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Chaoter 6 HEATEXCHANGERS319

6.7.3 InUne Exchangers (Fig. 6.84)

These exchangers are similar in design, materials and manufacture to tank suc-
tion heaters, except that their shell-side ends are flange-bolted on the piping.
The finned tubes are favorable to use for heating or cooling gases or viscous liq-
uids. They are installed in line on piping in order to offset thermal losses, to pre-
heat products to a desired temperature and to cool gases after compression.

Figure
6.84 M i n e exchanger (After Brown Fintube Co. Koch International).

Figure
6.85 Bayonet exchanger.
320 Chapter 6 HEATEXCHANGERS

The inner tubes in the bayonet are fixed to a tubeplate on the front end
head side and the outer tubes are fixed to another tubesheet on the collector
side. Each of the bayonet tubes is free at one end and can expand freely. This
is an enormous advantage over fixed plate-type tubular exchangers whose
tubes or tubesheets may undergo mechanical damage if differential thermal
stresses are high. The bayonet exchanger is therefore mainly used when ther-
mal exchange between the fluids occurs with great mean temperature poten-
tials that could induce excessive mechanical stresses if the tubes were unable
to expand freely.
Materials are chosen on the basis of selection criteria identical to those for
conventional exchangers, e.g. depending on problems of corrosion, operating
temperature, etc.
They are often used as vaporizers in the vertical position (Fig. 6.86), with
the process fluid being vaporized on the shell side. The heating fluid is gener-
ally condensing steam inside the bayonets. Shell side vaporization may be fol-
lowed by superheating.

Level measurem

Level measurem

Figure
6.86 Armstrong type vertical bayonet vaporizer (After Armstrong/Chemtec).
 Chapter 6 HEATEXCHANGERS 321

In the vertical bayonet, the rising steam circulates in the inner tube, the
condensed water coming back through the annulus in counter-current circula-
tion with the steam. This configuration is used to prevent condensate sub-
cooling and potential freezing problems if vaporization is performed at low
temperature. Cryogenic fluids to be vaporized can be used at a temperature
close to, or even lower than, that of the freezing point of the heating fluid
inside the tubes. An additional asset of the vertical bayonet vaporizer is that
it allows less process fluid hold-up than other types of vaporizers, such as the
kettle type.

6.7.5 Helical Wound Coil Tube Heat Exchangers

These are specially designed tubular exchangers that allow a large exchange
surface area to be installed with reduced floor space.

6.7.5.1 Construction Principle (Fig. 6.87)

The tube bundle consists of helical wound tubes coiled in layers around a cen-
tral cylindrical core or mandrel. The rolling direction is usually reversed for
each succeeding layer. The tube layers are supported by spacing strips or
spacers that provide constant transverse and longitudinal spacing between
the tubes. The ends are fixed in tubesheets and the tubes can be grouped
together and assigned to one or more fluids.
A cylindrical shell surrounds the helical tube assembly and is fed by a sin-
gle fluid circulating counter-currently in relation to the tube-side fluids. Inside
the shell special fluid distribution devices can be installed, such as perforated
plates, particularly in the event of two-phase feed.
In order to reduce the clearance between the coil tube assembly and the
shell, a cylindrical jacket can be incorporated. Another solution consists in
setting anti-bypass crowns around the helical tube assembly in order to redi-
rect the fluid to the assembly.

6.7.5.2 Materials
The same as for all the other exchangers, construction materials for the shell,
core and tubes are selected depending on criteria of corrosion resistance and
mechanical resistance to pressure and temperature. However, the tube mate-
rial must be ductile enough for tubes to be rolled up in a helical coil. For cryo-
genic applications, aluminum is most frequently used, but stainless steel and
copper alloys can also be appropriate. For high temperature applications,
stainless steel is employed.

