#First Week

Classification, Construction &

Manufacture of Heat Exchanger

Lecturer:

Ir. I Made Astina, M.Eng., Ph.D.

Associate Professor of Mechanical Engineering
Faculty of Mechanical and Aerospace Engineering
Institut Teknologi Bandung
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 1. Definisi Penukar Kalor
 2. Penukar Kalor di Kehidupan dan Industri
 3. Klasifikasi
 4. Geometri dan Konstruksi
 5. Fabrikasi

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 (K) Mahasiswa mendapatkan pemahaman signifikasi
penukar kalor
 (K) Mahasiswa dapat mengerti maksud dan tujuan
klasifikasi
 (K) Mahasiswa mengenal dan membedakan masing-
masing konstruksi dan geometri serta penamaannya
 (K) Mahasiswa mengenal manufaktur penukar kalor
yang umum

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Definition
 A heat exchanger is a device that is used to transfer thermal
energy (enthalpy) between two or more fluids, between a
solid surface and a fluid, or between solid particulates and a
fluid, at different temperatures and in thermal contact.
 In heat exchangers, there are usually no external heat and
work interactions.

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Possible Internal Energy Source in Heat
Exchanger

Electric Heater in Heat Exchanger

Nuclear fuel element in Nuclear Power Plant
Combustion and chemical reaction take place
within heat exchanger

Example: Boiler, fired heat exchanger, fluidized

bed heat exchanger
 Heat Exchanger Elements
Heat transfer elements:
• core or matrix containing the heat transfer surface

Fluid distribution elements:

• header, manifolds,
• tank, inlet outlet nozzles,
• pipes or seal.

Common: no moving parts

Exceptions: rotary regenerative exchanger
Heat Transfer Surface
A surface of the exchanger core that is in direct contact with fluids
and through which heat is transferred by conduction.

The portion of the surface that is in direct contact with both the hot
and cold fluids and transfers heat between them is referred to as
primary or direct surface

Increase of heat transfer surface may be intimately connected to the

primary surface to provide an extended, secondary or indirect surface.
These extended surfaces are referred to as fins
 Heat Exchanger Application

In Our Daily Live in Industry

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 Application of Heat Exchanger in Process Industries

 Chemical Reaction
 Combustion and gasification
 Pyrolysis, polymerization, synthesis
 Chemical purification and separation
 Smelting of ores, alloying, sintering
 Firing of ceramics, glass, coating
 Biological Reaction
 Cooling and freezing
 Pasteurization, purification
 Fermentation, brewing, baking
 Production of enzyme

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 Application (Cont’d)

 Physical Change
 Evaporation and condensation
 Melting and freezing
 Forming of solid
 Powder and fiber production
 Crystallization
 Power Generation
 Engine, power plant
 Air Conditioning and Space Heating
 Maintenance of required environmental condition
 Waste Heat Recovery
 Heat recovery to save energy. Cogeneration and tri-generation are system
interested in energy conservation.

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 Typical Application
Heating and cooling: fluid
Condensation and evaporation: single fluid component,
two or more

Objective Application
recovery or reject heat, sterilize or pasteurize,
fractionate, distill, crystallize, control a
process fluid
 Applications of Heat Exchangers

Heat Exchangers
prevent car engine
overheating and
increase efficiency
Heat exchangers are
used in Industry for
heat transfer

Heat
exchangers are
used in AC and
furnaces
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 Recuperator in Stack

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 Application in gas turbine

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 Classification, Geometry,
Construction
Recuperator & Regenerator

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 Heat Exchanger may be classified according
to following main criteria:

Recuperator and Regenerator

Transfer Process: direct and indirect contact
Geometry of Construction: tubes, plates, and
extended surface
Heat Transfer Mechanism: Single Phase and Two
Phase
Flow Arrangement: parallel, counter, and cross
flows

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Most Heat Exchangers have two streams, hot and
cold, but some have more than two stream

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 Classification According to Transfer Process

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Construction of Direct Contact Heat Exchanger

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 Classification According to Construction

