Outline

 Heat Exchanger:
Heat exchanger is an equipment, which
effects the transfer of heat from one fluid to
another through metal walls.

 Types of heat exchanger:

 Based on service
 Based on construction
 Types of Exchangers Based on Service
Exchanger:
 It is a unit that exchanges heat between two process streams without phase
change; i.e. liquids are not evaporated nor condensed.
 Examples: LAB - EA213, EA161

Cooler:
 Cools the process fluids without phase change.
 Examples: All cooling water exchangers in plants LAB - EA305- Reaction
cooler, PX -E1009, E8073 .

Condenser:
 Condenses process vapor stream.
 Examples: Some of the Fin fan Cooler LAB - EC401, PX-E1033

Re-boiler:
 Provides latent heat of vaporization to bottom of distillation / fractionation
column.
 Examples:
 LAB - EA405 Rerun column reboiler & PX –E1035 Stripper column reboiler

Pre-heater:
 Uses steam or hot process stream to heat & or vaporize the feed to
processing unit.
 Air Pre-heater of fired heaters. APH of PX-D5001, LAB-BA801,
Types of Exchangers Based on Construction:
Tubular heat exchanger:
 U tube type heat exchanger

 Fixed tubesheet heat exchanger

 Floating head type heat exchanger

 Hair pin type

 Pipe in pipe heat exchanger

 Fin fan type exchanger

Plate type heat exchanger

Spiral plate type heat exchanger

Major Parts of shell & tube heat exchanger:
Shellside
Flow In Nozzle
Tubeside
Flow Out
Shell
Channel

Baffles
Tube Bundle

Tube Sheet
Shellside
Flow Out

Tubeside
Flow In
 Exch. Major Parts & Generally used MOC
 Shell:
 Carbon steel (CS), Stainless steel (SS), Titanium, Carbon steel cladded
with SS, Titanium or Monel

 Channel:
 Generally similar to tube MOC.
 Carbon steel (CS) , Stainless steel (SS), Titanium, Carbon steel
cladded with SS, Titanium or Monel

 Tube sheet:
 Carbon steel (CS), Stainless steel (SS), Titanium , Carbon steel cladded
with SS, Titanium or Monel

 Tubes:
 Carbon steel (CS), Stainless steel (SS), Admiralty Brass, Titanium (Ti) ,
Monel

 Tubes are available in different diameters. Commonly used OD:

 3/8" - 9.5 mm 5/8” – 16 mm, ¾” - 19.05 mm, 1” – 25.4 mm, 2” –
50.8 mm
 Exch. Major Parts & Generally used MOC
 Gasket:
 CAF (Asbestos), Iron jacketed gasket with Asbestos
 Spiral wound gasket ( SS, Monel, Titanium filled with PTFE, Grafoil,
Asbestos)
 Solid flat metal : Soft Iron, Aluminum, Copper, Brass, Monel, SS
 O rings,

 Baffles:
 Types of baffles:
 Segmental baffle , Strip baffle, Disc and doughnut baffle, Orifice
baffle , Longitudinal baffle

 Tie Rods & Spacer Tubes:

 MOC of baffles, tie rods, spacer tubes are similar to tube MOC or shell
MOC.

 Tube Pattern, Pitch: Triangular, Square

 Tube to tubesheet Joints: Welded with light expansion, Expanded,

expanded with seal welded.
 Selection Of Heat Exchanger:
 It must meet the process requirements
 It must withstand the service condition
 It must be maintainable.
 Exchanger Cost
 Capital cost of installation
 Area occupied by the equipment
 Availability and cost of water
 Pressure drop
Significance of Different Types of Heat Exch.
U Tube:
 Only one tube sheet required, tube bends in U shape,
Bundle is removable

Application Best Suited:

 High temperature difference on shell & tube side

 Clean service on tube side

Limitations:
 Higher tube side velocities can cause erosion on tube
ends
 Fouling / subsequent cleaning problem
Significance of Different Types of Heat Exch.

Floating Head Type:

 One tubesheet floats in shell and bundle may be

removable from shell, back cover can be removed to

expose tube ends.

Application Best Suited:

 High temperature difference on shell & tube side

 Cleaning possible with floating end cover

Limitations:
 Internal gasket offer danger of leakage

 Only horizontal units

Significance of Different Types of Heat Exch.
Fixed Tube sheet Exchanger:
 Both tubesheet fixed to shell.

Application Best Suited:

 For cleaner fluid on shell side

 Low cost

Limitations:
 Temp. difference on shell side & tube side should be less

than 93 deg c.
Significance of Different Types of Heat Exch.
Hair Pin Type Exchanger:
 Extended surface due to longitudinal finning. Tube
bundle can be removed from shell for cleaning.

Application Best Suited:

 Smaller transfer area required

 Suitable for higher pressure requirement

 Low space

Limitations:
 Smaller capacity
Significance of Different Types of Heat Exch.
Plate Type Heat Exchanger
 Composed of metal formed thin plates separated by
gasket.