6.7.5.3 Use
Helical wound coil heat exchangers can absorb significant differential expan-
sion between the shell and the tubes that are coiled and tolerate radial expan-
322 Chaoter 6 HEATEXCHANGERS

Inlet of 3 tube fluids

1 - 1 1

. Core

Outlet of
shell fluid

Spacer

Tube layer

Inlet of
shell fluid

+ . +
Outlet of 3 tube fluids

Figure
6.87 Helical wound coil heat exchangers with several fluids (After Linde).

sion as a result. The exchangers have high thermal efficiency due to counter-
current circulation and are extremely compact from the standpoint of avail-
able exchange surface area per unit of volume occupied. They are particularly
suited to achieving the type of thermal exchanges characterized below in a sin-
gle apparatus:
A wide temperature difference between the inlet and outlet of fluids cir-
culating shell side or tube side (difference of approximately l0OT).
A significant temperature crossover between the hot and cold fluids most
commonly associated with close approaches or tight temperature
“pinches”.
Reduced temperature potential between the hot and cold fluids (a few
degrees).
 Chapter 6 HEATEXCHANGERS 323

Very high required thermal power (approximately 100 MW) associated

with very high fluid flow rates (several hundred t/h) and very large
exchange surface areas (approximately 20 000 m2>.
When services involve a change in phase, condensation or vaporization
can be contemplated both on the tube and the shell side. Rising condensation
on the tube side and falling vaporization on the shell side should not be ruled
out beforehand, since this option is favorable for the design of systems with
good shell side distribution.
Conventional tubular exchangers have a number of drawbacks for the
same service: a large number of shells, the obligatory arrangement in parallel
series bringing about distribution difficulties, and the required multiplication
of floating head or U-tube exchangers to overcome differential mechanical
stresses.
Although helical wound exchangers are expensive due to the high manu-
facturing cost of tube bundles, they find their application in cryogenics, natu-
ral gas liquefaction refrigeration cycles, air-gas separation units and large
capacity steam generators.

6.8 Compact Non*TubularExchangers

As the name indicates, these are heat exchangers with a large exchange sur-
face area per unit of volume, approximately 700 to 1000 m2/m3.In comparison,
the conventional tubular exchanger has a capacity of approximately 100 to
200 m2/m3.For equivalent service, compact exchangers offer less volume and
weight, generally have a greater thermal efficiency and are less expensive for
the same quality material. Their geometry promotes turbulence and usually
attenuates fouling phenomena. It also leads to small fluid hold-up volumes,
thereby limiting residence time in comparison with conventional exchangers.
Given recent technological developments, they are much more commonly
used than in the past in the refining, petrochemical and gas industries. Their
compactness in particular affords considerable advantages when they are to
be installed on offshore facilities where floor space and weight are determina-
tive.
Compact exchangers are available according to the following classification:

plate and frame exchangers,

brazed plate exchangers,
welded plate exchangers,
plate-fin exchangers,
printed circuit exchangers,
circular plate exchangers,
spiral plate exchangers.
324 Chapter 6 HEATEXCHANGERS

6.8.1 Plate and Frame Exchangers

6.8.1.1 Construction Principle (Fig. 6.88)
These exchangers consist of a pack of plates compressed between two outside
covers, a fixed end cover or frame with connections on it and a removable end
cover or pressure plate. Depending on the manufacturer, plate height can
range from 0.2 to 3 m for a width from 20 to 40%of the height.

carrying bar

Fixed end
cover

bolts

Figure
6.88 Component parts in a plate and frame exchanger (After Alfa Laoal).

The plates have stamped grooves provided with peripheral gaskets. The
plate stack is guided by carrying bars and compressed by tightening com-
pression bolts. After compression, the gasket assures tightness of the result-
ing exchanger and fluid distribution in the channels formed between two con-
secutive plates.
The simplest solution consists in setting up parallel circuits for each of the
fluids, with circulation most commonly counter-current (Fig. 6.89A).
Depending on process parameters, fluid characteristics and flow rates,
allowable pressure drops, etc. it is possible to adjust circulation by grouping
the plates in series and/or parallel. According to the combinations, circulation
is more or less counter-current and an appropriate correction of the mean
temperature potential must be taken into account (Fig. 6.89B). Additionally,
the exchange surface area can be adjusted on the same frame depending on
the number of plates installed. The area can reach 2500 m2 for the largest
(Fig. 6.90).
 Chapter 6 HEATEXCHANGERS 325

U L

-
Figur
Circulation types 6.85
in a plate and -
frame exchanger.
+I
A . Counter-current
with parallel cir-
cuits. B. Series-par-
allel arrangement:
2 series of 4 paral-
lel circuits associ- B
ated with 4 series
of 2 parallel cir-
cuits.

