HEAT EXCHANGER

 characteristic common to most heat exchangers is the

transfer of heat from a hot phase to a cold phase with two
phases being separated by a solid boundary.

 equipment through which the hot and cold streams are

separated by a barrier of metal

 The unit usually consists of a tube or bundle of tubes

contained in a shell
 permit one stock to pass through the tube(s) and the
other to pass over the outside of the tube(s).
TYPES OF HEAT EXCHANGERS

SHELL AND TUBE HEAT EXCHANGER

DOUBLE PIPE HEAT EXCHANGERS

PLATE HEAT EXCHANGERS

JACKET VESSEL HEAT EXCHANGERS

SHELL AND TUBE HEAT EXCHANGER

 large heat transfer surface can be achieved economically

and practically by placing the tubes in a bundle.

 The ends of the tubes are mounted in a tube sheet.

 The resultant tube bundle is then enclosed by a

cylindrical casing (the shell), through which the second
fluid flows around and through the tube bundle.
 TUBES SHELL

BAFFLE
 The tube bundle is made by fastening
the tube ends into openings in the
tubesheets.

 Because the tubes cannot move in the

tubesheets, the tubesheets and tubes
form a solid unit.
 TUBE JOINTS

 The tube joint is the connection between the tube and the tubesheet

 Tube joints are usually either rolled press fit or welded.

TUBE LAYOUT

 A disadvantage of square pitch is the relatively low, or small number of

tubes in a given area.

 The more tubes there are in a given area, the higher or greater the heat
transfer rate.

 When the pitch is triangular, the pressure drop is higher than when the
pitch is square.
BAFFLES

 Baffles support the weight of the tubes.

 baffles help to decrease or relieve the

stress on the tubing and tubesheet.

 In addition to supporting the tubes, baffles break up laminar flow,

decreasing the layer of insulating fluid.
TYPES OF BAFLES

SEGMENTAL BAFFLES

 A segmental baffle is a circle from which either a vertical or horizontal

portion has been cut
 Segmental baffles are positioned so that the cut-out areas face in alternate
directions.
 Alternating the baffles causes flow to cross, or pass tubes a number of times.

 It also provides better support for the tubes.

OTHER TYPES OF BAFLES

DISK & DOUGHNUT IMPINGEMENT

LONGITUDINAL
SHELL-SIDE FLOW ARRANGEMENT

SINGLE PASS

 Tube-side fluid enters one end of the

exchanger, flows through all the tubes
in the same direction, and leaves at the
opposite end of the exchanger.
TWO-PASS

 fluid flows through half the tubes in one direction and through the other
half of the tubes in the opposite direction.
 Increasing the number of
passes requires increasing the
number of baffles.
TYPES OF SHELL AND TUBE HEAT EXCHANGERS

FIXED TUBESHEET EXCHANGERS

U-TUBE OR U-BEND EXCHANGERS

FLOATING HEAD EXCHANGERS

FIXED TUBESHEET EXCHANGERS

 the tubesheet is welded to the shell.

 The tube bundle is permanently installed.

 Fixed tubesheet exchangers are used when the temperature range is

limited and because of the difficulties of inspecting and cleaning, they are
generally used where shell-side fouling is limited.
U-TUBE OR U-BEND EXCHANGERS

 a U-tube exchanger has only one

tubesheet

 A baffle channel is bolted between the

tubesheet and the channel cover.
 The tubesheet and tube bundle form a
unit.

 By unbolting the channel from the

shell, the tubesheet and tube bundle
can be removed from the shell so the
outside of the tubes can be cleaned.

 U-tube exchangers can be used where

temperature difference between shell-
side and tube-side fluids is quite high.
FLOATING HEAD EXCHANGERS

PULL-THROUGH TYPE

left
right

 the tubesheet on the right is bolted between the channel and shell in a fixed
position.

 the tubesheet on theleft, together with a cover, floats inside the shell, free
to move horizontally.

 After unbolting the channel flange and the stationary tubesheet, the tube
bundle and the floating head can be withdrawn as a unit. This permits
cleaning and inspecting the outside of the tubes.
FLOATING HEAD EXCHANGERS

SPLIT BACKING-RING TYPE

 the diameter of the shell cover is greater than the

diameter of the rest of the shell holding the tubes.

 The tubes and tubesheet and floating head cover cannot be pulled through
the channel as a unit.

 The split backing-ring type is harder to disassemble.

 Since disassembly is more time-consuming, it is more expensive.

EXCHANGER FOULING

 Fouling is a general term which describes the buildup of various kinds of

deposits on the parts of an exchanger.

 Since fouling particles adhere to the tube wall, fouling effectively increases the
thickness of the tube wall.

 When the tube wall is fouled, it takes heat longer to pass through the wall.

 In addition, the flow of fluids through the exchanger is restricted.

 If fouling restricts the passage of fluid, the drop in pressure across the
exchanger will increase.

 In addition, the flow rate may decrease. The temperature will indicate that
heat is transferred less effectively.
FOULING TYPES

SEDIMENTATION

 sedimentation involves deposits of dirt, clay and dust.

CORROSION

 Corrosion products are formed when exchanger materials interact

with the fluids

COKING

SALT DEPOSITS

CHEMICAL REACTION
FOULING PREVENTION

ANTIFOULANTS

 prevent the formation of deposits.

INHIBITORS

 prevent chemical reactions which might cause deposits to build up.

 OTHER TYPES OF HEAT EXCHANGERS

DOUBLE-PIPE HEAT EXCHANGER

Outer pipe

Inner pipe

 The simplest type of heat exchanger

 The double-pipe heat exchanger is essentially two concentric pipes with one fluid
flowing through the center pipe while the other fluid moves cocurrently or
countercurrently in the annular space.

 If the required area is too large, a double-pipe exchanger is not recommended.

 PLATE HEAT EXCHANGER

 equipment consists of a series of

parallel plates held firmly together
between substantial head frames

 The plates are one-piece pressings,

frequently of stainless-steel, and are
spaced by rubber sealing gasket
cemented into a channel around the
edge of each plate.

 Each liquid flows in alternate spaces and a large surface can be obtained in a
small volume.

 particularly successful in the dairy and brewing industries, where the low liquid
capacity and the close control of temperature have been valuable features.

 A further advantage is that they are easily dismantled for inspection of the
whole plate.
 JACKETED VESSEL HEAT EXCHANGER

STEAM

CONDENSATE

 The addition or removal of heat is conveniently arranged by passing steam or

water through a jacket fitted to the outside of the vessel
HEAT EXCHANGER PROBLEMS

SCALE
 Scale is basically a buildup of solid impurities on the inside of a tube wall.
Scale acts as an insulator, reducing the tube’s ability to effectively transfer
heat.

CORROSION
 corrosion can eat away and weaken tube metal, which may lead to another
problem – tube leakage. If a tube leaks, the heat transfer process is
affected.

TUBE LEAKAGE

 It can be caused by a buildup of aquatic life, micro-organisms or debris in

the tubes or on the tube sheet.