Selection of Heat

Exchangers and Their

Components
RC PRESENTATION
SELECTION CRITERIA BASED ON
OPERATING PARAMETERS
 1. Operating Pressures and Temperatures:
The exchanger must withstand the stresses produced by the operating pressure and the temperature differences between
two fluids.
• Shell-and-tube exchangers: These are versatile for medium to high-heat duties and can handle a wide range of
pressures (up to 30 MPa shell-side and 140 MPa tube-side) and high temperatures (limited by materials, but with a
maximum temperature difference of 508°C for certain designs).
• Double-pipe exchangers: Suitable for lower-heat duties, they can handle high vacuum to ultrahigh pressures.
• Plate exchangers: These come in gasketed/semi-welded (low pressure/temperature), fully welded/brazed (higher
pressure/temperature) variants and are suitable for liquid-liquid or liquid-phase change applications.
• Plate-fin extended surface exchangers: Designed for low pressures (up to 1000 kPa) and moderate temperatures (up
to 650°C), they are commonly used in cryogenic applications. Fins help with flow mixing and heat transfer.
• Tube-fin exchangers: Used when one fluid is at high pressure, they can handle a wide temperature range and employ
fins (especially on the gas side) for enhanced heat transfer.
• Rotary regenerators (870 to 1100°C) and fixed-matrix regenerators (up to 2000°C): These are for ultrahigh
temperatures (waste heat recovery) and near-atmospheric pressures.
2. COST
 Unit cost: Gasketed plate exchangers are pricier per unit heat transfer area than shell-and-
tube exchangers.
 Total cost: When using high-grade materials (stainless steel, titanium), plate exchangers
become cheaper overall (capital, installation, operation, maintenance) compared to shell-
and-tube exchangers.
 Reasoning: Tubes are more expensive than extended surfaces, making shell-and-tube
exchangers costlier per unit area. Additionally, they offer less surface area density
compared to extended surface or regenerative designs.
 Least expensive: Rotary regenerators made from paper or plastic have the lowest cost per
unit heat transfer area.
3. Fouling and Cleanability
 Fouling potential should be considered at design and off-design conditions.
 Shell-and-tube exchangers are good for moderate fouling when the fouling fluid can be
placed on the tube side for easier cleaning.
 Plate exchangers are ideal for low-temperature applications with severe fouling on one or
both sides due to their easy cleaning capabilities.
 Highly corrosive fluids require shell-and-tube exchangers regardless of pressure or
temperature.
 Plate-fin exchangers are discouraged for fouling applications unless they can be
chemically cleaned or thermally baked.
 Gas-to-gas exchangers and regenerators are less susceptible to fouling due to the nature of
the fluids.
 4. Fluid Leakage and Contamination
• Leakage tolerance varies by application: Some applications can handle minimal fluid crossover,
while others require zero contamination.
• Regenerators: Not ideal for zero contamination due to inherent leakage (carryover and bypass)
between hot and cold fluids.
• Leakage-proof options:
• Tubular exchangers
• Extended surface exchangers
• Plate-type exchangers (with limitations)
• Plate limitations:
• Gasketed plate exchangers: More prone to leakage than shell-and-tube.
• Plate-fin and tube-fin exchangers: Potential leakage at fin/header or tube/header joints.
• Zero contamination exchangers:
• Double-wall tubular/shell-and-tube exchangers
• Double-plate PHEs
 5. Fluids and Material Compatibility
• Material compatibility is crucial to avoid corrosion and ensure proper
operation at high temperatures.
• Shell-and-tube exchangers offer flexibility in material selection, while
compact exchangers often require specific materials like aluminum for its cost,
weight, and conductivity benefits.
• Plate exchangers often use materials suitable for food applications (like
stainless steel) or corrosion resistance.
• Corrosiveness of the working fluid is a major factor in material selection as
sjown in table 10.2.
 6. Fluid Type
• Gas-to-gas exchangers:
• Need more surface area due to lower gas heat transfer coefficients compared to liquids.
• Achieved through fins (extended surface), small passages (regenerators), or small tubes.
• Plate exchangers not ideal due to high pressure drops.
• Prime surface exchangers (un-finned plates) used in some waste heat recovery (pumping power a big factor).
• Liquid-to-liquid exchangers:
• Regenerators not preferred due to leakage concerns.
• Pumping power less critical compared to gas-to-gas.
• Liquid-to-gas exchangers:
• Lower gas-side heat transfer coefficient necessitates increased surface area on the gas side for balanced design.
• Achieved through fins (extended surface) or tubes.
• Plate and regenerative designs not commonly used.
• Phase-change exchangers:
• Heat transfer coefficients on the condensing/evaporating side can vary depending on the phase (gas or liquid).
GENERAL SELECTION GUIDELINES FOR
MAJOR EXCHANGER TYPES
 Shell-and-Tube Exchangers
 Popularity: Over 65% market share in process industries due to:
• Versatility across operating conditions and materials
• Proven design methods and adherence to codes/standards
 Selection Considerations:
1. Configuration: Choosing the right arrangement of tubes, baffles, shell, and heads.
2. Geometry: Selecting appropriate dimensions for each component.
3. Materials: Selecting materials compatible with the working fluids.
4. Design Optimization: Finding the "right" design for the specific application.