The plates are corrugated (Fig. 6.91A) to impart rigidity and promote flow
turbulence between two plates. Manufacturers have a whole range of plates
whose type is defined by specific stamping that gives them thermo-hydraulic
performance by the induced flow turbulence. The most common plates feature
chevron-patterned corrugations which provide contact points between two
adjacent plates, thereby creating a complex fluid circulation channel. The
chevron angle p is an important geometrical parameter for hydrodynamics
and thermal transfer (Fig. 6.91B). Regarding the resistance to fluid flow, plates
with small chevron angles are termed "hard", and with large angles, "soft". The
selection of hard or soft plates, or even a combination of hard and soft plates,
is used to optimize the thermal exchange coefficient and the pressure drop. In
addition, the high local velocities generated by turbulence in the channels
allows fouling to be reduced in a ratio of approximately 10 to 1 in comparison
with a tubular exchanger.
326 Chapter 6 HEATEXCHANGERS

Figure
6.90 Plate and frame exchangers (After Alfa Laval).

Some manufacturers have developed particular exchanger designs with

hybrid plates: welded plates alternating with a plate-gasket assembly (Fig.
6.92). They allow more severe services for aggressive fluids circulating in the
channels between welded plates. Exchangers can also be designed with dual-
walled plates (Fig. 6.93) offering greater protection against joint failure and
preventing contamination between the circulating fluids.

6.8.1.2 Materials
Plates can be manufactured to constructor standards from any material that
can be stamped: stainless, titanium, titanium-palladium, Hastelloy, Incoloy,
etc. They can also be made of graphite. The gaskets are adapted to the fluids
and the operating conditions and are selected from elastomers: NBR (nitrile
butadiene rubber), EPDM (ethylene propylene diene monomer), HNBR (hydro-
genated nitrile butadiene rubber), etc.
 Chapter 6 HEATEXCHANGERS 327

A B

./p
.

- I
Figure
6.91 Examples o f plates.
A. Corrugated plate. B. Chevron orientation.

Figure

exchangers,
termed “cassettee8
type (After Alfa
Laud)
328 Chapter 6. HEATEXCHANGERS

Figure
6.93 Dual-walled plate exchanger (After Alfa Laual).

6.8.1.3 Use
Besides the advantages inherent to all types of compact exchangers, easy
mounting and dismounting of plates allows total and rapid accessibility for
manual cleaning and inspection. It also permits operating performance to be
adapted by modifying the exchange surface area (adding or removing plates)
or the efficiency (changing the arrangement of circuits). Plate patterms gener-
ate significant turbulence that is particularly conducive to less fouling.
Furthermore, easy manufacture of standardized plates generally results in
short supply times.
In contrast, since plates are assembled by compression and because there
are a large number of gaskets, these exchangers are not highly recommended
for relatively severe temperature (above 200'C) and pressure (above 25-
30 bar) conditions. They are also not well suited t o the circulation of high gas
flow rates at low pressure because of the high velocities in the channels with
their small hydraulic diameter and high pressure drops. Likewise, except when
the between-plate spacing is modified, they are not suited to the circulation of
loaded or very viscous fluids.

6.8.2 Brazed Plate Exchangers

Here the design and construction principle is fairly similar to that of plate and
frame exchangers. The exchanger surface consists of corrugated plates
stacked up and connected to one another by brazing (Fig. 6.94). The space
 Chapter 6. HEATEXCHANGERS 329

Figure
6.94 Brazed plate exchanger (After Alfa Laual).

between plates forms channels where the fluids circulate counter-currently. A

weld around the circumference of each plate assures the seal. The stack of
plates is placed between two outside protective plates. The plates are gener-
ally made of stainless steel, whereas the brazing material can be copper or
nickel. The exchange surface areas available are relatively small (a few tens of
square meters). Working pressure and temperature are limited, respectively
30 bar and 200°C approximately.
This type of exchanger is used mainly in refrigeration cycles and more par-
ticularly in climate control, for example control-room air conditioning.

6.8.3 Welded Plate Exchangers

There is a very wide variety of welded plate exchangers that can not all be pre-
sented due to the very large number of manufacturers on the market. Only cer-
tain types considered representative of specific technologies are presented in
this section. The same as for plate and frame exchangers, they are composed
of a pack of corrugated plates whose advantages have already been discussed.
330 Chapter 6 HEATEXCHANGERS

The plates are welded together by a variety of techniques depending on the

manufacturer. This practically eliminates the leakage risks inherent to plate
and frame exchangers, thereby extending the allowable pressure and temper-
ature limits. The mechanical resistance to pressures of approximately 40 bar
is commonly guaranteed and certain types can work at much higher pres-
sures.
Their major drawback is that mechanical cleaning is impossible since plate
surfaces are not accessible. This is true with the exception of some particular
exchangers with removable covers and a gasket affording access to the cir-
cuits. When chemical cleaning is not feasible, welded plate exchangers are
used only for relatively clean non-loaded fluids.

