Professional Documents
Culture Documents
Heat Exchangers - Hassan ElBanhawi
Heat Exchangers - Hassan ElBanhawi
Baffles—evenly spaced partitions in a shell-and-tube heat exchanger that support the tubes, prevent vibration,
control fluid velocity and direction, increase turbulent flow, and reduce hot spots.
Counterflow—refers to the movement of two flow streams in opposite directions; also called countercurrent flow.
Crossflow—refers to the movement of two flow streams perpendicular to each other.
Differential pressure—the difference between inlet and outlet pressures; represented as ΔP, or delta p.
Differential temperature—the difference between inlet and outlet temperature; represented as ΔT, or delta t.
Fouling—buildup on the internal surfaces of devices such as cooling towers and heat exchangers, resulting in
reduced heat transfer and plugging.
Multipass heat exchanger—a type of shell-and-tube heat exchanger that channels the tubeside flow across the
tube bundle (heating source) more than once.
Sensible heat—heat that can be measured or sensed by a change in temperature.
Shell-and-tube heat exchanger—a heat exchanger that has a cylindrical shell surrounding a tube bundle.
Shell side—refers to flow around the outside of the tubes of a shell-and-tube heat exchanger.
Thermosyphon reboiler—a type of heat exchanger that generates natural circulation as a static liquid is heated to
its boiling point.
Tube sheet—a flat plate to which the ends of the tubes in a heat exchanger are fixed by rolling, welding, or both.
Tube side—refers to flow through the tubes of a shell-and-tube heat exchanger.
Introduction
Heat transfer is an important function of many industrial processes. Heat exchangers are
widely used to transfer heat from one process to another. A heat exchanger allows a hot
fluid to transfer heat energy to a cooler fluid through conduction and convection. A heat
exchanger provides heating or cooling to a process. A wide array of heat exchangers has
been designed and manufactured for use in the chemical processing industry.
Classification
1. Pipe Coil Heat Exchangers
In pipe coil exchangers, pipe coils are submerged in water or sprayed with water to transfer heat. This type of
operation has a low heat transfer coefficient and requires a lot of space. It is best suited for condensing vapors with
low heat loads.
In a parallel flow exchanger, the exit temperature of one fluid can only approach the exit temperature of the other
fluid. In a countercurrent flow exchanger, the exit temperature of one fluid can approach the inlet temperature of the
other fluid. Less heat will be transferred in a parallel flow exchanger because of this reduction in temperature
difference. Static films produced against the piping limit heat transfer by acting like insulating barriers. The liquid
close to the pipe is hot, and the liquid farthest away from the pipe is cooler. Any type of turbulent effect would tend to
break up the static film and transfer heat energy by swirling it around the chamber. Parallel flow is not conducive to
the creation of turbulent eddies.
Shell-and-tube heat exchangers are designed to handle high flow rates in continuous operations. Tube arrangement
can vary, depending on the process and the amount of heat transfer required. As the tube-side flow enters the
exchanger—or “head”—flow is directed into tubes that run parallel to each other. These tubes run through a shell that
has a fluid passing through it. Heat energy is transferred through the tube wall into the cooler fluid. Heat transfer
occurs primarily through conduction (first) and convection (second). Liquids move from the bottom of the device to
the top to remove or reduce trapped vapor in the system. Gases move from top to bottom to remove trapped or
accumulated liquids. This standard applies to both tube-side and shell-side flow.
The Tubular Exchanger Manufacturers Association (TEMA) classifies heat exchangers by a variety of design
specifications including American Society of Mechanical Engineers (ASME) construction code, tolerances, and
mechanical design:
• Class B, Designed for general-purpose operation (economy and compact design)
• Class C. Designed for moderate service and general-purpose operation (economy and compact design)
• Class R. Designed for severe conditions (safety and durability)
5. Reboilers
Reboilers are used to add heat to a liquid that was once boiling until the liquid boils again. Reboilers are closely
associated with the operation of a distillation column. Typical reboiler arrangements include five basic patterns:
flooded-tube kettle reboiler, natural circulation, forced circulation, vertical thermosyphon, and horizontal
thermosyphon. These types of devices are classified by how they produce fluid flow. If a mechanical
device, such as a pump, is used, the reboiler is referred to as a forced circulation reboiler. Circulation that does not
require a pump is classified as natural circulation.
Kettle Reboiler
Kettle reboilers are shell-and-tube heat exchangers designed to produce a two-phase, vapor-liquid mixture that
can be returned to a distillation column. Kettle reboilers have a removable tube bundle that uses steam or a high-
temperature process medium to boil the fluid. A large vapor cavity above the heated process medium allows
vapors to concentrate. Liquid that does not vaporize flows over a weir and into the liquid outlet.
Hot vapors are sent back to the distillation column through the reboiler’s vapor outlet ports. This process controls
the level in the bottom of the distillation column, maintains product purity, strips smaller hydrocarbons from larger
ones, and helps maintain the critical energy balance on the column. An important concept with a distillation
column is energy or heat balance. Reboilers are used to restore this balance by adding additional heat for
the separation processes. Bottom products typically contain the heavier components from the tower. Reboilers
take suction off of the bottom products and pump them through their system. Column temperatures are controlled
at established set-points. Product flow enters the bottom shell side of a reboiler. As flow enters the reboiler, it
comes into contact with the tube bundle. The tubes have steam or hot fluids flowing through them. As the bottom
product comes into contact with the tubes, a portion of the liquid is flashed off (vaporized) and captured in the
dome-shaped vapor cavity at the top of the reboiler shell. This vapor is sent back to the tower for further
separation. A weir contains the unflashed portion of the liquid in a reboiler. Excess flow goes over the weir and is
recirculated through the system. Kettle reboilers are easy to control because circulation and two-phase flow rates
are not considerations.
