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A Critical Review on Heat Exchangers used in Oil Refinery

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 Afro - Asian International Conference on Science, Engineering & Technology
A Critical Review on Heat Exchangers used in Oil
Refinery
Nikhil Deepak Kundnaney
Student, BE, Mechanical Engg.
AITS, Rajkot, Gujarat, India.
nkundnaney@gmail.com
Abstract: This review paper is comprehensive study of heat
exchangers used in oil refineries, their design consideration and
common type of heat exchanger failures. shell-and-tube type of heat
exchangers have been commonly and most effectively used in oil
refineries over the years. A large percentage of world market for heat
exchangers is served by the shell-and-tube heat exchanger. Apart
from oil industries Shell and tube heat exchangers (STHE) are widely
used in many industrial areas, such as power plant, chemical
engineering, food processing etc.
Keywords: heat exchanger, design consideration, shell and tube
heat exchanger.
I. INTRODUCTION
A heat exchanger is a piece of equipment built for efficient
heat transfer from one medium to another. The media may be
separated by a solid wall, so that they never mix, or they may
be in direct contact. They are widely used in space heating,
refrigeration, air conditioning, power plants, chemical plants,
petrochemical plants, natural gas processing, and sewage
treatment. The classic example of a heat exchanger is found in
petroleum refineries. Oil Refinery is an industry which refines
crude oil into more useful petroleum products, such as
gasoline, diesel fuel, asphalt base, heating oil, kerosene, and
liquefied petroleum gas by ]fractional distillation. The process
flow diagram for the same is given below [1].
Fig. 1. Flow process diagram of crude refining in oil industry
Akshar Publication © 2015
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AAICSET-2015
ISBN: 9-780993-909238
(Paper ID: Bharuch2k15C0109)
Deepak Kumar Kushwaha
Assistant professor, Mechanical Dept.
AITS, Rajkot, Gujarat, India.
dykushwaha@aits.edu.in
We can separate the components of crude oil by taking
advantage of the differences in their boiling points. This is
done by simply heating up crude oil, allowing it to vaporize,
and then letting the vapor to condense at different levels of the
distillation tower (depending on their boiling points). This
process is called fractional distillation and the products of this
fractional distillation of crude oil are called fractions. Heat
exchangers preheat feedstock in distillation towers and in
refinery processes to reaction temperatures. Heat exchangers
use either steam or hot hydrocarbon transferred from some
other section of the process for heat input.
A fraction from crude oil can be categorized into two
categories:
Refined Product: A crude oil fraction which contains a lot of
individual hydrocarbons (e.g. gasoline, asphalt, waxes, and
lubricants)
Petrochemical Product: A crude oil fraction which contain
one or two specific hydrocarbons of high purity (e.g. benzene,
toluene, and ethylene).
II. MAIN COMPONENTS/EQUIPMENTS OF CRUDE REFINING
OIL INDUSTRY[1][2]
 Desalters
 Atmospheric distillation tower
 Vacuum distillation tower
 Heat exchangers, coolers, and process heaters
 Tank storage
 Heater and boiler
 Gas and air compressor
 Turbines
 Pumps, piping and valves
Desalters
Crude oil often contains water, inorganic salts, suspended
solids, and water-soluble trace metals. To reduce corrosion,
plugging, and fouling of equipment these contaminants must
be removed by desalting (dehydration). This is done in
desalters.
Atmospheric Distillation Tower
Separation of crude oil into various fractions or straight-run
cuts by distillation in atmospheric and vacuum towers.
Vacuum Distillation Tower
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 Afro - Asian International Conference on Science, Engineering & Technology
AAICSET-2015
ISBN: 9-780993-909238