6.8.3.1 AlfaeRex Exchangers (Fig. 6.95)

The corrugated plates are laser welded in two dimensions in the plate plane.
In the direction perpendicular to the plates, the whole assembly can expand
or contract with temperature fluctuations. The same as for plate and frame
exchangers, the assembly is compressed between frame covers by bolts.

-
Figure
6.95 Alfu-Rex exchanger (After Alfu Luual).
 Chapter 6 HEATEXCHANGERS 331

Each modular exchanger affords an exchange surface area of up to approx-

imately 200 m2. Admissible operating conditions go from temperatures of
-50°C to 350°C and pressures of up to 40 bar. The use of stainless steel plates
allows them to be employed in an aggressive environment.

6.8.3.2 “Platular” Exchangers (Fig. 6.96)

The bundle consists of a stack of pairs of plates with stamped dents. Each pair
is made up of two symmetrically associated plates, thus creating two types of
channels: “corrugated” and “smooth”. The first type features alternating nar-
row and wide cross-sectional areas. Meanwhile the width of the second type
can be adjusted by changing the spacing between two consecutive pairs of
plates. This second type allows circulation of loaded fluids.
Circulation of the two fluids can be set u p with either counter- or cross-
flow. Distribution is provided by welded collectors or by boxes that can be
opened on one and/or the other of the two circuits, affording access to the
channels without unbolting the nozzles. Distribution can be adapted for use on
several fluids at the same time in a single exchanger. The exchange surface
area available for a single body can be several hundred square meters.

6.8.3.3 Compabloc Exchangers (Fig. 6.97)

The exchange surface consists of a stack of square plates stamped with 45”
corrugations and welded. The assembly is inserted in a casing whose side pan-
els are removable and allow access to the channels for cleaning and mainte-
nance operations.

Figure
6.96 1 “Platular” exchanger (After Barriquand).
A. “Corrugated” channel. B. “Smooth”channel.
332 Chapter 6 HEATEXCHANGERS

Figure
6.97 4-pass Cornpabloc exchanger. Exploded view (After Vicarbj.

Cornpabloc
exchanger with
37 passes and
375 plates, prooid-
ing 240 rn2 o f
surface area.
(After Vicarbj.
 Chapter 6 HEATEXCHANGERS333

The two fluids circulate in cross-flow, with multi-passes if needed, and with
an overall counter-current arrangement in order to meet the requirements of
significant outlet temperature crossovers.
Exchange surface areas are approximately 300 m2 per module at the most
(Fig. 6.98). The exchangers can be used for low temperatures in the cryogenic
range as well as up to 300°C. The operating pressure can go up to 30 bar.

6.8.3.4 Packinox Exchangers (Fig. 6.99)

Packinox exchangers consist of large size plates shaped by explosion forming,
then assembled and welded into a bundle. The main plate characteristics are:
length: 5 to 20 m,
width: 0.50 to 1.40 m,
thickness: 0.50 to 1.40 mm,
channel height: 2 t o 10 mm.

Fluid 1

frame

/
Fluid 1 I\
5
-00
Fluid 2
/
Fluid 1
\

Figure
6.99 Packinox exchanger plates (After Packinox).
 0
0
P
Feed Effluent Effluent
outlet t 1 inlet 1
,
F7- -
inlet
--
--
- ---A

Figure
6.100 Packinox exchanger on a catalytic reformer feedeffluentservice (After Packinox)
 Chapter 6 HEATEXCHANGERS 335

