CompactMultifunctionalHeat Exchangers

efkoikalo March2009

1.INTRODUCTION
Thefirstpart thedifferenttechnologiesofcompactheatexchangers and theirrangeofapplication. Thesecondpart the stateoftheart forheattransferandfluidflow characteristicsforsinglephase, evaporation,condensation,andheatand masstransfer. Thelastpart applicationsofcompactmultifunctionalheatexchangers.

Heatexchangersmaybecharacterized bythecompactness factor,inm2/m3,anditisgenerallyadmittedthatvalues greaterthan700m2/m3 characterizecompactheatexchangers.

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Often,compact heatexchangersalsorefertonontubularheat exchangers,evenifshellandtube heatexchangerscanhavehigh compactnessfactors. Fortheheatexchangerconsidered, thehydraulicdiameterrangesfrom lessthan1mmto10mm. Thereare mainlytwotypesofcompactheatexchangers: theplatetype(primarysurface heatexchanger)and theplatefintype(secondarysurfaceheatexchanger). Intheprocessindustry,thereareonlyfourbasicoperations: reaction, separation, mixing,and heattransfer.

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Thetraditionalunitoperationistoperformeach taskinoneormorepieces ofequipmentsequentially,forexample,heattransferin heatexchangers andreactioninreactors. Combiningtwoormoretasksinonepiece ofequipmentisimplemented onlyforcontrolorenhancementpurposes;oneexample iscoolingina jacketedstirredtankreactor. Butthisisnotanintensifiedprocess, becauseitrequiresabatchoperation, whichhaspoorefficiency,andthereaction cannotbecontrolledeffectively. Examplesofmultifunctionalheatexchangersare: Multistreamheatexchanger(heattransferbetweenmorethantwofluids) Reactorheatexchanger(reactionandheattransfer) Refluxcondenser(heattransferandseparation)

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Heattransferiscommonlyrequiredintheprocessindustryforheating, cooling, vaporizing,orcondensing. Inmostcases,onlytwostreams(onehot andone cold)areinthermal contactwithintheheatexchanger. Themostcommonlyused heatexchangeristheshellandtubeheat exchanger,whichhaspoorheattransfer performanceandrequiresa significantvolumeandgroundarea.

Compactheat exchangersandenhancementtechnologies allowreducingtheheatexchanger volume,toincreaseits effectiveness andtoreducecapitalandoperatingcosts.

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Compactheatexchangers include plateheatexchangersaswellas platefinheatexchangers, whichare characterizedbyhydraulicdiametersbetween1and10mm. Butrecentdevelopments inmanufacturingtechniques,suchas printedcircuitheatexchangersand diffusionbondedand superplasticformedheatexchangers, allowreachinghydraulic diametersbelow1mm. Theseheatexchangersoffercompactnessgreaterthan 1000m2/m3 andaresuitableforindustrialprocesses.

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Rapidadvancesinrangeofdesignandoperationalreliabilityhavemade compactheatexchangersattractiveformanyapplicationsinvarious industries. Theirhighperformancehasalreadymadetheirusewidespreadinthe automotive, aerospace,airconditioning,refrigeration,andelectrical equipmentindustriesfor singlephaseandphasechangeduties. Intheautomotiveindustry,platetypeheat exchangersareusedas heaters,evaporators,andcondensers,andsincethe 1970s,the volume/heatcapacityratiohasbeendividedbyafactorof2(Fig. 1 and2). Thisimprovementhasbeenachievedbecauseofaradicalchangeinheat exchangertechnology andbytheadoptionofmassproductionsystems integrating innovativetechnologies.

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Rebroicijev

PloastorebrastiST

Serpentinski

PloastorebrastiMS

FIGURE1Progressinevaporatortechnology.
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Compactheatexchangersproducedindividuallyaregenerallymore expensive thanaconventionalshellandtubeunit,andtheirpayback timewillbelonger. Buttakingspace,weight,andconvenience intoaccountcompact heatexchangers canbeusedcosteffectivelyinawiderrangeof applicationsthanthenichescurrently beingusedintheprocess industry.

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FIGURE2Progressincondensertechnology.

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2.COMPACTHEATEXCHANGERTECHNOLOGY
2.1.ClassificationofCompactHeatExchangers
Heatexchangerscanbeclassifiedinmanydifferentways,suchas accordingto transferprocesses, numberoffluids, surfacecompactness, flowarrangements, heattransfermechanisms, typeoffluids(gasgas,gasliquid,liquidliquid,gastwophase, liquidtwophase,etc.),and industry. Heatexchangerscanalsobe classifiedaccordingtotheconstruction typeandprocessfunction(Fig. 3).

