a Therma arco Some types of heat exchanger Introduction This chapter mainly contain information regarding the design and performance of some types ‘of compact heat exchanger, The standard shell and tube heat exchanger is the most commonly used heat exchanger and most ofits characteristics are widely known. Since there is a considerable amount of hecatare avaiable on this subject, the section handling the standard shell and tube heat Cachan Te ‘short and presented only as a background for the following sections ‘The other four types of compact heal exchanger described here have not been covered so wel in literature, and efforts nave theretore been made to give ae many aspects and goneval information of these types as possible, The reader who is interested in the calculation oy thee types, or intends to use any of them, will find it useful to go through this chapter belore going further, Most of the contents in the following chapters refer, in one way or the other, to these four {ypes and knowledge of this chapter wil theratre help the reader to understand the folowing discussions. The standard shell and tube heat exchanger Design featur The shell and tube heat exchanger is one of the oldest and most commonly used heat ex: changer in the industry. The heating surtace consists of a number of tubes, spaced sper mith one fluid owing through the tubes and the other tlid outside the tubes, The ende ol ecch lube are joined to corresponding holes in two tubesheets, being rolled of welded to the trent sheets. The tubes are generally kept in position on the outside by srossbarties, Fig. 1 shows 2 one pass fixed-tubesheet heat exchanger. The periphery of the sheet is welded to the shell at both ends. Endcovers are flanged to the shell at both ends, This type can bo built practically, im most any size 7 W A 8 2 2 2 Gasket 19 Gasket 13 Toros 5 sti re 1H Babe net 1 Bette seat Fig. 1. Fixed tube sheet — nonremovable tubebundle 1” 231chapter 3 Fig. 2 shows a typical floating heat exchanger with retractable tubebundles, giving one shell side pass and two tubeside passes. The floating tubesheet Is clamped between the floating head flange and its Backing device, and by removing these flanges after opening up the shell: flanges the tube-bundle can be taken out ee en ‘ng Fig, 2. Intornal tloating hoad-removable tubebunale Fig. 9 shows a U-tube heat exchanger 2 Shh ou or Fig. 3. “U"-tubedundle — mult-pass tube side The conventional shell and tube heat exchanger is easy to produce in large quantities. itis made of readily available standard materials and the manufacturing technique is well knows. Because of this and its simple design itis generally inexpensive in carbon steel and copper alloys, in spite of being larger and Meavier than other types of heat exchangers for a certain application It can be built to stand high pressure. 16 232“Thermal handbook Performance ‘The shell and tube heat exchangers are generally bult for crosstlow outside the tubes. The umber of tubes of @ certain diamater in parallel on the tubeside, Is decided by the flow on the tubeside, The number of passes, with a certain tubelangth, is decided by tho hoat transfer area required. The calculated croseflow velocity on the sheliside will then give the spacing required for the flow guiding cross battles, Countercurrent flow is seldom obtained for liquid to liquid duties and the officioncy will therefore be reduced, due to the reduction ineffective temperature difierance, The calculated velocities are difficult to obtain on the shellside because of stagnation behind battles and battle leakage. Repair and maintenance ‘The shell and tube heat exchanger is easy to repair in most cases, Ifa tube is damaged it can be plugged or exchanged. A shell and tube heat exchanger can be manually cleaned on the tubeside and if not to Dig, unite with retractable tudebundles can also be cleaned on the sholiside, These proceduras ara, howaver, rather timecensuming and the costs are not negli- ible, especially Ifthe costs for & plant shut down have to be taken into consideration, Its not vory suitable for chemical cleaning on the sheliside, or on the tubeside if @ tube 1s completely blocked The close tube heat exchanger Design features The close tube heat exchanger. CTHE, is an aliwoldes compact shell and tube heat ox ‘changer with longitudinal flow in one pass on both sides. Fig, 4 chows a version of the CTHE, espe cially arranged for high temperature service, to be mounted in a vartical position, Fig. 4.A vertical CTHE arranged for high temperature sevvice ‘Tho tubebundle is connected to the tube channel shroud which hangs in upper nozzles, and atthe