The plates can be stacked to a height of 0.2 to 2 m. The two fluids circulate
in the between-plate space counter-currently or cross-currently.
Fluid inlet and outlet collectors are welded at each end of the bundle. The
nozzles are connected to the collectors via pipes provided with expansion bel-
lows t o allow for differential expansion among the different component parts.
For some specific applications such as two-phase fluid feed, particular fluid
distribution systems are installed.
Since the plates are welded only around the periphery, even a small inside
overpressure will tend to push them away from one another. As a result, the
bundle is placed in a cylindrical chamber that is pressurized to keep the plates
pressed together and impart compressive resistance to the assembly. In most
applications the exchangers are installed vertically on site (Fig. 6.100).
The exchangers are normally built of stainless steel, but other materials
can be used for special corrosion resistance requirements, such as Hastelloy,
lncoloy and titanium.
They are well suited to installing large exchange surface areas (10000 to
15000 m2 per module), their thermal efficiency is high and their compactness
is an asset (150 to 300 m2/m3).Operating pressures can be high, approximately
300 bar, provided that the differential pressure between the circuits remains
lower than 30 to 40 bar. Likewise, the working temperature can reach 700°C, as
long as the temperature difference between the two fluids remains lower than
100°C. As mentioned earlier, expansion bellows are incorporated, they are
especially necessary during transient operating phases.
This type of exchanger is frequently used in the refining industry for feed-
effluent services in catalytic reforming, hydrotreating and hydrodesulfuriza-
tion units. Here the fluids involved are clean or very moderately fouling so
there is no need for mechanical cleaning.

6.8.4 Plate0Fin Exchangers

An exchanger with finned plates consists of an assembly of corrugated plates
separated by flat plates forming paths or channels for fluid circulation
(Fig. 6.101A). The heat flux is transmitted by conduction through the pass par-
titions which constitute the primary exchange surface. It then proceeds by
conduction once again through the parts of corrugations in contact with the
plates and by the corrugation side walls. The side walls fulfill the function of
fins by providing a secondary exchange surface. The corrugation geometry is
optimized according to the desired thermo-hydraulic performance. The sizing
parameters are fin height, their pitch or number per unit of path width and
their thickness. These parameters determine their efficiency. There is a vari-
ety of possible arrangements for stacking up the layers: the channels can be
differentiated according to the fluid involved, either by their geometrical char-
acteristics or by the number of channels provided for circulation. Moreover,
the fins serve as spacers between plates and impart mechanical resistance to
the assembly.
336 Chapter 6 HEATEXCHANGERS

r. I

A Primary exchange surface

Secondary exchange surface

Figure
6.10 1 Plate-fin exchangers.
A. Cross-sectiono f a channel. B. Fluid distribution along a path.

Distribution grooves proportion the fluids over the whole width of the
plates before they penetrate into the actual transfer zone as such and collect
them in the outlet zones (Fig. 6.101B).

6.8.4.1 Brazed PlateeFin Heat Exchangers: Brazed-PFHE

These exchangers have become very important due t o their increasing use,
their crucial role in the processes in which they are incorporated and their
cost [17, 181.

Construction principle (Fig. 6.102A)

The fins are formed by stamping sheet metal: stamping quality and dimen-
sion precision are essential to achieving excellent contact between corruga-
tions and separation sheets once they are assembled. The spaces between two
consecutive flat sheets are closed laterally by sealing bars from 3 to 25 mm
wide and the same height as the fin.
The exchanger consists of a stack of layers arranged to give one of the two
basic circulation modes: counter- or cross-current. The separation sheet thick-
 Chapter 6 HEATEXCHANGERS 337

ness is from 0.5 to 2 mm. At the ends, outside plates are thicker so as to make
the assembly sturdy and protect it from any impacts.
The body of the exchanger is a parallelepiped whose rigidity is imparted by
brazing. Beforehand, the various component parts are coated with a layer of
solder which is appropriate for the material. Brazing is performed in an elec-
tric oven. Vacuum brazing in an inert atmosphere is increasingly used as a pro-
cess and has displaced molten salt dip brazing. The control of the operation is
determinative for exchanger reliability. Generally semi-cylindrical collectors
are welded to the body at the fluid inlets and outlets. The collectors are
equipped with nozzles connecting them t o the piping.
A number of variations on this basic design are possible, with different
solutions involving the type and geometry of fins, the systems of distributing
fluids in the channels, the circulation configurations and the presence of sev-
eral fluids at the same time.