In order to further distill the residuum or topped crude from

the atmospheric tower at higher temperatures & reduced
pressure vacuum distillation towers.
Heat Exchangers, Coolers, and Process Heaters
Process heaters and heat exchangers preheat feedstock in
distillation towers and in refinery processes to reaction
temperatures. Heat exchangers use either steam or hot
hydrocarbon transferred from some other section of the
process for heat input. The major portion of heat provided to
process units comes from fired heaters fueled by refinery or
natural gas, distillate, and residual oils. Fired heaters are found
on crude and reformer preheaters, cooker heaters, and large-
column rebuilders.
Tank Storage
Atmospheric storage tanks and pressure storage tanks are used
throughout the refinery for storage of crudes, intermediate
hydrocarbons (during the process), and finished products.
Tanks are also provided for fire water, process and treatment
water, acids, additives, and other chemicals.
(a) Parallel flow
III. TYPES OF HEAT EXCHANGING PROCESSES USED IN OIL
REFINERY[3]
 Cooling – Cooling using water or air, without phase
change.
 Chilling – Refrigerating below that obtainable with
water.
 Condensing – Condensing vapour/ vapour mixture.
 Steam Heating – Using steam for heating.
 Steam Generating – Producing steam from water.
 Reboiler – Using steam/hot fluid to heat, for
distillation column.
To achieve a particular engineering objective, it is very
important to apply certain principles so that the product
development is done economically. This economic is
important for the design and selection of good heat transfer
equipment. In order to perform various heat exchanging
process described above heat exchangers are manufactured in
different types, however the simplest form of the heat (b) Counter flow
exchanger consist of two concentric pipes of different
diameters known as double pipe heat exchanger. In this type
of heat exchanger, one fluid flows through the small pipe and Fig. 2. Double pipe heat exchangers with different flow and their respective
temperature profile. [4]
another fluid flows through the space between both the pipes.
The flows of these two different fluids, one is at higher The further development is done in the heat exchangers to
temperature called hot fluid and another is at lower facilitate them in different applications as per requirement.
temperature called cold fluid, can be in same or in opposite These heat exchangers are different from the conventional
directions. If the flows are in same direction then the heat heat exchangers such that they have large heat transfer surface
exchanger is called as parallel flow heat exchanger and if the area per unit volume and are known as compact heat
flows are in opposite direction then the heat exchanger is exchangers. For the compact heat exchangers,
called as counter flow heat exchanger.

The heat exchangers having area density greater than 700 are
known as compact heat exchangers.[5]