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FIGURE3Classificationofheatexchangers.

Plateheatexchangers(PHEs)

Ploastiizmjenjivai
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2.2.PlateHeatExchangers
Plateheatexchangers(PHEs)wereformerlyusedformilkpasteurization and graduallybecamethestandardchoiceforheattreatmentintheliquid foodindustry. Actually,pasteurization mustbeconsideredabiologicalreaction,because the nativecompositionoftheliquidisdenaturedduringtheheattransfer process.In practicethisdenaturationleadstofouling. Thefacilityofdismantlingplateheat exchangersisoneofthemainreasons fortheirextensiveuseinthefoodindustry. Furthermore,becausetheheattransfercoefficientsarehigh,thefluidpath length willbeshorterandrelativelywelldefined. Duetothelackoflargedeadareasinthe channels,thecorresponding residencetimedistributionisshortandhomogeneous.
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Eventually,withthedevelopmentoflargerplates,theirusebeganto grow quicklyinthechemical,petrochemical,districtheating,andpower industries,but essentiallyforsinglephaseduties. TheconceptofphasechangeinPHEsoriginated inthe1970sforocean thermalenergyconversion(OTEC)applications;theworking fluidswere FreonR22orammonia. Thesefirststudiesonevaporation and condensation havebeenusedfor thedevelopmentofPHEsintherefrigeration industry. NowPHEshavecometobeusedmoreoftenintheprocess industry,but theiruseisstillnotwidespread.

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Intermsoftechnology,PHEsaremadefromcorrugatedplates(Fig. 4) that arepressedtogether. Theplatesizerangesfrom0.02m2 toover3m2 withconventional pressing technology(Fig. 5),butcanreachupto15m2 forexplosionformed plates (Fig. 6). Thehydraulicdiameterliesbetween2and10mmfor mostcommonplates, butfreepassagesandwidegapplatesexistforviscousfluid applications. Typically,thenumberofplatesisbetween10and100,whichgives 550 channelsperfluid. Furthermore,theuseofhighqualitymetalandmanufacturing techniques makesleadplateheatexchangerslesspronetocorrosion failurethanshell andtubeunits.

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FIGURE4Plateheatexchanger.(AlfaLavalVicarb.)

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FIGURE5Corrugatedplates.(AlfaLaval Vicarb.)

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Plateheatexchanger
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BrazedPlateHeatExchangers

Methodofedge sealing

Arangeofbrazedexchangers

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FIGURE6Explosionformedplate.(Packinox.)

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Toensuretightness,threetechnologiesareavailable: gaskets, semiwelded ortotallywelded,and brazing. ThegasketedPHEisthemostcommontype,withthegasketmaterial selectedasafunctionoftheapplication(temperature,fluidnature,etc.). Temperaturesupto200Candpressureupto25barscanbeachievedby suchheatexchangers.

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Forapplicationswheregasketsareundesirable(highpressureand temperatureorverycorrosivefluids),semiwelded ortotallyweldedheat exchangersareavailable(Fig.7). Thelastvariantisthebrazedplate heatexchanger. Theplatepatternissimilartoconventionalgasketedunits,but tightnessis obtainedbybrazingthepackofplates. Forcommonapplicationscopperbrazing isused,butforammoniaunits nickelbrazing ispossible. Thistechnologyleadstoinexpensiveunits,buttheplatesizeisgenerally limitedtolessthan0.1m2. Thedrawbackisthattheheatexchangercannotbeopened,andfouling willlimittherangeofapplication.

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(AlfaLavalVicarb)

Weldedreboiler(ACM)

(Barriquand)

(Ziepack) FIGURE7Variousweldedplateheatexchangers.
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2.3.SpiralHeatExchangers
Thespiralheatexchanger consistsoftwometalsheetsthatare weldedtogetherand thenrolledtoobtainspiralpassages. Thepassages canbeeithersmooth orcorrugated; insomecases, studs orspacers areintroducedbetweenthemetalsheets. Thesedeviceshavetwofunctions: (1)toadjustthespacingand (2)toinduceturbulence andincreaseheattransfer. Thegeneralflowconfigurationcanbecrossflow (singleormultipass) orcounterflow,dependingontheconfigurationoftheinletand outlet distributionboxes.