Different types of fins

Different types of fins are available (solid smooth, perforated smooth, ser-
rated, herringbone patterned) with variable dimensions and pitches
(Fig. 6.102B): 0.2 to 0.6 mm thick, 4 to 12 mm high, 240 to 800 fins per meter.
The selection is made according t o the required service. Solid smooth fins
allow low allocated pressure drops due to the small amount of turbulence they
generate. This is not necessarily a disadvantage for thermal transfer, particu-
larly for isothermal condensation.
The fins can be perforated. If the perforations cover between 5 and 25% of
the exchange surface depending on their density, they generate turbulence
that improves the transfer coefficient, but is detrimental for pressure drops.
Another advantage of perforations is that if the cross-sectional area should
become partially plugged up, the fluid can however be fed downstream from
the obstructed part. Furthermore, they also help limit fouling. They are used
particularly in distribution zones and for boiling, in which case they assure a
larger wetted surface area by breaking up any vapor film.
Serrated fins also generate turbulence due to the notches in the side faces
of the corrugations. This is favorable to transfer, but obviously at the expense
of high pressure losses. They are advantageous for low pressure one-phase gas
flow and, like the previous type with perforations, they also find an application
in boiling.
The performance of herringbone-patterned fins is somewhere between the
smooth and serrated type.
Distribution systems preferably use perforated smooth fins with a wide
pitch. For single-phase flows, distribution is fairly even. For two-phase streams
for which homogeneous liquid and vapor inlet is necessary, the two phases
must often be separated, introduced individually and then remixed in the heat
transfer zone passageways. Various systems have been developed by manu-
facturers, the principle of most of them is to use liquid or vapor spraying pipes
located in the collectors or upstream from the transfer zone.
338 Chapter 6 HEATEXCHANGERS

Straight solid Straight perforated

Serrated Herring bone

-
Figure
6.102 Plate fin heat exchangers.
A. Composition and assembly o f layers. B. Types o f fins (After Marston).

Arrangements
In order to adapt the cross-sectional area for fluid flow, it is also possible to
use double banking (Fig. 6.103) in addition to the option of selecting fin geom-
etry. The separation sheet becomes a secondary exchange surface and allows
pressure drop problems to be solved, obviously at the expense of the thermal
efficiency of a channel.
Several fluids - up to around ten - can exchange heat in the same appa-
ratus. Particular inlet and outlet collector arrangements are placed either at
the exchanger body ends or at intermediate locations where fluids can be
withdrawn and reintroduced if need be (Fig. 6.104). Circulation may be
counter-current or cross-current with one or more passes.
 Chapter 6 HEATEXCHANGERS 339

Double banking. 6.103

B Parting sheet

Figure
6.104 Plate-fin heat exchangers: three fluids (After Nordon Cryogtkie).
A. Seen from the outside. B. Close up of internal assembly.
340 Chaoter 6 HEAT EXCHANGERS

The size of the apparatus is essentially limited by the size of the manufac-
turer’s brazing furnaces. For aluminum exchangers, maximum dimensions are
approximately 7 m in length, 1.3 m in width and 1.5 m for the stack height.
Depending on the geometric definition of the fins, several thousand square
meters of finned exchange surface area can be installed per apparatus with 850
to 1500 m2/m3compactness.
Several blocks can be connected by a manifold system allowing layouts in
series, in parallel and both in series and in parallel (Fig. 6.105). Two blocks
may also be welded together to form a larger exchanger sharing a single man-
ifold.

--
Figure
6.105 Plate exchangers
-~ installed in parallel
(After Alpema).

Materials
Because of brazing techniques, these exchangers with brazed fins are
mostly made of aluminum or sometimes of stainless steel. The maximum work-
ing pressure for aluminum depends on the size. It may be approximately 120
bar for modest sizes with a width and stacked height of 0.60 m. The maximum
temperature is 65°C. The maximum pressure for stainless steel is 50 bar and
the maximum temperature, 650°C.
 Chapter 6. HEATEXCHANGERS 341

Use
Plate-fin heat exchangers are particularly used in cryogenics. The material
employed is aluminum, which has very good cold mechanical resistance and
a relatively low density, leading to savings in installation costs for supports
and foundations. However, aluminum is not recommended in cases of poten-
tial corrosion by fluids carrying mercury, wet ammonia, caustic soda, etc. Very
high thermal efficiency associated with good fluid distribution permit close
approaches of approximately 1°C. Modular manufacture lends itself to assem-
blies of several blocks in cold boxes, thereby minimizing on site construction
costs.
The temperature difference between fluids is limited to approximately 40 to
50°C, however, to limit differential thermal stress. Temperature variations
lower than l"C/min must be observed in order t o prevent thermal shocks dur-
ing transient phases, whether cooling down or heating up, or in the event of
rapid depressurization of one or more circuits.
Because of the narrow passages in the channels and the risks of plugging
by deposits, plate fin heat exchangers are reserved for clean fluids. Otherwise
they require filters to be placed up stream. In the event of plugging, they are
cleaned by reversing fluid circulation or by rapid expansion of compressed air
or nitrogen to detach the deposits.
This type of exchanger is widely used in gas processing plants, ethylene
production, ammonia synthesis, natural gas liquefaction and air separation
units, among others.