Vertical and Horizontal Thermosyphon Reboilers
A thermosyphon reboiler is a fixed head, single-pass heat exchanger connected to the side of a distillation
column. Thermosyphon heat exchangers can be mounted vertically or horizontally. The critical design factor is
providing sufficient liquid head in the column to support vapor or liquid flowback to the column. Natural circulation
occurs because of the differences in density between the hotter liquid in the reboiler and the liquid in the
distillation tower. One side of the exchanger is used for heating, usually with steam or hot oil; the other side takes
suction off the column. When steam is used as the heated medium in a vertical exchanger, it enters from the top
shell inlet and flows downward to the shell outlet, to allow for the removal of condensate. The lower tube inlet of
the exchanger usually takes suction at a point low enough on the column to provide a liquid level to the
exchanger. A pump is not connected to the column and exchanger unless a forced circulation system is required.
This system uses buoyancy forces to flash off and pull in liquid. Newton’s third law of motion, which states that for
every action there is an equal and opposite reaction, is a basic operating principle of thermosyphon reboilers. As
liquids and vapor circulate back to the column, the inlet line provides fresh liquid to support the circulation.
Stab-In Reboiler
The stab-in reboiler is mounted directly into the base of the distillation column. Steam or hot oil is used as the
heating medium. Heat energy is transferred directly into the process medium. The lower section on a distillation
column is specially designed to allow the bottom product to boil. This lower section maintains a liquid seal as hot
vapors move up the column and heavy liquids collect in the bottom.
The openings on the plate exchanger are located typically on one of the fixed-end covers. As hot fluid enters the hot
inlet port on the fixed-end cover, it is directed into alternating plate sections by a common discharge header. The
header runs the entire length of the upper plates. As cold fluid enters the countercurrent cold inlet port on the fixed-
end cover, it is directed into alternating plate sections. Cold fluid moves up the plates while hot fluid drops down
across the plates. The thin plates separate the hot and cold liquids, preventing leakage.
Fluid flow passes across the plates one time before entering the collection header. The plates are designed with an
alternating series of chambers. Heat energy is transferred through the walls of the plates by conduction and into the
liquid by convection. The hot and cold inlet lines run the entire length of the plate heater and function like a
distribution header. The hot and cold collection headers run parallel and on the opposite side of the plates from each
other. The hot fluid header that passes through the gasketed plate heat exchanger is located in the top. This
arrangement accounts for the pressure drop and turbulent flow as fluid drops over the plates
and into the collection header. Cold fluid enters the bottom of the gasketed plate heat exchanger and travels
countercurrent to the hot fluid. The cold fluid collection header is located in the upper section of the exchanger.
Plate-and-frame heat exchangers have several advantages and disadvantages. They are easy to disassemble and
clean and distribute heat evenly so there are no hot spots. Plates can easily be added or removed. Other advantages
of plate-and-frame heat exchangers are their low fluid resistance time, low fouling, and high heat transfer coefficient.
In addition, if gaskets leak, they leak to the outside, and gaskets are easy to replace. The plates prevent cross-
contamination of products. Plate-and-frame heat exchangers provide high turbulence and a large pressure drop and
are small compared with shell-and-tube heat exchangers.
Disadvantages of plate-and-frame heat exchangers are that they have high-pressure and high-temperature
limitations. Gaskets are easily damaged and may not be compatible with process fluids.
7. Air Coolers
A different approach to heat transfer occurs in the fin fan or air-cooled heat exchanger. Air-cooled heat exchangers
provide a structured matrix of plain or finned tubes connected to an inlet and return header. Air is used as the outside
medium to transfer heat away from the tubes. Fans are used in a variety of arrangements to apply forced convection
for heat transfer coefficients. Fans can be mounted above or below the tubes in forced-draft or induced-draft
arrangements. Tubes can be installed vertically or horizontally.
The headers on an air-cooled heat exchanger can be classified as cast box, welded box, cover plate, or manifold.
Cast box and welded box types have plugs on the end plate for each tube. This design provides access for cleaning
individual tubes, plugging them if a leak is found, and rerolling to tighten tube joints. Cover plate designs provide
easy access to all of the tubes. A gasket is used between the cover plate and head. The manifold type is designed
for high-pressure applications.
Mechanical fans use a variety of drivers. Common drivers found in service with air-cooled heat exchangers include
electric motor and reduction gears, steam turbine or gas engine, belt drives, and hydraulic motors. The fan blades
are composed of aluminum or plastic. Aluminum blades are designed to operate in temperatures up to 300°F
(148.88°C), whereas plastic blades are limited to air temperatures between 160°F and 180°F (71.11°C, 82.22°C).
Air-cooled heat exchangers can be found in service on air compressors, in recirculation systems, and in condensing
operations. This type of heat transfer device provides a 40°F (4.44°C) temperature differential between the ambient
air and the exiting process fluid. Air-cooled heat exchangers have none of the problems associated with water such
as fouling or corrosion. They are simple to construct and cheaper to maintain than water-cooled exchangers. They
have low operating costs and superior high temperature removal (above 200°F or 93.33°C).
Their disadvantages are that they are limited to liquid or condensing service and have a high outlet fluid temperature
and high initial cost of equipment. In addition, they are susceptible to fire or explosion in cases of loss of
containment.
References
1-ENGINEERING DATA BOOK by Gas Processors Suppliers Association
2-Process Technology - Equipment and Systems by Charles E. Thomas