Professional Documents
Culture Documents
PED 5 Heat Exchangers
PED 5 Heat Exchangers
PED 5 Heat Exchangers
Design
5. Heat Exchangers
http://fsinet.fsid.cvut.cz/cz/U218/peoples/hoffman/index.htm
e-mail: pavel.hoffman@fs.cvut.cz
Tubular heat exchangers (HE)
Steps of HE design (more see exercises)
t11
Symbol of HE and
t12
definition of flows t22
M2, t22 t21
parallel flow
Q1 = Q2 = Q (exactly Q1 = Q2 + ∆QL)
Q1 = M1 * c1 * (t11 – t12) heat removed from hot fluid
Q2 = M2 * c2 * (t21 – t22) heat transferred to cool fluid
PDE-5 4
2. Hydrodynamic calculations
For optimal fluid speeds wopt we can calculate (estimate) a total
cross-sectional area (clear area) of flows (they depend on
pressure loss ΔpLmax1,2)
f dTe
f1 = V1 / w1opt and f2 = V2 / w2opt f dTi
where is V1 = M1 / ρ1 and V2 = M2 / ρ2 s
nTT A / (π*dTø*LT)
Number of passes in the HE (for fluid flows in tubes)
PDE-5 6
3. Estimation of basic size
t ≥ 1,2 * dTe
t
PDE-5 7
4. Strength calculations
• According standards we can specify or check tube wall
thickness, shell wall thickness and tube plate thickness.
PDE-5 8
Výměník tepla s pevnými trubkovnicemi Výměník tepla s kompenzátorem v plášti
HE with fixed plates HE with bellows expansive joint in shell
p1
p2 p1
p2
p1
Výměník tepla s vlásenkovými trubkami
p2
HE with „hair tubes“
p1
p2 Příklady výměníků tepla a jejich
konstrukčního řešení podle ČSN 690010
Examples of Hes and their design
PDE-5 9
Výměník tepla s pevnými trubkovnicemi, přepážkami v mezitrubkovém
prostoru a dvěma tahy v trubkách
HE with fixed tube-plates and baffles in inter mediate tube space and 2 passes in tubes
1 9 3 5 6 4 7 8
3 2 9
PDE-5 10
Trubkový výměník s plovoucí hlavou
HE with floating head and 2 passes
1 9 10 3 5 6 4 7 8
Dilatace
3 2 9 Dilatation
Vlnovcový kompenzátor
Bellows expansion joint
Ucpávkový kompenzátor
Expansion point with packing
PDE-5 12
Trubkový výměník s U trubkami
HE with „hair pin“ tubes
Deflegmátor
Deflection plate (baffle)
Dilatace
Dillatation
PDE-5 13
Různé typy výměníků tepla, vík a trubkovnic, hrdel a přepážek Typy spoje trubkovnice s pláštěm
Various type of HE, heads and tube-plates, necks and baffles Type of joints of tube plate and
shell
ξ=1,7 ξ=1,2
ξ=1,2 ξ=2,2 ξ=2,5
t
t
lR=Min[0,5.l1;Max(0,7.l1; l2)]
Stupňovitý otvor
Two diameters of hole Trubkovnice vevařená do pláště nebo příruby
Tube plate welded in shell or flange
Drážka v trubkovnici
Groove in tube plate
pro sp > lmax
lmax~ 45mm
pro zaválcování
for beading
PDE-5 15
Rozměry oválu vepsaného do největší neotrubkované plochy
Dimensions of oval inscribed in the biggest area Pevná trubkovnice výměníků s plovoucí hlavou, vlásenkovými
trubkami nebo s ucpávkou, sevřená mezi přírubami
without tubes
Fix tube plate gripped between two flanges
PDE-5 16
Plovoucí hlava se zámkem Floating Geometrie vlny kompenzátoru
head with on „lock“ flange Geometry of flexible bellows wave
Nedoporučuje se
Not recommended
PDE-5 17
Odparka na zahušťování roztoku NaOH
Evaporator for concentration of NaOH solution
Brýdy
Odparka: 36 TR 33,4x2,77-2500 – Nikl Vapour
Evaporator : 36 tubes from nickel
400kg/h
Nekond. plyny 0,1MPa Odlučovač
Inerts DN120 Vapour-liquid separator
DN15
Trubková odparka
Tubular evaporator
Pára
Steam
Nosná konstrukce
188°C; 1,2MPa
Supporting structure
DN50
Vlnový kompenzátor
Bellows expansion joint
Recirkulace čištění
42% NaOH Recirc. for chem.cleaning
DN25
2080kg/h; DN40 DN40
kondens.