Application Best Suited:

 1/3 to 1/2 area required compared to shell & tube type -
Compact design
 Higher efficiency - Higher surface area

Limitations:
 Temperature / pressure limitation due to gasket (Temp
limitation max 300 deg C).
 Cleaner fluid requirement
Significance of Different Types of Heat Exch.
Spiral Plate Type Heat Exchanger
 Concentric plates, no bypassing , higher turbulence.

Application Best Suited:

 Improved overall heat transfer coeff. - curved flow

 Scrubbing effect due to spiral passage - fouling factor 1/3 of

shell & tube
 Thermal insulation is not required.

Limitations:
 Process corrosion

 Suspended materials

 Low capacity

 Difficulty in fabrication
 Applicable Codes & Standards:
 ASME SEC VIII Rules for Construction of
D1/D2 Pressure Vessels

 TEMA Standards of the Tubular

Exchanger Manufacturer's Association

 API 660 Shell and Tube Heat Exchangers

for General Refinery Services

 API 661 Air-Cooled Heat Exchangers

for General Refinery Service
 TEMA Classifications
TEMA Class Application Example
_______________________________________________________________________________________________________________________________

_ R Severe environments Refineries

C Moderate service Building

services,
commercial,
and general
process
industries

B Chemical process Chemical

manufacturing
TEMA Types
Significance of Different Types of Heat Exch.
Fin Fan Cooler
 No shell required, Header ends similar shell & tube type.

Application Best Suited:

 High level of heat removal is required
 Where cooling water not available.
 Where ambient temp is low

Limitations:
 Problem of frequent fouling and corrosion.
 Higher investment
 4 to 10 times more ground space in shell & tube type
 Air-Cooled Heat Exchangers
 Forced-draft
 Air forced across tube bundle by fan located in air
plenum below bundle. (Fin fan coolers)

 Induced-Draft
 Fan located above hood covering tube bundle.
 Air pulled across tube bundle and exhausted
through hood. (PTA Air fin coolers)

 Humidified Forced-Draft
 Air humidified before forced across tubes.
 Evaporation draws heat from air and cools air
below temperature of process fluid.
 Air-Cooled Heat Exchangers
Hood or Plenum Fan Ring
Fan
Return
Inlet Headers
Nozzles

Inlet
Headers

Outlet
Headers

Outlet
Nozzles Tube Bundle

Drive Assembly

Supports

Horizontal Tube, Induced-Draft Air-Cooled Heat Exchanger

 Typical Air-Cooled Heat Exchanger
Lifting Lug Air Seal
Tube Keeper
(top)
Air Seal Header

Tube
Nozzle Air Seal

Header Fins
Tube spacer Side Frame
Tube Support
(bottom)
 Air-Cooled Heat Exchangers

Inlet Nozzles Tube Bundle

Return
Header(s)

Inlet
Headers
Outlet
Headers

Outlet
Nozzles

Fan Plenum
Supports
Fan Ring
Drive
Assembly

Typical Forced-Draft Air-Cooled Heat Exchanger

 Air-Cooled Heat Exchangers
Hot Air

Tube Process Nozzle

Bundle
Partition Plate
Header
Header

Fine Water Mist

Plenum Process Nozzle
Chamber
Water Header
Nozzles (above
fan Typical)
Forced
Draft Fan

Water Header
Nozzles (below
fan Sometimes)

Humidified Forced-Draft Heat Exchanger

U Tube type Heat Exchanger
 U Tube type Heat Exchanger
Front End Rear End
Shell Type
Stationary Head Type Head Type
C E U

Channel Integral
with Tube sheet and One Pass Shell U-Tube Bundle
Removable Cover
 Fixed Tubesheet type Heat Exchanger
Front End
Rear End
Stationary Head Shell Type
Head Type
Type

A E M

Channel and Fixed Tubesheet

One Pass Shell
Removable Cover Stationary Head
 TEMA Designation System Example

TEMA Size and Type Normally Written: 23–192 AES

Straight Tube
Length 192”
23”
(16’ – 0”)
Shell
I.D.

Type “A” Channel

Type “E” Shell Type “S” Split-Ring
Single-Pass Floating Head
 Hair Pin type Heat Exchanger
Shell Cover Gasket External Fin Pipe
Vent Shell

Shell
Cover

Return Bend
(welded)

Drain Sliding Support Fixed

Support

Twin Flange Shell End Piece

 Plate-and-Frame Heat Exchanger
A Bin out Nozzle
Header
Separating
Sheet
Cin

Corrugated
Sheet Effective
Width

Heat Transfer
Effective Section
A Side Bar
Length

Distributor

Cout Distribution
Section

Ain Bout
A Two-Pass Plate and Frame Flow Arrangement
B
Plate-and-Frame Heat Exchanger

Spiral Flow-Spiral Flow Heat Exchanger

Thank
you