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2.3.SpiralHeatExchangers
Theheattransfersurfacerangesfrom0.05m2 forrefrigeration applications(Fig. 8)to500m2 forindustrialprocesses(Fig. 9). Spiral heatexchangersareoftenusedforphasechangeapplications, becausethegeometry ofthehotandcoldstreamchannelscanbe adaptedtotheprocessspecifications. Recentdevelopmentsinmanufacturingtechnologies(laserwelding)have allowedthemanufactureofcosteffectiverecuperatorsbasedonthe spiralconcept (Fig. 10)orthefoldedplaterecuperator.

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FIGURE8Spiralheatexchangerforthe refrigerationindustry.(Spirec.)

FIGURE9Spiralheatexchanger fortheprocessindustry.(Kapp.)

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FIGURE10Laserweldingofaspiralrecuperator.(ACTE.)

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AcompactSpiralHeatExchanger

SchematicofSpiralHeatExchanger

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Spiralplateheatexchangerwithbothfluidsinspiralcounterflow.

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Fluid2

Fluid1

(a)

(b)

(c)

(a)Lamellaheatexchanger;(b)crosssectionofalamellaheatexchanger; (c)lamellas.

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2.4.PlateandShellHeatExchangers
Thebasicprincipleoftheseheatexchangersistoinsertabundleofplatesin a shell(Fig. 11). Ontheplateside,thefluidflowsinsidecorrugated orembossed channels (moreoftenintwopasses). Ontheshellside,theflowissimilartoshellandtubeheatexchangers,and bafflescanbeinserted. Thistechnologycanbe usedforrevamping anapplication,becausetheshell canbekeptidenticaltothat forabundleoftubes. Theseheatexchangersareoftenusedintheprocessindustry asboilers (boilingontheshellside)becausehighpressurescanbereachedvery easily ontheshellside. Furthermore,alargegapontheshellsideallowstheuse ofdirtyservices, becausecleaningispossibleviaremovalofthebundleofplates.

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FIGURE11Shellplateheatexchangers.(ACMandBarriquand.)

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PLATEANDSHELLHEATEXCHANGERS
Theplateandshellheatexchangercombinesthemeritsofshelland tubewithplateheatexchangers Currentplateandshellheatexchangermodelsaccommodateupto 600platesinashell2.5mlongwitha1mdiameter

2.5.PlateFinHeatExchangers
Aluminiumplatefinheatexchangers(PFHEs)wereinitiallydevelopedin the1940stoprovidetheaerospaceindustrycompact,light,andhighly efficient heatexchangers forgas/gasapplications. Becausethemechanicalcharacteristics ofaluminumareincreasedatlow temperatures,thistechnologyhasbeenused since1950forthe liquefactionofnaturalgases. Nowadays,aluminumplatefinheatexchangersareextensivelyusedin applicationssuchasairseparation, hydrocarbonseparation,andindustrial andnaturalgasliquefaction. The platefin heatexchangeroffersprocessintegrationpossibilities simultaneous differentstreamsandmoreinonesingleheatexchanger) andhighefficiencyunder closetemperatureapproach(12C)inalarge varietyofgeometricconfigurations. Thebrazedplatefinexchangerconsistsofstackedcorrugatedsheets (fins) separatedbyflatplates,formingpassagesthatareclosedbybars,with openings forthefluidinletandoutlet(Figs. 12and13).
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1.Partingsheet;2.Heattransferfins;3.Distributorfins;4. Sidebars; 5.Capsheet;6.Headers;7.Nozzles;8.Block(core) L Length;W Width;H Height FIGURE12Componentsofabrazedaluminumplatefinheatexchanger.

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BasicstructureofPlateFin HeatExchanger(PFHE)

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Bavexweldedplateheatexchanger
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FIGURE13Platefinheatexchangers.(NordonCryognie.)

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Initssimplestform,aheatexchangermayconsistoftwopassages,withthe coolingfluidinonepassageandthewarmingfluidintheother. Theflowdirection ofeachofthefluidsrelativetooneanothermaybe countercurrent,cocurrent, orcrossflow. Thefinsandthepartingsheetsareassembledbyfusionofabrazingalloy to thesurfaceofthepartingsheets.Thebrazingoperationhappensina vacuum furnaceinwhichthebrazingalloyisheatedtoitspointoffusion.All partsin contactarebondedbycapillaryaction(Fig. 14). Oncethebrazingalloyhas solidified,theassemblybecomesonesingle block. Allpassagesforflowdistribution andheattransferofthestreamsare containedintheinternalgeometryof theblock.Inletandoutletheaders withnozzlesforthestreamsarefitted,bywelding, aroundtheopeningsof thebrazedpassages.Thesenozzlesareusedforconnecting theheat exchangertoexistingplantpipework.