TUBES
Tube Types:
• Plain tubes: Most common choice for good balance between performance and ease of cleaning.
• Low-finned tubes: Increase surface area for compensating low heat transfer on the shell side. They offer 2-3 times more
surface area compared to plain tubes and reduced fouling on the fin side.
 Tube Diameter:
• Heat transfer: Smaller diameters improve heat transfer but are harder to clean.
• Cleaning: Larger diameters are easier to clean but less efficient in heat transfer.
• Common sizes: 15.88 mm (5/8 in), 19.05 mm (3/4 in), and 25.40 mm (1 in) offer a compromise.
• Mechanical cleaning: Minimum diameter is 19.05 mm for practical reasons.
• Chemical cleaning: Smaller diameters are possible if complete plugging is avoided.
 Number of Tubes:
• Depends on desired flow rates and pressure drop limitations.
 Number of Tube Passes:
• Determined by available pressure drop.
• Higher velocities (fewer, longer tubes) lead to higher heat transfer coefficients but also increased pressure drop. Typical
range: 1 to 10 passes (1, 2, or 4 passes are standard).
 2. Tube Pitch and Layout
• Close pitch (small pt/do):
• Increases shell-side heat transfer
• More compact design
• Open pitch (large pt/do):
• Reduces shell-side plugging
• Easier shell-side cleaning
 Tube Layout Options:
• Square: for jet or mechanical cleaning (needs space for cleaning lane).
• Equilateral Triangle:
• More compact design (smaller shell).
• Stronger header for high pressure difference.
• Heat transfer coefficient and pressure drop (decreasing order): 30° (triangular), 45° (square), 60°
(triangular), 90° (square).
• Cleaning needs:
• Square for jet/mechanical cleaning.
• Triangular for cleaning from multiple directions (if designed properly).
• 45° triangular for laminar/turbulent single-phase flow or condensing shell-side fluid (mechanical cleaning
required).
• Pressure drop: 90° square for limited shell-side pressure drop (turbulent flow).
• Boiling applications: 90° square for vapor escape lanes.
• Non-cleaning situations (single-phase, condensing):
• 30° triangular (high ΔT range).
• 60° triangular (low ΔT range or pure vapor condensation).
 BAFFLES
 PLATE BAFFLES:
• Segmental: Most common (single or double).
• Guides shell-side flow for heat transfer.
• Supports tubes (sometimes called support plates).
• Single segmental spacing: 1.5 - 2.5 times shell diameter (min 2 in).
• Baffle cut (percent of shell diameter):
• 20-25% typical, adjust for spacing and fouling concerns.
• Horizontal or vertical cut depending on shell-side fluid.
• Double-segmental (strip baffle): Lower pressure drop than single segmental.
• Not ideal for small spacing (creates stagnant flow zones).
• Triple-segmental: Lower pressure drop, closer tube support, prone to vibration.
• Segmental with no-tubes-in-window: Eliminates vibration, good flow, reduces fouling.
• Requires larger shell due to lost surface area (increases cost).
• Disk-and-doughnut: Lower pressure drop than single segmental, eliminates bypass stream.
• Tie rods and central tube support can be disadvantages.
 Rod Baffles
Advantages:

•Eliminates flow-induced vibrations (supports tubes at multiple points).

•Lower shell-side pressure drop compared to segmental baffles.
•Reduced fouling and corrosion due to no stagnant flow areas.
•Potentially higher effectiveness and lower temperature differences.
•Lower cost and better heat transfer to pressure drop ratio.

Disadvantages:
•Lower shell-side heat transfer coefficient compared to segmental baffles.
•May not be suitable if tube-side pressure drop is critical.
 SEGMENTAL BAFFLES
 Purpose:
• Protect tubes near the inlet nozzle from erosion, cavitation, and vibration caused by high-velocity fluid.
 Design:
• Solid square plate located under the inlet nozzle (see Fig. 10.2).
• Placement is critical to minimize pressure drop and high escape velocity.
• Achieved by:
• Omitting tubes in the area.
• Modifying the nozzle to have an expanded section.
• Enough space needed between the plate and tubesheet/first baffle.
 Failure Cause: Improper location and size of the impingement plate.