lower end its connected to the shell via a bellow. The tubebunale is thus hanging free ‘rom all external stresses and any differance in thermal expansion is taken by the bellow at the cold end of the heat exchanger. The tubs bundle is surrounded by a shroud of thin sheet, ‘rom which the hot fluid enters direcly into the channel ouside the tubes without being in ‘contact with any pressure taking parts (shell, langes ang nozzles). ‘The hot fluid is cooled evenly, by the fluid in the tubes, during is longitudinal flow inside the shroud, and then after leaving the tubebundile at the cold end it passes upwards between the shroud and the shell to the cold fluid outlet nozzle in tha upper end, All other parts under pressure are subjected to an even temperature close to the cooled fluid outlet tomperature, ‘which roleases them from thermal stresses, caused by Nish temperature, and the loss in ma. terial strength, The tubes are closely pitched and welded to the tubesheets, which are made of ferrules In a honeycomb pattorn or of thin sheet depending on the pitch, The thickness of the tubesheet 233chapter 3 material is chosen as close to the wall thickness of the tubes as possible, to ensure stress- free weld joints, and to avoid a differential tomperature belweon the tubesheet and tubeonds uring temperature cycling, Because of the close tube pitch and the pressure balance ie ihe tube bundle the tubesheet can be made of very thin material, since the strain i has to taxe caused only by its weight and the forces from the bellow. The tube joints are completely protected from temperature attack from tho hot fluid, and gee nerally the tubesheet is protected on the shell side by a fullsized crossbattie close to. we tubesheet with stagnant fiuid in between, ‘The bellow which has to take the differential pressure at the cold end, is cooled by the cold fluid going in and has cooled hot fluid an the shellside, stagnant in a pocket In order to support the tubes on the shellside and still permit a well distibuted flow along the tubes, spiral wires of a diameter close to the distance between the tubewalls are wound around the tubes in a steep pitch ‘The design of the GTHE may seam costly, but when the cost of the materials involved is the deciding factor it can, in spite of the exclusive design, be less expensive than @ conventions! shell and tube heat exchanger. partly bacause of the lower heat transter area needed avd Partly because of the lower total weight due to its compact design, For some high temperature applications the pressure vessel authorities have approved the alculation of stresses on the covers, shell and flanges for a temperature close te the mene ‘mum outlet temperature of the cooled hot fluid. Since the extornal dimensions are emetic than a conventional tubular, a great saving in material is achloved and the cost Is cortesponey ingly lower. Pertormance The CTHE is easily arranges for true countercurrent flow and is thus better able to utilize given temperature ditference, and therefore requires less heat transter area, Its also possible to design 8 greater or smaller longitudinal flow section on the shell side than on the tube side which facilitates the right choice of velocities on both sides. Also since the flow dlstribetog 's good the heat transfer cooticients are generally he highest possible in a tubular onchsnuor The heat exchanger is also manufactured ina less exclusive design as a medium temperature Niquid to liquid, oF hot liquid heated reboiter, in high alloy material, The close tube design has certain advantages regarding resistance to vibration and reso- anes phenomena. A tube firmly supported on the outside along a spita line wil not have fesonantfrequence ofits own. Since the cubebundie Is assembled and completed separately before itis inserted in the shel, the tle ands around the tubebundle can be tightened sue, cessivaly, while hammer tests for vibrations ar@ made, until the bundle 's one tixed unit without any possibilty of the separate tubes vibrating. A tubebundie manufactured in this way shows complete resistance to vibration during opera tion, Other types of heat exchangers, failing because of vibrations, ave therefore somodncs substituted by CTHE. Repair and maintenance The repair of a CTHE is accomplished In the same way as for a conventional tubular. The \ubejoints have to be drilled away. Each tube replacement. however, has to be completed be fore the next tube can be withdrawn by pushing the failed tube out with the mont abe, Thee welding in of the replaced tubes can be made in one continous operation, If required the whole tubebundie can also be taken