Pozn.: Viz příklad o plátovaných ocelích. See example with cladded steel
PDE-5 18
Tube arrangement in tube plate
30° 45°
60° 90°
t
t t
t t t t t
t fT1t
t
PDE-5 21
Tube plate area that is equivalent to 1 tube (pitch of tubes is t).
fT1t = t2 * √3 / 2 fT1t = t2
Tubes minimal plate area = minimal shell internal area
*D 2
ATtot nTtot * fT 1t Acutout i
4
Shell internal diameter
ATtot nTtot * fT 1t Acutout
Di 2 * 2*
For tube plate totally full of tubes (without any cutout against
inlet etc.) is
nTtot * fT 1t
Di 2 *
22
PDE-5
nTtot nTtot
Di 2 * t * Di 2 * t *
*1,15 *1,00
nTtot
Di 2 * t *
*
Θ = 1,15 Θ = 1,00
PDE-5 23
Example:
Area of central circulation tube (φ 600 mm) is ACCT = 282 600 mm2;
area of cutout for steam inlet is Acut = 120 000 mm2.
PDE-5 24
tubes bundle
PDE-5 25
Total minimal area of tube plate
3
ATtot nTtot *t * 2
ACCT Acutout
2
3
ATtot 1250 * 48 *2
282600 120000 2896753 mm 2
2
PDE-5 26
Connection of tubes with tube plate
Beading (tubes expanding)
in smooth holes in holes with small grooves in holes with grooves
Ød Ød Ød
Ød´1 a Ød´1 a Ød´1 a
s1
s l s l
s l
0,5÷0,7
~0,3
for p ≤ 3 MPa
~0,3
3÷6
• Beading principle is that expanded tube has plastic deformations but tube
plate elastic. So the tube plate compresses tubes.
PDE-5 28
Tubes welding
• It has very good tightness, it can be used for temperatures > 300 °C.
• Disadvantage is that in case of need a change of corroded tube is its
removal difficult (weld must be grinded away).
Examples of welds types:
Ød 1,2·sT
1,5·sT 1,5·sT sT ~sT
2 ≥1,5·sT
s s
2 2
30° 30° sT
sT sT
Ød1 Ød1
Ød2 Ød2
Ød
external fillet weld ½ V + koutový svar p front butt weld with groove
sT = 2 – 4 mm for sT ≥ 4 mm sT ≤ 2 - 3 mm + for Al always
PDE-5 29
Combined joints
• Tubes are beaded and than welded.
• The joint is used if there are requirements for very high
strength and tightness. It is reliable for dynamic loading
(stress) of HE.
expanding cone
tube
tightness check-up
More baffles:
tp=(0,2÷1,0)D
P1=P3
bottom
hp=(0,6÷0,8)D
ØD P1 P3
P2
Baffles shape and location, neck location etc. depend on a type of fluid and HE (e.g.
moisture condensation from gas.
These baffles are very often used in HE (all baffles are the same, simple design).
PDE-5 34
Double segments baffles
(P1, P2)
P1 P2
P2
P1
P1
P2
PDE-5 35
Ring and disc shape Baffles of shape of turned
segments (baffles) (P1, P2) sectors of a circle
P2
P1
PDE-5 36
Spiral baffles
(continuous or from segments)
Longitudinal baffles
PDE-5 37
Passes in HE = flow inside tubes
Multi pass arrangement makes possible to choose a proper fluid
speed in tubes and thus optimization of a HE design (optimal
relation between heat passage coefficient (coefficient of heat
transfer) and pressure loss).
Single pass HE
inlet outlet
chamber (head, bottom)
PDE-5 38
Two passes HE
přepážka
inlet/outlet back
baffle in the front chamber
chamber (cover)
(inlet/outlet)
Four passes HE
baffle
PDE-5 39
Twelve passes HE
PDE-5 40
Examples of tubular heat exchangers
PDE-5 41
baffles separating
passes
Zahřívače šťávy
(12-ti chodé)
Juice heaters
(12 passes)
PDE-5 42
Tříchodý trubkový výměník Tubular HE with 3 passes
(každý chod po 11 trubkách) (every pass with 11 tubes)
baffle with
sealing
flange with
flat cover of sealing
back chamber
PDE-5 43
Upper cover Steam inlet
Connecting bar
Condensate
Bottom outlet
tubeplate
Bottom cover
Lower chamber
Condensate outlet
Steam neck
Juice necks
Condensate outlet
PDE-5 44
Sketch of juice heater
Baffles in chambers have various shape (line, arc ..) → optimal tube plate design
and space utilization (in the place where are baffles are not tubes), optimal flow,
easy production and cleaning, good tightness ....
In sugar industry HE with number of passes on juice side from 6 to 12 are used.