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 Classification According to Flow Arrangements

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 Classification According to Heat Transfer
Mechanisme

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(a) Shell-and-tube exchanger (BEM)
with one shell pass and one tube pass

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Multi Configuration

Single Configuration

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 Plate & frame heat exchangers
(gasketed, semi-welded, welded)
 Spiral
 Blazed plate & frame
 Plate-fin heat exchanger
 Printed circuits

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 Spiral Plate

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 Spiral plate heat exchanger with both fluids in spiral
counter flow
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 Lamella Heat Exchangers
A lamella heat exchanger consists of an outer tubular shell surrounding
an inside bundle of heat transfer elements.

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The tubular and plate-type exchangers described
previously are all prime surface heat exchangers,
except for a shell-and-tube exchanger with low
finned tubing. Their heat exchanger effectiveness is
usually 60% or below, and the heat transfer surface
area density is usually less than 700 m2/m3.

In some applications, much higher (up to about 98%)

exchanger effectiveness is essential, and the box
volume and mass are limited so that a much more
compact surface is mandated.

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Individually finned tubes
Flat fins on an array of round, flat, or oval tubes: (a) wavy fin; (b)
multilouver fin;
both fins with staggered round tubes; (c) multilouver fin with inline
elliptical tubes.

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Internally fined tube
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 Regenerators
The regenerator is a storage-type heat exchanger.
The heat transfer surface or elements are usually referred to as a matrix in
the regenerator.

Rotary Regenerator: the matrix must be moved periodically into and

out of the fixed streams of gases,

Fixed Matrix Regenerator: the gas flows must be diverted through

valves to and from the fixed matrices.

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A third type of regenerator has a fixed matrix (in disk form)
and fixed streams of gases, but the gases are ducted through
rotating hoods (headers) to the matrix as shown in following
Figure.
This Rothemuhle regenerator is used as an air reheater in
some power generating plants. Since the basic thermal design
theory of all types of regenerators is the same, no specific
attention will be given to the Rothemuhle regenerator for the
thermal design.

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 Rotary Regenerators
Depending on the applications, rotary regenerators are variously referred
to as a heat wheel, thermal wheel, Munter wheel, or Ljungstrom wheel.
When the gas flows are laminar, the rotary regenerator is also referred to
as a laminar flow wheel.
In this exchanger, any of the plain plate-fin surface geometries could be
used in the matrix made up of thin metal sheets. Interrupted passage
surfaces (such as strip fins, louver fins) are not used because a transverse
(to the main flow direction) flow leakage is present if the two fluids are at
different pressures. This leak mixes the two fluids (contaminates the lower
pressure fluid) and reduces the exchanger effectiveness.
Hence, the matrix generally has continuous (uninterrupted) flow passages.
Flat or wavy spacers are used to stack the ‘‘fins’’. The fluid is unmixed at
any cross section for these surfaces.

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 View of Regenerator

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 Heat Exchanger & Manufacturing

Building Heat Exchanger

Fined Tube & Fin Manufacturing
Flaring & Bending
Retubing

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 Building Heat Exchanger

 https://www.youtube.com/watch?v=LsfRQGm4-Lc
 https://www.youtube.com/watch?v=5BKyIq5zlDk
 https://www.youtube.com/watch?v=MdlnnPnexEU

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 Fined Tube & Fin Manufacturing

 https://www.youtube.com/watch?v=FFew27JUyKs
 https://www.youtube.com/watch?v=T5CN-WD2edc
 https://www.youtube.com/watch?v=_J8lMSlsRbU
 https://www.youtube.com/watch?v=Pnc9H-lvldk

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 Flaring, Bending, Expander

 https://www.youtube.com/watch?v=WXOo8MtDv7A
 https://www.youtube.com/watch?v=L293sC2CiK0
 https://www.youtube.com/watch?v=rxKga-fDgHw
 https://www.youtube.com/watch?v=VHOFP828BvM

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 Retubing

 https://www.youtube.com/watch?v=DA-U1YXuIzY

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 Discussion

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