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Stackingbeforebrazing

Afterbrazing

FIGURE14Stainlesssteelbrazedplatefinheatexchanger.(Nordon.)

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Numerousfincorrugationshavebeendeveloped,eachwithitsownspecial characteristics(Fig. 15).Straightfinsandstraightperforatedfinsactlike parallel tubeswitharectangularcrosssection.Convectiveheatexchange occursdue tothefrictionofthefluidincontactwiththesurfaceofthefin. Thechannelsof serratedfinsarediscontinuous,andthewallsofthefins areoffset.Forairflows, louverfinsareextensivelyused;forprocess applications(single andtwophase), continuousoroffsetstripfinsare used.
Straightfin Straightperforatedfin SerratedfinsOSF zupasti

FIGURE15Differentfingeometries.

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Plane(ravno)

Herringbone(ribljakost)

Perforated(perforinana) OffsetStripFin(Smaknutarebra) FintypesofPlateFinHeatExchanger(PFHE)

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Primaryairairheatexchanger,AirbusA320

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Tubeandfinexchangersurfaces

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Forhighertemperatureapplicationsorwhenaluminumisnotacceptable, stainlesssteel(temperaturesupto700C)orcoppermaterialscanbeused. Forveryhightemperatures(gasturbineheatrecovery;T>1200C),aceramic platefinheatexchanger hasalsobeendeveloped(Fig. 16). Forhighpressureapplicationsinthehydrocarbonandchemicalprocessing industries,atitaniumcompactheatexchangerhasbeendevelopedbyRolls Laval. Thisheatexchangerconsistsofdiffusionbondedchannelsthatarecreated bysuperplasticformingoftitaniumplates. Thisheatexchangercanhandlehighpressureandcorrosivefluidsandis suitableformarineapplications.

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FIGURE16Ceramicrecuperator.(CramiquesetComposites.)

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2.6.FlatTubeandFinHeatExchangers

Theconceptofflattubeandfinsinheatexchangershasbeendevelopedin the automobileindustry forenginecoolingand airconditioning. Insuch applicationsoneofthetwofluidsisair andtheotheriseitherwater orarefrigerant. Thenonequilibriumoftheheatcapacitiesofthetwofluidsleadstothe adoption ofdifferentenhancementtechnologiesforbothfluids. Generallyontheair sidethesurfaceisfinned(plain orlouver fins),andon theothersidethefluid flowsinsmalldiameterchannels (Figs. 17and18). Thetechnologyisbasedon assemblingaluminumelements,byeither mechanicalexpansionorbrazing. For conventionalapplications,thepressurecanbeupto20bars. Recently,heat exchangerswithoperatingpressuresup140barhavebeen manufacturedfor carairconditioningsystems,usingcarbondioxideas refrigerant.

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FIGURE18Extrudedaluminumminitube.

FIGURE17Condenser.(Livernois.)
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WeldedPlateHeatExchanger Interplate channel

Platebundle Doubleplate channel TheZiepackplatepack Hydraulicdiamterisoftheorder610mm.

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RecuperatorSketchshowingFlow Paths.Manifoldsforcoldairentering andhotair leavingtherecuperatorare createdbyweldedcircularflanges (Kesselietal.,2003). EllipticalTubeRecuperator(McDonald,2003).

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2.7.MicrochannelHeatExchangers
Microchannelheatexchangersarecompactheatexchangerswherethe channel sizeisaroundorlowerthan1mm. Suchheatexchangershavebeendevelopedfor severeenvironments,such asoffshoreplatforms. Newapplicationsarealso arisingforhightemperaturenuclearreactors. Tomanufacturesuchsmall channels,severaltechnologiesareavailable: chemicaletching,micromachining, electrodischarge machining,etc. Themostcommononeistheprintedcircuitheatexchangerdevelopedby theHeatricCompany. Thechannelsaremanufacturedbychemicallyetching into aflatplate.The platesarestackedtogetheranddiffusionbonded. Theseheat exchangerscansupportpressuresupto5001000barand temperaturesupto 900C (notsimultaneouslywithhighpressure).The typicalsizeofthechannels is1.02.0mm,andtheplatesize canbeupto 1.20.6m(Fig. 19).
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Detailofthebondedplates

FIGURE19Printedcircuitheatexchanger.(Heatric.)