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 Afro - Asian International Conference on Science, Engineering & Technology
IV. HEAT E XCHANGERS USED IN REFINERY
In oil refineries and petrochemicals we generally use shell and
tube type of heat exchangers which are classified under
TEMA (Tubular Exchanger Manufacturers Association) to
transfer heat between two fluids. Heat Exchangers here
generally find their application in preheating of the fluids.
More than 35-40 % of heat exchangers are of the shell and
tube type due to their robust geometry construction, easy
maintenance and possible upgrades. [6]
V. EXPLANATION OF E ACH TYPE OF HEAT EXCHANGER
USED IN OIL REFINERY. [7][8][9]
A. U-TUBE Heat Exchanger-
Fig. 3. U tube heat exchanger
A U-TUBE heat exchanger generally is taken less under
consideration for heat exchanging because in case of any
leakage or testing the tubes are difficult to clean. Here the tube
expansion is independent of other tubes. This is used in oil
refinery in crude distillation unit for heat exchange between
crude and medium pressure steam.
B. Fixed Tube Sheet Heat Exchanger-
Fig. 4. Fixed tube sheet heat exchanger
A fixed tube sheet heat exchanger is the most cheapest and
economical type of heat exchanger used in any oil refinery
for heat exchanging because the mechanism of its
operation is simple and also the testing and repair of the
same is easy to perform.
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ISBN: 9-780993-909238
C. Floating Head Heat Exchanger-
Fig. 5. Floating head type heat exchanger
A floating head type of heat exchanger is the most efficient
type of heat exchanger used in an oil refinery. It has a floating
head attached to one of its end which helps in the proper heat
transfer between fluids. The floating heat permits the free
expansion and contraction. Also this type of heat exchanger is
easy to clean and test for performance enhancements purpose.
This is used in oil refinery in crude distillation unit for heat
exchange between crude and naphtha. It increases the
temperature of crude. It is used to preheat the heat exchanger
before sending it to crude distillation column.
D. Kettle Type Heat Exchanger-
Fig. 6. Kettle type heat exchanger
A kettle type heat exchanger is a special type of heat
exchanger which is used when the fluid s used consist of high
pressure gases and this heat exchanger has a specially
designed shell that gives expansion space to the heat
exchanger. This heat exchanger can handle large amount of
load fluctuation. This is used in oil refinery in crude
distillation unit for heat exchange between naphtha and diesel
or between kerosene (light and heavy) and heavy atmospheric
gas oil (HAGO).
VI. RELATIVE IMPORTANCE OF SHELL AND TUBE HEAT
EXCHANGER [10][11]
Shell and tube heat exchangers are the most widespread and
commonly used basic heat exchanger configuration in the
process industries. The reasons for this general acceptance are
several.
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 Afro - Asian International Conference on Science, Engineering & Technology
• The shell and tube heat exchanger provides a
comparatively large ratio of heat transfer area to
volume and weight.
• It provides this surface in a form which is relatively
easy to construct in a wide range of sizes.
• It is mechanically rugged enough to withstand normal
shop fabrication stresses, shipping and field erection
stresses, and normal operating conditions.
• The shell and tube exchanger can be reasonably
easily cleaned, and those components most subject to
failure - gaskets and tubes – can be easily replaced.
• Shop facilities for the successful design and
construction of shell and tube exchangers are
available throughout the world.
VII. EXISTING INDUSTRIAL SCENARIO IN INDUSTRIES.
Heat exchangers are used in industrial process to recover heat
between two process fluids. Shell-and-tube heat exchangers
(STHE) are the most widely used heat exchangers in process
industries because of their relatively simple manufacturing and
their adaptability to different operating conditions. But
nowadays numbers of industries are searching for effective
and less time consuming alternatives of designing of shell-
and-tube heat exchangers. As per literature and industrial
survey it is observed that there is need of effective design
options for STHE. Shell and tube heat exchangers are
designed normally by using either Kern’s method or Bell-
Delaware method. Kern’s method is mostly used for the
preliminary design and provides conservative results. In this
paper we have described Kern’s method of designing in detail.
The steps of designing are described as follows: [12][13][14]
i. First we consider the energy balance to find out the values of
some unknown temperature values. Certainly some inputs like
hot fluid inlet and outlet temperatures, cold fluid inlet
temperature, and mass flow rates of the two fluids are needed
to serve the purpose. The energy balance equation may be
given as:
Q  mh c ph (th1  th 2 )  mc c pc (tc1  tc 2 ) ….. (1)
ii. Then we consider the LMTD expression to find its value:
T1  T2
LMTD  ….. (2)
T1
ln( )
T2
Where, T1  th1  tc 2 and T2  th 2  tc1
iii. Our next step is to calculate the area required of the heat
exchanger (on the basis of assumed), number of tubes, tube
bundle diameter, diameter of shell and its thickness with the
help of following expressions: 4
Akshar Publication © 2015
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ISBN: 9-780993-909238
Q
A ….. (3)
U 0 T
A
Nt  ….. (4)
 d t 0l
N
Db  d t 0 ( 1 )1/ n1 ….. (5)
N2
iv. Then we calculate the proper baffle dimension viz. its
diameter, thickness and baffle spacing.
v. Our next step is to find out heat transfer coefficients on the
inner and outer surface of the tubes using following
correlation:
Nu  0.27( Re )0.68 ( Pr ) 0.86 ( Pr / Prw ) 0.25 ….. (6)
vi. Then by the values obtained by the above equation we
calculate the actual value of heat transfer coefficient and check
whether the actual value is greater than the assumed one or
not. If the actual overall heat transfer coefficient is greater
than the assumed one then the designing is considered correct,
otherwise the steps need to be repeated guessing more
accurately the value of overall heat transfer coefficient.
VIII. FAILURE AND REPAIRING TECHNIQUE[15][16]
E. Mechanical Failure
Anything which is not able to perform its desired function
comes under the category of failures. Some the mechanical
failure are tube-to-tube sheet joint leakage, loosening of gasket
bolting, erosion of tubes at entry side, erosion of tubes on
outside surface, erosion of inlet/outlet nozzles. The repair of
mechanical failure is generally following the maintenance
procedure or upgrading the metallurgy.
F. Tube leak failure
A tube leak failure can be repaired by cutting of leaky
tube, investigating the same and plugging the leaky tube by
tapper plugs.
G. Tube to tube sheet joint failure
Roll Expanded joint leak can be repaired by re-rolling or by
drilling out the old tube and reinserting new tube and
expansion.
H. Gasket failure
Gasket leakage can be generally repaired by replacing the
same by a proper gasket with standard installation and
tightening procedures.
I. Shell failure
Shell failure generally occurs due to corrosion of the inner
surface of the metal or by the erosion of the metal used in
shell. For repairing the same we overlay using suitable filter
wire. Window cutting and replacement is also a suggested
repair in many cases.
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 Afro - Asian International Conference on Science, Engineering & Technology
AAICSET-2015
ISBN: 9-780993-909238

