellandtubeheatexchangerstypically
exchangeheatbetweencrudeoilandotheroilstreamstoheatthecrudeto260Cpriortoheatingina
furnace.Foulingoccursonthecrudesideoftheseexchangersduetoasphalteneinsolubility.The
natureofasphaltenesolubilityincrudeoilwassuccessfullymodeledbyWieheandKennedy.
[20]
The
precipitationofinsolubleasphaltenesincrudepreheattrainshasbeensuccessfullymodeledasafirst
orderreactionbyEbertandPanchal
[21]
whoexpandedontheworkofKernandSeaton.
CoolingWaterFouling.Coolingwatersystemsaresusceptibletofouling.Coolingwatertypicallyhas
ahightotaldissolvedsolidscontentandsuspendedcolloidalsolids.Localizedprecipitationof
dissolvedsolidsoccursattheheatexchangesurfaceduetowalltemperatureshigherthanbulkfluid
temperature.Lowfluidvelocities(lessthan3ft/s)allowsuspendedsolidstosettleontheheat
exchangesurface.Coolingwateristypicallyonthetubesideofashellandtubeexchangerbecauseit's
easytoclean.Topreventfouling,designerstypicallyensurethatcoolingwatervelocityisgreaterthan
0.9m/sandbulkfluidtemperatureismaintainedlessthan60C.Otherapproachestocontrolfouling
controlcombinetheblindapplicationofbiocidesandantiscalechemicalswithperiodiclabtesting.
Maintenance
Plateheatexchangersmustbedisassembledandcleanedperiodically.Tubularheatexchangerscanbe
cleanedbysuchmethodsasacidcleaning,sandblasting,highpressurewaterjet,bulletcleaning,or
drillrods.
Inlargescalecoolingwatersystemsforheatexchangers,watertreatmentsuchaspurification,
additionofchemicals,andtesting,isusedtominimizefoulingoftheheatexchangeequipment.Other
watertreatmentisalsousedinsteamsystemsforpowerplants,etc.tominimizefoulingandcorrosion
oftheheatexchangeandotherequipment.
Avarietyofcompanieshavestartedusingwaterborneoscillationstechnologytopreventbiofouling.
Withouttheuseofchemicals,thistypeoftechnologyhashelpedinprovidingalowpressuredropin
heatexchangers.
Humans
HeatexchangerWikipedia,thefreeencyclopedia http://en.wikipedia.org/wiki/Heat_exchanger
12of19 8/29/20143:20PM
Countercurrentexchangeconservationcircuit
Thehumannasalpassagesserveasaheatexchanger,whichwarmsairbeinginhaledandcoolsair
beingexhaled.Itseffectivenesscanbedemonstratedbyputtingthehandinfrontofthefaceand
exhaling,firstthroughthenoseandthenthroughthemouth.Airexhaledthroughthenoseis
substantiallycooler.
[22][23]
Inspeciesthathaveexternaltestes(suchashumans),thearterytothetestisissurroundedbyamesh
ofveinscalledthepampiniformplexus.Thiscoolsthebloodheadingtothetestis,whilereheatingthe
returningblood.
Birds,fish,marinemammals
"Countercurrent"heatexchangersoccurnaturallyin
thecirculationsystemoffish,whalesandother
marinemammals.Arteriestotheskincarryingwarm
bloodareintertwinedwithveinsfromtheskin
carryingcoldblood,causingthewarmarterialblood
toexchangeheatwiththecoldvenousblood.This
reducestheoverallheatlossincoldwaters.Heat
exchangersarealsopresentinthetongueofbaleen
whalesaslargevolumesofwaterflowthroughtheir
mouths.
[24][25]
Wadingbirdsuseasimilarsystemtolimitheatlossesfromtheirbodythroughtheir
legsintothewater.
Carotidrete
Thecarotidreteisacountercurrentheatexchangingorganinsomeungulates.Thebloodascending
thecarotidarteriesonitswaytothebrain,flowsviaanetworkofvesselswhereheatisdischargedto
theveinsofcoolerblooddescendingfromthenasalpassages.ThecarotidreteallowsThomson's
gazelletomaintainitsbrainalmost3Ccoolerthantherestofthebody,andthereforeaidsin
toleratingburstsinmetabolicheatproductionsuchasassociatedwithoutrunningcheetahs(during
whichthebodytemperatureexceedsthemaximumtemperatureatwhichthebraincould
function).
[26]
Heatexchangersarewidelyusedinindustrybothforcoolingandheatinglargescaleindustrial
processes.Thetypeandsizeofheatexchangerusedcanbetailoredtosuitaprocessdependingonthe
typeoffluid,itsphase,temperature,density,viscosity,pressures,chemicalcompositionandvarious
otherthermodynamicproperties.
Inmanyindustrialprocessesthereiswasteofenergyoraheatstreamthatisbeingexhausted,heat
exchangerscanbeusedtorecoverthisheatandputittousebyheatingadifferentstreaminthe
process.Thispracticesavesalotofmoneyinindustry,astheheatsuppliedtootherstreamsfromthe
heatexchangerswouldotherwisecomefromanexternalsourcethatismoreexpensiveandmore
harmfultotheenvironment.