6.8.4.2 Welded PlateeFin Exchangers

These exchangers are made of titanium and feature forged fin plates that are
welded together by diffusion. The manufacturing process is derived from
those used in the aerospace industry. Forging and welding without filler metal
are performed at a temperature close to the melting point of the metal.
The stack is closed on the sides and ends by thick flat plates (Fig. 6.106A)
to form a block that yields a total finned exchange surface area of up to 600 m2.
The fluids circulate counter-currently in the different channels that can be
from 2 to 5 mm high. Fluid inlet-outlet collectors are welded with their nozzles
at the ends of the block (Fig. 6.106B).
This type of exchanger can withstand very high pressures, up to 500 bar,
and temperatures up to 400°C. Made of titanium, it was developed especially
for direct cooling of high pressure, possibly corrosive, fluids by seawater. It
makes an auxiliary seawater-fresh water cooling circuit unnecessary, the aim
of this auxiliary circuit being to overcome the corrosion problems due to sea-
water. Filters can be placed upstream on the seawater circuit to prevent plug-
ging by suspended particles settling out and to minimize fouling. Chemical
treatments can also be used to protect against biological fouling.
Rolls Lava1 exchangers are used on offshore platforms for cooling gases,
crudes or condensates.
342 Chapter 6 HEATEXCHANGERS

Figure
6.106 Welded plate-fin exchangers.
A. Assembly principle (After Rolls Laual). B. Rolls Lava1 exchanger.
 Chapter 6 HEATEXCHANGERS 343

6.8.5 Printed Circuit Heat Exchangers (PCHE)

These are plate exchangers without fins, with a channel manufacturing tech-
nique similar to those used for printed circuits in electronics. The channels are
etched on the plates by chemical attack after applying a photosensitive layer
which delimits the zones to be etched. The channel profile corresponding to
the etching is semi-circular, 1 mm deep with a diameter of 2 mm. The result is
small hydraulic diameters of approximately 1.2 mm.
The standard plates are rectangular, measuring 1.2 m x 0.6 m , and com-
monly 1.6 mm thick. They are stacked up and welded at the edges to form
modular blocks before the diffusion welding operation (Fig. 6.107).

Printed circuit
exchanger stack
of plates for two
fluids (After
Heatric Ltd.)

These elementary blocks of standard dimensions, 1.2 m x 0.6 m x 0.5 m, are

assembled in parallel by conventional welding to make up the body of the
exchanger (Fig. 6.108) and obtain the desired exchange surface area. Up to sev-
eral thousand square meters are possible with great compactness depending
on the etched channel size (1 000 to 5000 m2/m3).
The collectors and nozzles of the various circuits are welded on the blocks.
The channel and collector arrangement can be adjusted to obtain countercur-
rent or cross-current circulation and all the combinations possible.
344 Chapler 6. HEATEXCHANGERS

rigure
Assembling printed circuit blocks for two fluids and cross-
current circulation (After Heatric Ltd.).

Standard plate construction material is stainless steel, but other materials

can be used such as titanium for seawater. The construction principle and dif-
fusion welding give the assembly great mechanical integrity and allow opera-
tion under very severe pressure conditions of over 400 bar. The use of stain-
less steel permits operation in a wide temperature range from the cryogenic
range up to 300400°C.
Since these exchangers can not be disassembled, there is no access to the
channels, so only chemical cleaning can be contemplated. In the event of plug-
ging risks by deposition of suspended particles, it is mandatory to filter the
feed. A 200 to 400 pm mesh size is often used for the filters.
 Chapter 6 HEATEXCHANGERS 345

This type of exchanger is used in gas processing units. Since some low tem-
perature applications can lead to formation of hydrates and plugging, special
glycol injection channels can be incorporated at the block inlet with injection
in each passage. The same design can be chosen to remix in each passage the
liquid and vapor that was previously separated from a two-phase feed in order
to achieve good phase distribution. The exchanger is employed in different
high pressure processes: ethylene, ammonia and methanol manufacture, etc.