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The processingtechniqueisasflexibleasforplatefinheatexchangers,and crossflow andcounterflow configurationsareemployed. Themainlimitationofthe microchannelheatexchangeristhepressure drop,whichisroughlyinverselyproportional tothechanneldiameter. Forhighpressureapplications,thepressure dropisnotaconstraint;butfor otherfieldsofapplicationitwillbethemainbarrier totheuseofsuchheat exchangers. Morerecently,ChartMarston hasdevelopedtheMarbonheatexchanger. Thisheatexchangerismadeofstainlesssteelplatesstackedandbonded together (Fig. 20). Severalconfigurationsarepossible:(1)shellandtube,and(2)platefin. Theuseofsuchaheatexchangerasachemicalreactorisunder consideration, andthethermalandhydrauliccharacterizationhasbeen undertakenasEuropeanfunded project.

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FIGURE20Marbondheatexchanger.(Marston.)

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Verycompactheatexchangersarealsousedforcoolingelectronicdevices ormicroreactors (Fig. 21). Intheseheatexchangersthechannelsizerangesfrom 50m to1mm. Singlephaseandboilingareencounteredinsuchapplications . Applicationsinthechemicalprocessingindustriesarealsoforeseen. Theseunitscanbeverysmallinsizeandtheheatdutyperunitvolumeis very high,upto 15kW/cm3.

Siliciumdeepetchingmicrochannels(CEA)

Microchannelsheatexchangers(FZK)

FIGURE21Microchannelheatexchangers.
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PanelcoilHeatExchangers.

Diestampedplatecoils:(a)serpentine,(b)multizone,(c)avessel;(d) spotwelded Econocoilbank.

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2.8.MatrixHeatExchangers
Perforated,ormatrix,heatexchangersarehighlycompactandconsist ofastack ofperforatedplatesmadeofhighthermalconductivity material,suchascopper oraluminum,alternatingwithspacersoflow thermalconductivity,suchasplastic orstainlesssteel. Thepackofalternatelow andhighthermalconductivity platesare bondedtogethertoformleakproofpassagewaysbetweenthestreams (Fig. 22). Themainbondingtechniqueadoptedisdiffusionbonding. Suchheatexchangershavebeendevelopedforcryogenicandlow temperature applications andforfuelscells. Theyaresuitableforalarge rangeofoperatingconditions,butthereis verylittleinformationontheirthermal andhydraulicbehavior. Furthermore,astheheatistransferredbyconductionin theplate,the temperaturedistributionisnothomogeneous.

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FIGURE22Matrixheatexchanger.

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2.9.SelectionofHeatExchangerTechnology
Theselectionofthetechnologyofcompactheatexchangersdependson theoperating conditions,suchaspressure,flowrates,andtemperature, aswellasonother parameters,suchasfouling,corrosion,compactness, weight,maintenance,and reliability. Table1 summarizesthemajorlimitsforthedifferenttypesofcompact heatexchangers.

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TABLE1OperatingConditionsofCompactHeatExchangers
Technology Aluminum platefin heat exchanger Stainless steel platefin heat exchanger Ceramic platefin heat exchanger Diffusion-bonded heat exchanger Spiral heat exchangers Matrix heat exchangers Flat tube-and-fin heat exchanger Brazed-plate heat heat exchanger Welded-plate heat exchanger Plate-and-shell heat exchanger Gasketed-plate heat exchanger Graphite-plate heat exchanger Plastic-plate heat exchanger Maximal pressure, (bars) 80120 80 4 5001000 30 1000 200 30 3040 3040 2025 7 5
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Maximal Number of Fouling temperature, streams (C) >10 No 70200 650 1300 8001000 400 800 200 200 300400 300400 160200 180 200250 >2 2 >2 2 >2 2 2 >2 2 >2 2 >2 No No No Yes No No No Yes/no Yes/no Yes Yes Yes/no
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FIG.5.28.8Heatexchangersforheatrecovery ventilator. A heatexchangeelementisthebasisofaheat recoveryventilator. Freshoutdoorair(1)iswarmedasitpasses throughtheexchanger andentersthehouse(2). Staleindoorair(3)leavingthe houseiscooledas ittransfersheattotheexchangerandisvented outside(4). Inthefixedplatetype,heatistransferred through plastic,metal,orpaperpartitions. Theturningwheeloftherotary typepicksup heatasitpassesthroughthewarmairpath and surrendersheattothecoldairstreamhalfa rotationlater. Liquidrefrigerantinthepipesoftheheatpipe typeevaporates atthewarmendandcondenses atthecoldend,transferringheat tothecoldair.
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(FrederickLjungstromin1922)

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Ljungstromairpreheater.

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Heatwheelorarotaryregenerator madefromapolyesterfilm.

Rotaryregeneratormadefroma treatedJapanesepaper.

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