out by grinding away lwo welds, The tubes are not s0 easy to clean manually because of the small tube diameter, Ya"—1" onerally used. However, because of high turbulence and well distributed flaw with the hig. best possible velocities on both sides tho CTHE does not foul up easily, For the seme ressoce itis well suited for chemical cleaning, 20 234‘Thermal hancook The spiral heat exchanger Design features The spiral heat exchanger, SHE, sometimes called the spiral plate heat exchanger was otic Ginaily designed to solve various kinds of heat exchange problem in the cellulose industry, which were often cases of severe fouling or corrosion, It was one of the first heat exchangers ‘made of stainless stee! plate The heating surface consists of two relatively long strips of plate, spaced apart and wound round an open, split center to form a pair of concentric spiral passages. Space studs, lash Welded to the two strips, maintain a uniform spacing between these strips Principle oftype 1g. Principle of ype? Principle of type 3 Fig. 5. Spiral heat exchanger, SHE Depending on the type, the edges of the strips can be bent and seamwelded on one or both sides af the channel, or only machined against the covers, to prevent bypassing, {type 1 in fig. Sb the edges are formed and seamwelded alternatively, so that one channel {s open on one side and the other channel on the other side when the covers on each side are temoved. Type 1 is mainly used for haat exchange in true countercurrent manner be- tween liquids oF other fluids af limited volume. In type 2 in fig. Sc one channel is completely clasad by welds both in the upper and lower Side of the channel, and the other channel is open at both sides to allow vertical crosstlow through the spiral. Type 2 is generally made for handiing large volumes on the open cross. flow side, the other fluid flowing in the closewelded side in a spiral flow pattern {mn ype 3 in fig. Sd one channel is open upwards and the other downwards as in type 1. Part ‘of the upper cover, however, is cut away in the center and equipped with a distribution device (in the figure shown as a cone), so that a large volume can enter in crosstiow, being distr. buted to the main part of the inner channel simultaneously. When the volume has been ra. duced by partial condensation, the remaining volume is cooled in true countercurrent spiral flow and exhausted at the periphery. The distribution device can be calculated and executed 50 that a spiral flow of even high velocity is accomplished even in the middle section. The steam, vapour or fumes are fed into each turn of the channel in quantitas just sufficrent to replace the successively condensed volume and maintain the required velocity in apiral flow in the center section. Fig. 6 shows a type 4 SHE, also called type G, which is specially designed for use as an over- head condensor mounted on top of a column or tower. One channel, for the cooling fluids, 's Close welded completely and the vapour or fumes enter through a big nozzle at the bottom, ed, The vapour passes upwarde through the center and fs distr. buted in eresstow to the central turns of the channel from above at 235°The tow is then, in principle, as in type 3, but the condensate or reflux can be drained from any part or parts of the condensing channel under control. A in type 8 the vents land condensate can be cooled down to any temperature required providing it ig above ‘the temperature of the cooling fluid in coun. torcurrent flow. ‘The SHE, which Is generally custommade, can be designed with a channel-spacing of ‘between § and 25 mm, channel width of 100 {fo 1800 mm and a heat transfer surtace up to 180-200 m’, Type 1 can be mounted in the Vertical or horizontal position. It can also be made with the nozzles symmetrically ranged, so that when it ie turned around, the ozale positions fit but the sides are intor- ‘changed. For low pressure service it can be designed Fig, 6, Cross section of overhead without spacing studs in the channels, ‘condenser Performance Since the SHE as described here offers such a wide varity of channel arrangements it gone- fally has @ high performance, when properly calculated and custommade to sult a conan Because ol iis compactness and since the cold end ofthe cooling luld channel is generally in {the outer spiral turn the radiation losses are small and no insulation is generally todwired The SHE is not suitable for high pressure service, The upper pressure limit depends on the size, but 18 atmospheres can be considered as an average. The design pressure is goseraly less than 10 atmospheres Repair and maintenance Repair of corroded channel