Examples of baffles sealing
sealing
HE cover
baffle
• For multi passes HE flat heads (covers) are often used with stiffening ribs (see
exercises) owing to easier design, manufacturing and maintenance.
• Baffles can be welded to tube plate and sealed on a flat cover (usual) or welded to
cover (dished) and sealed on tube plate.
45
PDE-5
Inlet and outlet necks
• Necks cross sections are determined by speed of flow and
depends on its density, pressure loss, droplets or particle
contents (abrasion), HE design etc.
• Speeds are chosen individually.
Ex.:
• Mixture state on a boundary line: 105 °C, 120,8 kPa
• Condensate specific volume is 0,001047 m3/kg
• Specific volume of arisen vapour is 1,419 m3/kg → 1355 krát větší
PDE-5 48
Tubes protection against of dynamic effect of
entering fluid
If the incoming fluid has too high speed it causes vibration of
tubes that are in front of the inlet (wake wortexes – see later),
or their abrasion → danger of theor rupture.
PDE-5 49
Examples of inlet necks design
cutout in bundle
baffle (deflector)
cutout in tube
bundle
+ baffle
PDE-5 50
Annulus around inlet and slots in inner shell
distributing annulus
PDE-5 51
HE supporting
Horizontal HEs are usually on saddle supports or footings,
vertical HEs are on footings (foots) - more later.
PDE-5 52
Tube plates
Welded in shell Welded in flange
tube plate
sp
sP
flange
shell
shell
ØdT
sK ØDK
ØDK
PDE-5 53
Locked between two Floating tube plate
flanges (cover and shell) (it is used for high thermal
dilatations)
cover flange flange of floating cover
sealing
tube plate
shell flange
floating tube plate
PDE-5 54
For high thermal dilatations HEs with U shape tubes are used too
(hairpin tubes).
• Advantage:
It is possible to take out the tube bundle from a shell.
• Disadvantage:
Problematic cleaning of tubes inside (only by a chemical way
but not mechanically).
PDE-5 55
Other way how to solve problems with dilatations is installation
of a compensator in a HE shell
PDE-5 56
Jacketed kettles – shell heating or cooling
(examples according ČSN)
Nádoby s úplným duplikátorovým pláštěm Nádoby s válcovým duplikátorovým pláštěm
Vessels with total jacketed kettle Vessels with cylindrical jacketed kettle
1) 2) 1) 2)
PDE-5 58
Spojení duplikátorového pláště s nádobou deskovým
Nádoby s kanály a registrem přechodem
Vessels with channels and input/output wall tubes Joint of jacked kettle and vessel shell with conical transition
PDE-5 59
Spojení duplikátorového pláště s nádobou trubkovými rozpěrkami
Joint of jacketed kettle and vessel shell with spacers
Kanály
Channels
PDE-5 60
Supporting elements of pressure vessels, apparatuses and HEs
They are used for mounting of vessels etc., their settlement on a given place
(basement, supporting structure etc.).
s1
Ød1
e
F s Ø DR
61
PDE-5
Other supporting elements are lifting eyes (see next page).
Examples of saddle supports, footings, and supporting foots
are on following pages.
PDE-5 62
Nosná oka Válcová skořepina s výztužným prstencem
Lifting eyes Cylindrical shell with reinforcing ring
(pokud pevnostně nevyhovuje tloušťka pláště)
Axiální
Radiální
A Welded footing
with or without
supporting
plate
B
Bended footing
C with or without
sup. plate
Welded footing
to I profile
Supporting plate
Supporting plate Saddle support
Foundation
(concrete) PDE-5 64
Opěrné nohy Válcová skořepina vyztužená prstenci
Supporting foots Cylindrical shell with reinforcing rings
PDE-5 65
Nosná oka Lifting eyes
PDE-5 66
PDE-5 67
Podpěrné nohy Supporting foots
PDE-5 68
Cylindrical vessel support with manhole („skirt“)
PDE-5 69
Alfa Laval has the widest range of compact heat
exchangers:
Brazed
PDE-5 70
Rekuperace tepla Heat recovery
Deskový Spirálový
výměník výměník tepla
tepla Spiral HE
Plate HE
AlfaRex
Compabloc celosvařovaný
výměník tepla výměník tepla
Compabloc HE Full welded HE
PDE-5 71
Prostorové nároky deskového a trubkového
výměníku o stejném výkonu
prostor pro montáž
trubkového svazku
PDE-5 72
Spirálový výměník tepla Spiral heat exchanger
(výhodný pro kaly a jiné (useful for sludge and other
kapaliny obsahující částice) liquids containing particles)
Teplota (°C)
-50 160 350 400
Temperature
PDE-5 74