Heatexchangersareusedinmanyindustries,including:
Wastewatertreatment
Refrigeration
Wineandbeermaking
HeatexchangerWikipedia,thefreeencyclopedia http://en.wikipedia.org/wiki/Heat_exchanger
13of19 8/29/20143:20PM
Petroleumrefining
Inwastewatertreatment,heatexchangersplayavitalroleinmaintainingoptimaltemperatures
withinanaerobicdigesterstopromotethegrowthofmicrobesthatremovepollutants.Commontypes
ofheatexchangersusedinthisapplicationarethedoublepipeheatexchangeraswellastheplateand
frameheatexchanger.
Incommercialaircraftheatexchangersareusedtotakeheatfromtheengine'soilsystemtoheatcold
fuel.
[27]
Thisimprovesfuelefficiency,aswellasreducesthepossibilityofwaterentrappedinthefuel
freezingincomponents.
[28]
Early2008,aBoeing777flyingasBritishAirwaysFlight38crashedjustshortoftherunway.Inan
early2009Boeingupdatesenttoaircraftoperators,theproblemwasidentifiedasspecifictothe
RollsRoyceengineoilfuelflowheatexchangers.
[28]
Otherheatexchangers,orBoeing777aircraft
poweredbyGEorPrattandWhitneyengines,werenotaffectedbytheproblem.
[28]
EstimatedatUS$42.7billionin2012,theglobaldemandofheatexchangerswillexperiencerobust
growthofabout7.8%annuallyoverthenextyears.ThemarketvalueisexpectedtoreachUS$57.9
billionby2016andtoapproachUS$78.16billionby2020.Tubularheatexchangersandplateheat
exchangersarestillthemostwidelyappliedproducttypes.
[29]
Asimpleheatexchanger
[30]
mightbethoughtofastwostraightpipeswithfluidflow,whichare
thermallyconnected.LetthepipesbeofequallengthL,carryingfluidswithheatcapacity (energy
perunitmassperunitchangeintemperature)andletthemassflowrateofthefluidsthroughthe
pipesbe (massperunittime),wherethesubscriptiappliestopipe1orpipe2.
Temperatureprofilesforthepipesare and wherexisthedistancealongthepipe.
Assumeasteadystate,sothatthetemperatureprofilesarenotfunctionsoftime.Assumealsothatthe
onlytransferofheatfromasmallvolumeoffluidinonepipeistothefluidelementintheotherpipeat
thesameposition.Thereisnotransferofheatalongapipeduetotemperaturedifferencesinthatpipe.
ByNewton'slawofcoolingtherateofchangeinenergyofasmallvolumeoffluidisproportionalto
thedifferenceintemperaturesbetweenitandthecorrespondingelementintheotherpipe:
where isthethermalenergyperunitlengthandisthethermalconnectionconstantperunit
lengthbetweenthetwopipes.Thischangeininternalenergyresultsinachangeinthetemperatureof
thefluidelement.Thetimerateofchangeforthefluidelementbeingcarriedalongbytheflowis:
HeatexchangerWikipedia,thefreeencyclopedia http://en.wikipedia.org/wiki/Heat_exchanger
14of19 8/29/20143:20PM
where isthe"thermalmassflowrate".Thedifferentialequationsgoverningtheheat
exchangermaynowbewrittenas:
Notethat,sincethesystemisinasteadystate,therearenopartialderivativesoftemperaturewith
respecttotime,andsincethereisnoheattransferalongthepipe,therearenosecondderivativesinx
asisfoundintheheatequation.Thesetwocoupledfirstorderdifferentialequationsmaybesolvedto
yield:
where , , andAandBaretwoasyetundeterminedconstantsof
integration.Let and bethetemperaturesatx=0andlet and bethetemperaturesat
theendofthepipeatx=L.Definetheaveragetemperaturesineachpipeas:
Usingthesolutionsabove,thesetemperaturesare:

Choosinganytwoofthetemperaturesaboveeliminatestheconstantsofintegration,lettingusfindthe
otherfourtemperatures.Wefindthetotalenergytransferredbyintegratingtheexpressionsforthe
timerateofchangeofinternalenergyperunitlength:
Bytheconservationofenergy,thesumofthetwoenergiesiszero.Thequantity isknownas
HeatexchangerWikipedia,thefreeencyclopedia http://en.wikipedia.org/wiki/Heat_exchanger
15of19 8/29/20143:20PM
theLogmeantemperaturedifference,andisameasureoftheeffectivenessoftheheatexchangerin
transferringheatenergy.
Architecturalengineering
Chemicalengineering
Coolingtower
Copperinheatexchangers
Heatpipe
Heatpump
Heatrecoveryventilation
Jacketedvessel
Logmeantemperaturedifference(LMTD)
Mechanicalengineering
Microheatexchanger
Movingbedheatexchanger
PackedbedandinparticularPackedcolumns
Pumpableicetechnology
Reboiler
Recuperator,orcrossplateheatexchanger
Regenerator
Runaroundcoil
Steamgenerator(nuclearpower)
Surfacecondenser
Toroidalexpansionjoint
Thermosiphon
Thermalwheel,orrotaryheatexchanger(includingenthalpywheelanddesiccantwheel)
Wasteheat
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heatexchanger.html)AirCooledHeatExchanger
Retrievedfrom"http://en.wikipedia.org/w/index.php?title=Heat_exchanger&oldid=622000992"
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