seamwelds can generally be done without difculties since most of them are easily accessible. Corrosion damage on the inner parts of the stips me mace complicated to eepair, and are often dificult to do wail on site. In most vases pats ch he Strip have tobe cut away, tun by turn, unl the damaged spot ie reached and ean be repalioa ‘The cut away parts thon have to be welded back again, one by one working Dulwards cat oc, I the sholl is reached, Fortunately repairs on SHES are seldom required il the right rateriat for the application has been chosen, Manual cleaning cannot be done easly on the standard spiral with spacer studs in the chan- nels. such cleaning is requited a special execution without studs must be choses witch an require thicker plate and is generally uneconomic in high alloy materials, Carson stect shies are howaver sometimes specially made without studs and with easily romovabie covers tar manual cleaning. These units wil be easy to clean manually, The SHE is weil sulted for cleaning in place because ofits good flow distribution and the one single channel for each fluid 2 236_ Thermal hanabook The plate heat exchanger Design features ‘The gasketed plate heat exchanger, PHE, was known and used originally extensively by in usteies having sanitary requirements, While there has been an increasing use of the PHE in the chemical processing industries, especially during the last 10 years, its advantages have not beer fully explored nor its possibilities and limits recognized. Fig.7. PHE, type 4 LS with titanium plates intended for heal reco- ‘ery from @ salt solution con- taining chiorides. The heating surface area is 242 square metres ‘The PHE, see fig. 7, ls a simple heat transfer apparatus, resembling a filter press. Its made Up of a "package" of generaly identical gasketed plates, aligned top and bottom on carrier bars between two rigid covers or frames, and clamped together by bolts or a compression vice. The plates generally have four corner ports, open or blind according to need. Nozzles for the fuid flows extend through the frames to the plate package. Fig. 8 Exploded view of @ PHE hav- ing one pass tow for both {Hulds. Grouping 1 6117 4 Saving ba {= Chatmetpates wih Theler Uti Geimten the plates there is fre space forthe passage of fuid and the plates are kept apart saually by dimples, ridges or erossing corrugations. One fluid lows in evary second miter Space from a port in one end of the plate to a corresponding port tho citer The other fluid flows between the remaining two ports into the internal spaces formed co te other sides of the plates. The heat is thus translerred tiwough the plate ecnion boundary gaskets, from one fluid to the other. The port gaskats are, in princine, ‘Gasket should leak it wil Be to the atmosphere rather then Fig. 0 Flatege diagram 4x2/2%-4, which means for cold fluid: 2 channels in parallel, each 4 passes, and for hot tuid: 4 channels in parallel, each 2 passes Grouping When two fluids are handled in one pass as in fig. 8 and 9 all plates have all four holes punched out. one in each corner, except for the nd plate located agsinsl the pressure pie The plates can be divided into several groups by a suitable arrangement of punched out and blind ports. When the parallel flow has to be interrupted the corresponding part mil ke beng and the fluid will enter the next group through the corresponding hele in the other andlor the Plate and tlow through the channels of this nex! group in the opposite dieeien roparalel flow can be interrupted for each fluid at diferent points in the plate package Independent of the other fluid. When the flow of bath fluids is interrupted atthe sare oats there will be two blind ports, one for each fluis, Te channels for egch fluid can therefore, Independent of the other, be arranged in parallel or in Series within the range of the total number of plates. When 2 tte countercurrent tlow is required both fluids must have the same number of passes Each tuid which flows through the unit in more than one pass must have the inlet nozzle at {ne end and the outlet nozzle atthe other end ofthe package. Fer such a unit the connector 124 beth Muids, all channels are connected in one parallel pass, all four nozzles wil ke oe ths ecarame 28 shown ints. 8. The plate package can here Be opened up wilhout oscning the connections. 