J. Tube to tube sheet joint failure [12] R. Mukherjee, “Practical Thermal Design of Shell and Heat
Roll Expanded joint leak can be repaired by re-rolling or by Exchangers,” 2nd Edition, Chapter 1-5, 8 Begell House, Redding, 2004.
[13] A. D. Patil, P. R.Baviskar, M. J.Sable, S. B.Barve , “Optimization of
drilling out the old tube and reinserting new tube and Economiser Design for the Enhancement of Heat Transfer Coefficient”,
expansion. International Journal of Applied Research in Mechanical Engineering,
K. Gasket failure Volume-1, Issue-2, 2011.
[14] P. S. Amrutkar, S. R. Patil, “Automotive Radiator Performance-
Gasket leakage can be generally repaired by replacing the
Review”, International Journal of Engineering and Advanced
same by a proper gasket with standard installation and Technology, Volume-2, Issue-3, Feb-2013
tightening procedures. [15] Joe Bell, Tranter, “Maintaining a Plate Heat Exchanger”. Tranter, Inc.
L. Shell failure 2002.
[16] Macro Trenghai “Preventive mentenance for plate heat exchanger”
Shell failure generally occurs due to corrosion of the inner RSES Journal JUNE 2012
surface of the metal or by the erosion of the metal used in
shell. For repairing the same we overlay using suitable filter
wire. Window cutting and replacement is also a suggested
repair in many cases.
IX. CONCLUSION
This review paper present the importance of heat exchanger in
oil refineries. Petroleum refineries are the continuous process
industry. Extraction of oil and other by product are very
complicated and continuous chain process, which requires
most reliable and efficient equipment’s. So it is obvious that
the heat exchangers are the useful tools in the industries. After
the above discussion it is easy to say that the shell & tube type
heat exchangers has been given a great respect among all the
classes of heat exchangers due to their virtues like
comparatively large ratios of heat transfer area to volume and
weight and many more. Moreover well designed as well as
described methods are available for its designing and analysis.
REFERENCES
[1] James R. Couper; W. Roy Penney, James R. Fair, Stanley M. Walas,
Chemical Process Equipment: selection and design, Elsevier Inc., 2nd
ed. 2005.
[2] USGS (United States Geological Survey). Heavy oil and natural
bitumen—strategic petroleum resources, ed. Richard F. Meyer and Emil
D. Attanasi. Reston, VA: United States Geological Survey.2003
[3] USGS (United States Geological Survey). 2000. World Petroleum
Assessment, 2000
[4] TEMA, “Standards of the Tubular Exchanger Manufacturer’s
Association [TEMA],” 8th Edition,Section 1-5
[5] S. T. M. Than, “Heat Exchanger Design, ” World of Science, Engg. and
Technology, Vol. 46, pp.604-611, 2008
[6] R. K. Shah,”Fundamentals of Heat Exchanger Design,”2nd edition,
Chapter 1-5,Wiley,Hoboken,2003
[7] Apu Roy, D.H.Das, “CFD Analysis of a Shell and Finned Tube Heat
Exchanger for Waste Heat Recovery Applications”, International
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[8] S. S. Shinde, P. V. Hadgekar, S. Pavithran, “Comparative Thermal
Analysis of Helixchanger with Segmental Heat Exchanger Using Bell
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[9] Design & Development of Shell & TubeType Heat exchanger Modern
Mechanical Engineering, 2012, 2, 121-125: 10.4236/mme.2012.24015
Published Online Nov 2012.
[10] ASME Section VIII, Division I, “Rules for Construction of Pressure
Vessels,” 2007.
[11] Manish Baweja, Dr. D. N. Bartaria, “A Review on Performance
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Volume-3, Issue-1, Jan-Feb 2013.

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