6.8.6 Circular Plate Exchangers

These exchangers employ corrugated circular plates, welded in pairs and
stacked to make up a bundle inserted in a cylindrical shell (Fig. 6.109A). The
fluid circulation inside can be set up in all the ways mentioned for conven-
tional plate-and-frame exchangers. On the shell side, the fluid circulates in the
channels provided between the pairs of welded plates. The shell can be
equipped with removable covers t o afford shell-side access for cleaning and
maintenance. Segmental baffles can be installed to obtain counter-current cir-
culation with several passes (Fig. 6.109B).

- L / v v "

~ , [ l l l O-l ~ l ~ l ~ ~ ~ ' ~ ~ -
~ ~ ~ ' - l ~

Figure
6.109 Circular plate exchangers.
A Construction principle (After APV)
346 Chapter 6 HEATEXCHANGERS

The plates are made of stainless steel, titanium or other alloys. The shell
may be made of carbon steel if there are no particular corrosion problems.
Circular plate exchangers are suited for exchange surface areas of approx-
imately 100 m2 for applications such as waste heat recovery and cooling cir-
cuits. They can be used up to a pressure level of approximately 70 to 100 bar
and for temperatures of up to 350°C. The fluid circulating inside the plates
should not be excessively fouling.

6.8.7 Spiral Plate Exchangers

A spiral plate exchanger is constructed from an assembly of two plates form-
ing a pair of concentric spiralled passages. Any material that can be cold rolled
and welded can be used (carbon steel, stainless steel, etc.). The body of the
exchanger is obtained by rolling up the passages (Fig. 6.110).
At each end of the body, one out of every two channels is blocked by weld-
ing. Flat covers with gaskets assure the seal and are held onto the ends of the
body by a system of tightening clamps to complete the closure of the open
channels.

Figure
6.1 10 Spiral plate exchangers. Set up with countercurrent fluid circulation (AfterAlfa
Laval).
 Chapter 6 HEATEXCHANGERS 347

The fluids circulate counter-currently in the spiral channels, with each

channel continuous and fluid-tight. For each of the two fluids, the inlet and out-
let connections are placed respectively laterally on the outside casing of the
spiral and axially on each cover.
Cross-current fluid circulation can also be achieved,particularly for con-
densation or vaporization services. The vapor enters the open spiral body of
a condenser directly and the cooling fluid circulates in the closed spiral pas-
sages (Fig. 6.11 1).

l L

Figu
Spiral condenser. 6.11

J, .

The cross-sectional area for the vapor is adapted to the large volume flow
rates found in low pressure operations and allows low pressure drop, also due
to the short flow length. If inert gases accompany the condensate, a draw-off
nozzle is placed laterally at the spiral zone outlet.
 Next Page

348 Chapter 6. HEAT EXCHANGERS

-
Figure
6.1 12 Spiral plate exchangers.
A. Integrated condenser. B. Integrated dephlegrnator (AfterAlfa Laual).

Spiral equipment can be directly bolted t o the top of distillation columns

or reactors to accomplish total or partial condensation of vapors with with-
drawal of products (Fig. 6.112A). For dephlegmators, the internal reflux
required by the process can be drawn off (Fig. 6.112R).
The same concept of a cross-current circulation set up is used for vaporiz-
ers and reboilers, with the rising two-phase fluid circulating in the open spiral
body and the heating fluid in the closed spiral passages. This concept is also
advantageous when a fluid is loaded with solid particles. It then circulates in
the open channels that are accessible for cleaning. Whatever the circulation
mode, only clean fluids can be contemplated on the inaccessible channel side.
Spiral exchangers can have widely varying heights and diameters. The
maximum exchange surface area conceivable is approximately 500 m2, for a
diameter of 2 m and a spiral width of 2 m. Compactness is comparable to that
of tubular exchangers (100 m2/m3), but much lower than that of plate exchang-
ers (Fig. 6.113). Limiting operating conditions depend on the size of the
exchanger, particularly on the diameter. Maximum working pressure and tem-
perature are approximately 30 bar and 400°C.