24 238____. Thermal hancock lt more than two fluids neve to be handled in the PHE, connection plates must be inserted betwoon plates as shown in fig 10 oF the unit must be arranged as shown in fig. 11 for example, where two one-pass duties are assembles in one unit with all eight nozzles on the fixed frames This latter arrangement facilitates the opening up of the plate packages when thtee or four tluids have to be handled in one unit, but al fluids must run in one pase 8 Fig. PHE with two fixed frames and two pressure plates handling 3 or 4 fluids, all in one pass 7 7 7 thew. Ail nozzles on the fixed tramas 8 234reactors, & Ye of PHE especially designed for condensing vapour. The plate package Reread in 4 eylindseal drum, into which the vapour enters. The Rorizontal plate peckace {he Gagty cond channel, the vapour condensing channels, with tho gasket cut susp ateoy ihe ope side of the plate as shown inti. 126. This makes lt possibe forthe wagon, amet Channel sacePats ar toe small to handle the volume, to antar into the vapeur condonsien Fig. 12. PHE, ype "boxcondenser Plate design From a strength point of view the plates are designed 10 withstand the required ditferential pressure all over the plate surface without permanent (plastic) Uelormation, ang aah Wn Sragen Possible elastic deformation. The plates are therefore pressed with simples, ridges Pr corrugations al over the plate surtace in order to achieve the rigidly reduised ana ase heating surface also to promote turoulence and improve heat tranciee ‘gations can be parallel to each other running across the flow channel, with bridges Between the corrugations to maintain the required space between the platos Tite eee ‘fig. 138 and 14a, ©. Croseconugated pate Chertingbone pater) Fig. 19. Two different type of gasketed plate for the PHE 2 240“Theemal handbook The corrugations can also cross each other when every second plate Is turned through 180) leach crossing point giving support between the plates, see fig. 13 b and 14, This type gives) in a simple way, a very rigid support between the plates and promotes turbulence very eff- ‘between the plates then flows mainly in a spiral helical between the ross Perforated sheets can be inserted between parallal-corrugated plates. Such an arrangement as shown in fig. 14, will improve turbulnce stil more, These insert plates force the fluid 10 flow through holes at high velocity, and the streams from the holes hit the heat transter sur- face at an angle and decrease the thickness of the boundary layer, thus improving heat trans- fer. The inserts utilize the pressure drop for heat transfer most etficienty for viscous fluids (6 centistokes ang higher) but are not worthwhile for water and other nan viscous fils, The plate material thickness is generally between 0.5 and 1.2 mm and the channel spacing is small, seldom over 5—8 mm, ‘The plates are manufactured in many different shapes and sizes, the heating surface per plate varying from a few hundreds of a square metre up to around two square metre per plate ‘The plates can be prossed in many different materials, such as carbon steel, aluminium, cop- ‘er and copper alloys, pure titanium, stainless steel with more than 8 Js nickel and high nickel or nickel-molyodenum alloys, tantalum and other noble metals, ‘The plate material must be easily formed by pressing. Certain alloys of chromium, zirconium and titanium are considered too dificult to prass for PHE use. As a guide to the possibility of pressing a materia table T 002 can be used. The pressure and temperature range is shown in {raph G 005. Gasket design The gaskels are generally made of elastomers like natural rubber, itil, butyl, neoprene, EP, silicone, viton etc. Plastic material like teflon or other plastics have not been sucessful because of their bad compression set. The gasket material chosen depends on the working temperature and fluid to be handled, For temperatures over 180°C or when elastomers are attacked by the tivid, rubberbound asbestos gaskels can be chosen The gasket cross section varies from plate to plate. Ractangular, trapezoid or oval sections are the most common. The width is generally 5—15 mm, cepending on spacing, The height of the gasket before i is compressed Is 15 to 50% higher than the spacing, depending on ‘material, cross section of gasket, gasket track and gasket hardness For sanitary applications the cross section of gaskets and tracks are designed without cre: vices, between the groove wall and the gasket on the wet side, in order to prevent tesiduary Contamination ‘The gaskets are cemented to the gaskst track, The glue ar cement should be such that it gives ‘2 g00d bond during service and opening up of the plate package, but it should also be pos. sible to remove a gasket without 100 much trouble ita gasket replacement ie required, ‘The gaskets are generally aranged in such a way that the through pass portal is sealed inde- endently of the boundary