INTRODUCTION: Shell and tube heat exchangers are one of the most common equipment found in all plants. How it works?
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1 HEAT EXCHANGERS 1
2 INTRODUCTION: Shell and tube heat exchangers are one of the most common equipment found in all plants How it works? 2
3 WHAT ARE THEY USED FOR? Classification according to service. Heat Exchanger Both sides single phase and process stream Cooler One stream process fluid and the other cooling water or air Heater One stream process fluid and heating utility as steam Condenser One stream condensing vapor and the other cooling water or air Reboiler One stream bottom stream from a distillation column and the other a hot utility or process stream 3
4 DESIGN CODES: Code Is recommended method of doing something ASME BPV TEMA Standard is the degree of excellence required API 660-ASME B16.5 ASME B36.10M ASME B36.19-ASME B16.9 ASME B16.11 Specifications Is a detailed description of construction, materials, etc Contractor or Owner specifications 4
5 MAIN COMPONENTS 1- Channel Cover 2- Channel 3- Channel Flange 4- Pass Partition 5- Stationary Tubesheet 6- Shell Flange 7- Tube 8- Shell 9- Baffles 10- Floating Head backing Device 11- Floating Tubesheet 12- Floating Head 13- Floating Head Flange 14 Shell Cover 5
6 TEMA HEAT EXCHANGER 6
7 TEMA HEAT EXCHANGER Front Head Type A - Type B - Type C - Type 7
8 TEMA HEAT EXCHANGER Shell Type E - Type F - Type J - Type K - Type 8
9 TEMA HEAT EXCHANGER Rear End Head Types M - Type S - Type T - Type Fixed Tubesheet Floating Head Pull-Through Floating Head 9
10 CLASSIFICATION: U-Tube Heat Exchanger Fixed Tubesheet Heat Exchanger Floating Tubesheet Heat exchanger 10
11 EXAMPLE AES 11
12 EXAMPLE AKT 12
13 HEAT EXCHANGERS MECHANICAL DESIGN Terminology Design data Material selection Codes overview Sample calculations Hydrostatic test Sample drawing 13
14 DESIGN DATA Heat Exchanger Data Sheet : TEMA type Design pressure Design temperature Dimensions / passes Tubes ( dimensions, pattern) Nozzles & Connections Baffles (No. & Type) 14
15 MATERIAL SELECTION Strength Cost & Availabilit y Material Selection Corrosion Resistance Fabricability 15
16 HEAT EXCHANGERS: DESIGN CONSIDERATIONS
17 TYPES Heat Exchanger Types Heat exchangers are used to energy conversion and utilization. They involve heat exchange between two fluids separated by a solid and encompass a wide range of flow configurations. Concentric-Tube Heat Exchangers Parallel Flow Counterflow Simplest configuration. Superior performance associated with counter flow.
18 TYPES (CONT.) Cross-flow Heat Exchangers Finned-Both Fluids Unmixed Unfinned-One Fluid Mixed the Other Unmixed For cross-flow over the tubes, fluid motion, and hence mixing, in the transverse direction (y) is prevented for the finned tubes, but occurs for the un-finned condition. Heat exchanger performance is influenced by mixing.
19 TYPES (CONT.) Shell-and-Tube Heat Exchangers One Shell Pass and One Tube Pass Baffles are used to establish a cross-flow and to induce turbulent mixing of the shell-side fluid, both of which enhance convection. The number of tube and shell passes may be varied, e.g.: One Shell Pass, Two Tube Passes Two Shell Passes, Four Tube Passes
20 TYPES (CONT.) Compact Heat Exchangers Widely used to achieve large heat rates per unit volume, particularly when one or both fluids is a gas. Characterized by large heat transfer surface areas per unit volume, small flow passages, and laminar flow. (a) Fin-tube (flat tubes, continuous plate fins) (b) Fin-tube (circular tubes, continuous plate fins) (c) Fin-tube (circular tubes, circular fins) (d) Plate-fin (single pass) (e) Plate-fin (multipass)
21 OVERALL COEFFICIENT Overall Heat Transfer Coefficient An essential requirement for heat exchanger design or performance calculations. Contributing factors include convection and conduction associated with the two fluids and the intermediate solid, as well as the potential use of fins on both sides and the effects of time-dependent surface fouling. With subscripts c and h used to designate the hot and cold fluids, respectively, the most general expression for the overall coefficient is: UA UA UA c h R R R 1 f, c f, h 1 w ha A A ha o c o c o h o h
22 OVERALL COEFFICIENT R f 2 Fouling factor for a unit surface area (m K/ W) Table 11.1 Rw Wall conduction resistance (K/W) o o, c or h Overall surface efficiency of fin array (Section 3.6.5) Af 1 1f A c or h A At A f total surface area (fins and exposed base) surface area of fins only Assuming an adiabatic tip, the fin efficiency is f, c or h tanh ml ml m 2 U / k t U c or h p w c or h c or h h, partial overall coefficient 1 hr f p c or h c or h
23 A Methodology for Heat Exchanger Design Calculations - The Log Mean Temperature Difference (LMTD) Method - LMTD METHOD A form of Newton s Law of Cooling may be applied to heat exchangers by using a log-mean value of the temperature difference between the two fluids: q U A T 1m T 1m T1 T2 1n T / T 1 2 Evaluation of T and T 1 2 depends on the heat exchanger type. Counter-Flow Heat Exchanger: T T T T T 1 h,1 c,1 h, i c, o T T T T T 2 h,2 c,2 h, o c, i
24 LMTD METHOD (CONT.) Parallel-Flow Heat Exchanger: T T T T T 1 h,1 c,1 h, i c, i T T T T T 2 h,2 c,2 h, o c, o Note that T c,o can not exceed T h,o for a PF HX, but can do so for a CF HX. For equivalent values of UA and inlet temperatures, T T 1 m, CF 1 m, PF Shell-and-Tube and Cross-Flow Heat Exchangers: T F T 1m 1 m, CF F Figures
25 ENERGY BALANCE Overall Energy Balance Application to the hot (h) and cold (c) fluids: Assume negligible heat transfer between the exchanger and its surroundings and negligible potential and kinetic energy changes for each fluid. q m i i h h, i h, o c c, o c, i q m i i i fluid enthalpy Assuming no l/v phase change and constant specific heats, h p, h h, i h, o Ch Th, i Th, o c p, c c, o c, i Cc Tc, o Tc, i q m c T T q m c T T CC h, c Heat capacity rates
26 SPECIAL CONDITIONS Special Operating Conditions Case (a): C h >>C c or h is a condensing vapor Ch. Negligible or no change in Th Th o Th i,,. Case (b): C c >>C h or c is an evaporating liquid Cc. Negligible or no change in Tc Tc o Tc i Case (c): C h =C c. T T T 1 2 1m,,.
27 PROBLEM: OCEAN THERMAL ENERGY CONVERSION Problem : Design of a two-pass, shell-and-tube heat exchanger to supply vapor for the turbine of an ocean thermal energy conversion system based on a standard (Rankine) power cycle. The power cycle is to generate 2 MW e at an efficiency of 3%. Ocean water enters the tubes of the exchanger at 300K, and its desired outlet temperature is 292K. The working fluid of the power cycle is evaporated in the tubes of the exchanger at its phase change temperature of 290K, and the overall heat transfer coefficient is known. FIND: (a) Evaporator area, (b) Water flow rate. SCHEMATIC:
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