HEAT EXCHANGERS

Marine Engine System II

(CEng). Francis Kofi Korsah
MSc. Marine Operations & Survey
 THEORY OF HEAT TRANSFER

The mediums by which heat can be transferred are :

Conduction
Convection
Radiation
 CONDUCTION

Conduction is the process by which heat flows by molecular transportation

along or through a material or from one material to another, the material
receiving the heat being in contact with that from which it receives it
 CONVECTION

Convection occurs in liquids and gases. For any solid to lose or gain
heat by convection it must be in contact with the fluid. Convection
cannot occur in a vacuum. Convection results from a change in density
in parts of the fluid, the density change being brought about by an
alteration in temperature.
 RADIATION

The process by which heat is emitted from a body and transmitted across
space as energy is called radiation. Heat radiation is a form of wave
energy in space similar to radio and light waves. Radiation does not
require any intermediate medium such as air for its transfer. It can
readily take place across a vacuum.
 HEAT EXCHANGERS

Heat exchangers are equipment designed to enable heat to be transferred from

one medium to another.

They are classified as either heaters or coolers. Most coolers used on board ship
transfer heat from a hot fluid to sea water.

For main engine the jacket water, lubricating oil, charge air and water or oil
used in cooling the pistons must be cooled.
 HEAT EXCHANGERS
In a steam ship apart from the heat yielded to the main condenser, the turbine
and gearbox lubricating oils provide the principal sources of heat which are
rejected to the circulating cooling water

Steam heated heat exchangers include heavy oil heaters, units to heat sea
water for tank washing, evaporators, feed heaters and calorifiers
In almost all heat exchangers, heat flows from the hot fluid to a cooler one
through an intermediate heat – conductive wall, which takes up some
intermediate temperature
 HEAT EXCHANGERS

In a practical heat exchanger, the thermal performance is described by the equation

Q = UθA
Where;
Q = rate of heat transfer;
θ = logarithmic mean of temperature differences at the inlet and outlet of the heat
exchanger;
A = surface area of heat transfer wall.
U = the overall coefficient of heat transfer from one fluid to another in a heat
exchanger
HEAT EXCHANGERS
FLOW PATTERNS USED IN HEAT EXCHANGERS
 FLOW PATTERNS USED IN HEAT EXCHANGERS

Counter flow is the best thermodynamically of the basic patterns.

In practice most heat exchangers use mixed flow to obtain the best result.
For efficient heat transfer turbulent flow is best, but erosion of metal surface
will be greatest.
For little erosion of metal surface streamline flow is required, but heat
transfer will be relatively poor.
 TYPES OF HEAT EXCHANGERS

 Shell and tube type

 Plate Type
 SHELL AND TUBE
In the shell and tube design a tube bundle or stack is fitted into a shell.

The stack comprises a number of tubes secured into a tube plate at each end, and a
series of baffles directs the flow of hot fluid back and forth across the tube bundle.

The end plates are sealed at either end of the shell and provision is made at one end
for expansion.

At each end of the heat exchanger also is a header (also called water box), whose
purpose is to conduct the other fluid (usually sea water) through the tubes
SHELL AND TUBE
SHELL AND TUBE
 SHELL AND TUBE
These headers may be designed to give a single pass through the tubes or two
passes.
Removable covers are normally provided on the headers to facilitate access to the
tubes for cleaning.

Depending on the size and duty of the cooler the cylindrical shell may be of
fabricated steel, cast iron or occasionally aluminium bronze.

The tube plates are usually of naval brass and the tubes of aluminium brass;
occasionally 70 / 30 cupro-nickel tubes are used.
SHELL AND TUBE (SINGLE & DOUBLE PASS)
 SHELL AND TUBE

The cooler headers may be of cast iron. In such instances the headers act as
sacrificial anodes, wasting in preference to the aluminium-brass tubes.

Unless soft iron or mild steel sacrificial anodes or impressed current cathodic
protection is used to protect the cooler from corrosion, such headers should not
be painted internally.
COOLER EXPANSION ARRANGEMENT

At one end of the heat exchanger, gaskets are

fitted between the tube plate and both the shell
and header.

At the other end, two elastomer seals lie both side

of a safety leakage ring in the event of leakage
past either seal, the two fluids cannot intermix.

The arrangement also permits movement of the

tube plate to accommodate differential expansion
between tube bundle and shell
COOLER EXPANSION ARRANGEMENT
 PLATE TYPE HEAT EXCHANGER
They are made up from an assembly of identical metal pressings with horizontal
or chevron pattern corrugations; each with a nitrile rubber joint.
The plates, which are supported beneath and located at the top by parallel metal
bars, are held together against an end plate by clamping bolts
These make the plates stiffer and therefore permit the use of thinner material.
They also increase the heat exchange area and produce a turbulent flow.
 PLATE TYPE HEAT EXCHANGER

Turbulence, as opposed to smooth flow, causes more of the liquid to come into
contact with them.
It also breaks up the boundary layer of liquid which adheres to the metal and acts
as a heat barrier in smooth flow.
Turbulence can cause plate damage due to erosion and metals normally used in
the tube coolers for sea water contact, may not be suitable in plate type coolers.
Plate material for sea water is titanium. This is an expensive metal but apparently
able to withstand the conditions of service.
PLATE TYPE HEAT EXCHANGER
THE PLATE TYPE HEAT EXCHANGER