gasket. Ifa gaskat leak should occur, there can thus be no inter- mixing between the two fluids ‘The gaskets can be arranged depending on the gasket groove arrangement in two different ways. Itis either made so that the inlet and outlet connections are on the same side of the plate as in fig. 19a or diagonally opposite as in fig. 130, aChapter 3 Performance ‘Since most types of plates are designed to form channels giving highly turbulent flow the PRE, when suitable, has higher heat transfer cootticients for liquid than most other types Even at very low Re-numbers, below 2--300 and, for some types, below 100, the flow ia ei turbulent, One of the most important features is that all channels for each tuid can be arranged in pac fallel or series according to the requirements on both sides. The flowrates, and eresance Grops determine how many channels should be arranged in parallel, and the fomporature Programme determines the number of passes in series, ie. the length of tho transier eectece "ts thus easy to achieve optimum conditions for Both media as regards velocity, tawperaiare, pressure drop, ete When the tow rates for the two fluids to be handled are about the same itis easy to arrange the heat exchanger for true countercurrent flow. ‘A duty can be accomplished frequently in a PHE with a smaller heating surface then for other types. {A change in the performance requirements, even atter installation, can be accomplished within the range of the frame by rearrangement of the plates, Fig. 14. Three types of channel *Parlis-comugeted plates ‘perforated fat insert plate Repair and maintenance ita part ofthe heating surtace has been damaged the fallure can generally be corrected easly by removing the pressure plate and repairing or replacing the damaged plate, When gaskets have been damaged, the failing gaskets have to be cemoved from the plate and new caskets ‘cemented to the plate ‘Most PHE types can be completely taken apart by loosening a few bolts and It makes them {specially suitable for manual cleaning. The heating surface will then be accessible tor clean, Ing all over with water jets or by brushing. A stainless steel brush should not bo usee as Scratches the surface, which often has a high finish in order to help to keep It clean Chemical cieaning can generally be carried out efficiently because of the earlier mentioned high-turbulent flow and good flow distribution conditions over the plate surface, 28 22chapter The theory of heat transfer inside the heat exchanger ear 10,000. Stromning gjennom varmevekslerkappen: Nu = 0.36 Re Pr° “(4)’ " Ho. Det korrigeres for ikke sirkulaere former, gjelder beregning av Re, ved hydraulis- ke diametere. Der de dimensjonslose gruppene er definert. som folger; Nu= 2 Nusselts tall Re = 22 Reynolds tallPra at Prandils tall Nomenclature: k = termisk konduktivitet W/mK. A= varmeledningsareal, vinkelrett pa varmestrommen m2. AT/AX = temperaturgradient K/m. D = rordiameter m. T = temperatur K. h = varmeovergangskoefisient W/m? K. R= beleggmotstand m2K/W. U = varmegiennomgangskoeffesient W/m?K. Cp = spesifikk varmekapasitet J/kg. H/o = viskositet gj.snitt. temp. dividert pa viskositet ved overfl. temp. = lengde m. 253FIG, 9-4 LMTD Correction Factor (1 shell pass; 2 or more tube passes) & & Fi LMATD Correction Factor temperature efficiency LTO Correction Factor 2 or more tube pass Tita OMTD = (LMTO\F)) FIG. 95 Lum coueetian taste Fo 2 sna passes LUD Correction Factor ‘over ue passes ah owro = (LUTON, 4Tabell 6.2: Termisk konduktivitet for faste stoffer Materiale Termisk konduktivitet ved 20°C, (Wimk) Aluminium 200 - 240 Kopper 350 - 360 Karbonstal 40 - 60 ‘| Stepejern 50 - 60 Syrefast stal, Inkonel 15 - 20 Nikkelstél, 407 Ni ca. 10 Vindusglass 0.75- 0.80 Jord, halvterr 1.0 - 1.5 Berg, fuktig 2.0 - 2.5 Sement ( API klasse G } ca. 0.95 Tabell 6.3 : Typiske beleggmotstander for rervarme- vekslere (m? K/W) 151 Sjevann under 52°C : 0.00009 Sjevann over 52°C : 0.0002 Behandlet vann over 52°C : 0.0002 Brenselolje (ref. TEMA) : 0.0008 Kondensat (C, Riolje (C,H): 0.00018 - 0.0005 Cys nec): 0-0.00018 (Ref. Schlinder/1983/TABELL 6.1.: Typiske totale overgangskoeffisienter for rervarmevekslere (GPSA/1980/) Driftsforhold u (wim? ky Vann mot gass ved 7 bar 200 - 225 -- 20 bar 225 - 205 -- 50 bar 340 - 400 ‘- 10 bar 450 - 570 Vann mot kerosen 450 - 500 Vann mot monoetanolamin (HEA) 140 - 850 Vann mot luft 110 - 140 Vann mot vann 1000 - 1160 Olje mot olje 450 - 570 Flytende propan mot fiytende propan 625 - 140 Fordampende propan mot gass ved 70 bar 340 - 450 Gass ved 7 bar mot gass ved 34 bar 280 - 400 Gass ved 10 bar mot gass ved 70 bar 360 - 450 seo - 140 MEA mot MEA