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    Heat Exchanger Design (Theory)

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    Iqra Mubeen
    Heat exchangers transfer thermal energy between two or more fluids at different temperatures. They are classified based on their transfer process (direct or indirect contact), geometry (tubes, plates, extended surfaces), heat transfer mechanism (single or two phase flow), and flow arrangement (parallel, counter, cross flow). Common types include shell and tube heat exchangers, which are further classified by construction details like tube sheets and shell/head configurations. Selection depends on required heat transfer rate and factors like cost, size, pumping power, and materials.

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    Heat Exchanger Design (Theory)

    Uploaded by

    Iqra Mubeen
    46 views20 pages
    Heat exchangers transfer thermal energy between two or more fluids at different temperatures. They are classified based on their transfer process (direct or indirect contact), geometry (tubes, plates, extended surfaces), heat transfer mechanism (single or two phase flow), and flow arrangement (parallel, counter, cross flow). Common types include shell and tube heat exchangers, which are further classified by construction details like tube sheets and shell/head configurations. Selection depends on required heat transfer rate and factors like cost, size, pumping power, and materials.

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    heat exchanger design(theory)

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    Heat exchangers transfer thermal energy between two or more fluids at different temperatures. They are classified based on their transfer process (direct or indirect contact), geometry (tubes, plates, extended surfaces), heat transfer mechanism (single or two phase flow), and flow arrangement (parallel, counter, cross flow). Common types include shell and tube heat exchangers, which are further classified by construction details like tube sheets and shell/head configurations. Selection depends on required heat transfer rate and factors like cost, size, pumping power, and materials.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    46 views20 pages

    Heat Exchanger Design (Theory)

    Uploaded by

    Iqra Mubeen
    Heat exchangers transfer thermal energy between two or more fluids at different temperatures. They are classified based on their transfer process (direct or indirect contact), geometry (tubes, plates, extended surfaces), heat transfer mechanism (single or two phase flow), and flow arrangement (parallel, counter, cross flow). Common types include shell and tube heat exchangers, which are further classified by construction details like tube sheets and shell/head configurations. Selection depends on required heat transfer rate and factors like cost, size, pumping power, and materials.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 20

    Heat Exchangers:

    Heat exchangers are devices that provide the flow of thermal


    energy between 2 or more fluids at different temperatures.
    They are used in a wide variety of applications. These include
    power production, process, chemical, food and manufacturing
    industries, electronics, environmental engg. , waste heat
    recovery, air conditioning applications.
    Heat Exchangers may be classified according to the following criteria.
    •Recuperators/ regenerators
    •Transfer process: direct and indirect contact
    •Geometry of construction; tubes, plates, and extended
    surfaces.
    •Heat transfer mechanism: single phase and two phase
    •Flow arrangement: Parallel, counter, cross flow.
    Heat Exchanger Classification
     Recuperative:
    Cold and hot fluid flow through the unit
    without mixing with each other. The transfer
    of heat occurs through the metal wall.
     Regenerative
    Same heating surface is alternately exposed
    to hot and cold fluid. Heat from hot fluid is
    stored by packings or solids; this heat is
    passed over to the cold fluid.
     Direct Contact
    Hot and cold fluids are in direct contact and
    mixing occurs among them; mass transfer
    and heat transfer occur simultaneously.
    CLASSIFICATION OF HEAT
    EXCHANGER
    Based on process function:

    • COOLER – Cools using water or air, without phase change.


    • CHILLER – Refrigerates below that obtainable with water.
    • CONDENSER – Condenses vapour/ vapour mixture.
    • STEAM HEATER – Uses steam for heating.
    • STEAM GENERATOR – Produces steam from water.
    • REBOILER – Uses steam/hot fluid to heat, for distillation
    column.
    Some common heat-exchanger
    terms
     Tube side: Inside the tubes.
     Shell side: Outside the tubes, between the tubes
    and the shell.
     Tube sheet A thick plate provided with holes
    (one per tube) in which the tubes are fixed.
     Tube bundle Consists of tubes, tube sheet and
    baffle plates
     Shell A cylinder of plate in which the tube bundle
    is placed
    Types of Shell and Tube HEAT EXCHANGERS
    Types of shell and tube type heat exchanger most commonly used in
    refinery and petrochemicals :

    1. U-TUBE Exchanger –

    • Tube Expansion independent of other tubes.


    • Tubes difficult to clean.
    2. FIXED TUBE SHEET EXCHANGER –

    • Cheapest and most economical.


    3. FLOATING HEAT EXCHANGER –

    • Permits free expansion/contraction.


    • Easy to clean.
    4. REBOILER/ KETTLE TYPE EXCHANGER

    • Can handle large fluctuation of loads.


    TEMA Standards:

     R C B Fundamental classes -
    • Class R – Used for severe requirement of
    petroleum related processing applications.
    • Class C – Used for moderate requirements of
    commercial and process applications.
    • Class B – Used for chemical process service.

     TEMA designations for shell and tube heat


    exchanger -
    • STATIONARY HEAD TYPES – A,B,C,D
    • SHELL TYPES – E,F,G,H,J,K
    • REAR HEAD TYPES – L,M,N,P,S,T,U
    Air-cooled exchanger
     Air blown across finned tubes (forced
    draught type)
     Can suck air across (induced draught)

    Finned tubes
    Spiral Heat Exchangers
     Spiral heat exchangers can be used in most applications in the
    chemical process industry
     In many difficult applications where fouling and plugging are
    problems, a standard shell and tube design may not be
    effective
     While a spiral heat exchanger often has a higher initial cost, it
    may provide a lower life cycle cost due to lower fouling rates
    and ease of maintenance
     A spiral heat exchanger is composed
    of two long, flat plates wrapped
    around a mandrel or center tube,
    creating two concentric spiral
    channels
     In a spiral heat exchanger, the hot
    fluid flows into the center of the unit
    and spirals outward toward the outer
    plates while at the same time, the cold
    fluid enters the periphery and spiral
    inward, exiting at the center
    Selection of Heat Exchangers
    • The selection depends on several factors:
    – heat transfer rate
    – cost
    • procurement, maintenance, and power.
    – pumping power,
    – size and weight,
    – Type,
    – Materials,
    – miscellaneous (leak-tight, safety and reliability, Quietness).
    Design of Shell and Tube Heat
    Exchangers
     Kern method:
     Does not take into account bypass and leakage streams.
     Simple to apply and accurate enough for preliminary design
    calculations.
     Restricted to a fixed baffle cut (25%).

     Bell-Delaware method
     Most widely used.
     Takes into account:
     Leakage through the gaps between tubes and baffles and the
    baffles and shell.
     Bypassing of flow around the gap between tube bundle and
    shell.
    Fluid Allocation

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