University of Anbar Ministry of Higher Education

College of Engineering and Scientific Research

HEAT EXCHANGERS

Prepared by ‫׃‬
1. Ahmed Hamad Mutlak

2. Emaan Naem

3. Baker Mansour Nafaa

4. Rosl Basim

Supervised By ‫׃‬

Dr. Mustafa B Al-haddithi

Introduction

A heat exchanger is a heat transfer device that exchanges

heat between two or more process fluids. Heat exchangers
have widespread industrial and domestic applications. Many
types of heat exchangers have been developed for use in steam
power plants, chemical processing plants, building heat and air
conditioning systems, transportation power systems, and
refrigeration units. The actual design of heat exchangers is a
complicated problem. It involves more than heat-transfer
analysis alone. Cost of fabrication and installation, weight, and
size play important roles in the selection of the final design
from a total cost of ownership point of view. In many cases,
although cost is an important consideration, size and footprint
often tend to be the dominant factors in choosing a design.
Applications of Heat Exchanger

Heat exchangers are often classified based on the application for which
they are intended, and special terms are employed for major types.
These terms include

1. Heating

2. refrigeration and air conditioning system

3. Petroleum refineries

4. Chemical plants

5. Power plants

6. Cryogenic

7. Heat recovery

8. Manufacturing Industries Space heating, etc..

Classifications of Heat Exchanger

1-Based on transfer process

1. Indirect Contact - Shell & Tube Heat

2. Direct Contact - Cooling Towers

2-Based on phase of fluids

1. Gas-Liquid exchangers

2. Liquid-Liquid exchangers

3. Gas-Gas heat exchangers

3-Based on construction

1. Tubular

2. Double pipe heat exchanger Shell and tube heat

exchangers
3. Spiral heat exchangers

4. Plate-type Plate and frame heat exchangers

5. Spiral plate heat exchangers Extended Surface

6. Plate-fin exchanger Tube-fin exchanger

4-Based on flow arrangements

1. Parallel flow / Co-current flow

2. Counter flow

3. Cross flow
1- Temperature Profile: Co-current flow

2- Temperature Profile: current flow

Types of Heating and Cooling Curves

Temperature distribution for a different counter current heat exchanger

Techniques to Control Fouling

There are a number of strategies to control fouling. Additives that act as

fouling inhibitors can be used while the heat exchanger is in operation. If
it is not possible to stop fouling, it becomes a practical matter to remove
it. Surface cleaning can be done either online or offline. The following
sections provide a discussion of some of these techniques.

1-Surface Cleaning Techniques

If prior arrangement is made, cleaning can be done online. At other

times, offline cleaning must be used. Cleaning methods can be classified
as continuous cleaning or periodic cleaning.

1.1-Continuous Cleaning

Two of the most common techniques are the sponge-ball and brush
systems. The sponge-ball system recirculates rubber balls through a
separate loop feeding into the upstream end of the heat exchanger. The
system requires extensive installation and is therefore limited to large
facilities. The brush system has capture cages at the ends of each tube. It
requires a flow-reversal valve, which may be expensive

1.2-Periodic Cleaning

Fouling deposits may be removed by mechanical or chemical means. The

mechanical methods of cleaning include high-pressure water jets, steam,
brushes, and water guns. High-pressure water works well for most
deposits, but, frequently, a thin layer of the deposit is not removed,
resulting in Fouling of Heat Exchangers
2-Additives

Chemical additives are commonly used to minimize fouling. The effect of

additives is best understood for water. For various types of fouling,

2.1-Crystallization Fouling

Minerals from the water are removed by softening. The solubility of the
fouling compounds is increased by using chemicals such as acids and
polyphosphates. Crystal modification by chemical additives is used to
make deposits easier to remove. Preventive techniques are to keep a
surface temperature above the freezing value of vapors if it is possible
and to avoid the fouling, preheating should be done

2.2-Particulate Fouling

Particles are removed mechanically by filtration. Flocculants are used to

aid filtration. Dispersants are used to maintain particles in suspension.
Increasing an outlet temperature value of the exhaust gases, above the
melting point of the particulates, decrease particles fouling done

2.3-Biological Fouling

Chemical removal using continuous or periodic injections of chlorine and

other biocides is most common

2.4-Corrosion Fouling

Additives are used to produce protective films on the metal surface.

Corrosion pollution in a heat exchanger depends on the temperature of
the exhaust stream. Since there are electrochemical reactions on active
metal surfaces; increasing stream velocity up to the maximum value will
also increase the corrosion rate. However, there is no effect observed
for a passive surface. pH value plays an important role on this fouling,
where steel surfaces have a pH value in the range from 11 to 12, there is
corrosion occured. A number of additive options may be available
depending on the type of fluid and application. Additional information
on additives is given by Marner and Suitor. Some techniques should be
considered parallel to or before the above techniques such as removal of
potential residues from inlet gas and adjusting design up front to
minimize fouling.

How to make a heat exchanger more efficient

1-Temperature differential - the difference between the hot fluid

and coolant is very important when designing a heat exchanger. The
coolant always needs to be at a lower temperature than the hot fluid.
Lower coolant temperatures will take more heat out of the hot fluid
than warmer coolant temperatures. If you had a glass of drinking water
at room temperature for example, it is much more effective to cool it
down using ice rather than just cool water, the same principle applies to
heat exchangers.

2-Flow rate - Another important factor is the flows of the fluids in both
the primary and the secondary side of the heat exchanger. A greater
flow rate will increase the capability of the exchanger to transfer the
heat, but a greater flow rate also means greater mass, which can make it
more difficult for the energy to be removed as well as increasing velocity
and pressure loss.

3-Installation - The heat exchanger should always be installed based

on a manufacturers' guidelines. Generally speaking the most efficient
way to install a heat exchanger is with the fluids flowing in a counter-
current arrangement (so if the coolant is travelling left to right, the hot
fluid travels right to left) and for shell and tube heat exchangers the
coolant should enter at the lowest inlet position (as shown in the
diagrams above) to ensure that the heat exchanger is always full of
water. For air cooled heat exchangers it is important to consider the air
flow when installing a cooler, any part of the core which is blocked will
compromise cooling capacity. To find out more about counter-flow and
why it is more efficient

Reference

1. HEAT EXCHANGERS Selection, Rating, and Thermal Design From Liley, P. E.

Thermophysical properties, Boilers, Evaporators, and Condensers, Kakaç, S. (Ed.),
Wiley, New York, 1987.
2. https://www.real-world-physics-problems.com/heat-exchanger.html

3. Compact Heat Exchangers: Selection, Application, Design and Evaluation Bahman

Zohuri
4. https://www.researchgate.net/publication/308464270_Heat_Exchanger_Types_and
_Classifications