Question 1: Explain the types of heat exchangers used in the following industries?

Heat exchangers are devices that transfer thermal energy from one fluid to another without
mixing the two fluids. The fluids are usually separated by a solid wall (with high thermal
conductivity) to prevent mixing, or they may be in direct contact.

A) Steam power plant

In a steam power plant, the most common type of heat exchanger used is a "shell and tube
heat exchanger." It is also sometimes referred to as a "surface condenser." This type of heat
exchanger is used to transfer heat from the exhaust steam leaving the turbine to the cooling
water, allowing the steam to condense back into water.

The shell and tube heat exchanger consists of a shell (outer vessel) and a series of tubes
inside the shell. The exhaust steam flows through the tubes, while the cooling water flows
around the outside of the tubes within the shell. Heat is transferred from the steam to the
cooling water through the tube walls, causing the steam to condense.

The condensed water, known as condensate, is collected at the bottom of the heat exchanger
and typically sent back to the boiler for reuse. The cooling water, after absorbing heat from
the steam, is usually circulated through a cooling tower to remove the absorbed heat and then
returned to the heat exchanger for further cooling.

Shell and tube heat exchangers are preferred in steam power plants due to their ability to
handle high pressures and temperatures, their efficiency in transferring heat, and their robust
design. They are widely used in power generation industries to maximize the thermal
efficiency of the plant by recovering heat from the exhaust steam.
B) Gas turbine power plant

Gas turbine power plants typically use two types of heat exchangers:

1. Air-Cooled Heat Exchangers (ACHE): In this type of heat exchanger, the cooling medium
is air. ACHEs are commonly used in gas turbine power plants located in areas where water
availability is limited or where environmental regulations restrict the use of water for cooling.
ACHEs consist of finned tubes through which the hot exhaust gases from the gas turbine
flow, and ambient air is forced over the tubes to remove heat and cool the gases.

2. Shell and Tube Heat Exchangers: Shell and tube heat exchangers are used in gas turbine
power plants where water is available and can be used for cooling. They consist of a shell (a
large cylindrical vessel) with a bundle of tubes inside it. The hot exhaust gases from the gas
turbine flow through the tubes, while cooling water flows through the shell, absorbing heat
from the gases.

Both types of heat exchangers are used to extract heat from the exhaust gases of the gas
turbine, either by transferring it to the ambient air (in the case of ACHE) or by transferring it
to water (in the case of shell and tube heat exchangers). This heat transfer helps improve the
efficiency of the gas turbine and can be used for various purposes, such as preheating
combustion air or generating steam for additional power generation in a combined cycle
configuration.
C) Heating, ventilation, and air conditioning (HVAC)

Finned Tube Heat Exchanger: Finned tube heat exchangers consist of tubes with
extended surfaces (fins) attached to the outside. The fins increase the surface area and
enhance heat transfer between the fluid inside the tubes and the surrounding air. They are
commonly used in air-cooled HVAC systems.

D) Internal Combustion Engine

Radiator: Radiators are the most common type of heat exchanger used in automotive
engines. They transfer heat from the engine coolant to the surrounding air. Radiators typically
consist of a network of tubes through which the coolant flows, surrounded by fins that
enhance heat dissipation. Air passing over the fins cools the coolant.

E) Oil refinery and petrochemical

Oil refineries and petrochemical plants use various types of heat exchangers to transfer
heat between different fluids or streams in their processes. Some common types of heat
exchangers used in these industries include:

Shell and Tube Heat Exchanger: This is one of the most widely used types of heat exchangers
in the oil refinery and petrochemical industry. It consists of a bundle of tubes enclosed in a
shell. One fluid flows through the tubes (tube-side) while the other fluid flows around the
tubes (shell-side). Heat is transferred between the fluids through the tube walls.
Question 2: For each heat exchanger mentioned above, explain its type and operation
with the help of a diagram.

1) STEAM POWER PLANT

A shell and tube heat exchanger is a common type of heat exchanger used in
various industries for transferring heat between two fluids. It consists of a shell (a
cylindrical vessel) and a bundle of tubes inside it. The shell is usually made of metal
and has inlet and outlet ports for the hot and cold fluids.

Here's a textual representation of a shell and tube heat exchanger:

In the above representation, the hot fluid enters through Inlet1 and flows through the
tube bundle. The tube bundle consists of a series of tubes that are connected to the
shell on one end and open on the other end. The cold fluid enters through Inlet2 and
flows around the outside of the tubes inside the shell. As the fluids pass through the
heat exchanger, heat is transferred from the hot fluid to the cold fluid through the tube
walls. The hot fluid exits through Outlet1, and the cold fluid exits through Outlet2.

This arrangement allows for efficient heat transfer between the fluids while keeping
them separated. The larger surface area provided by the numerous tubes enhances
heat transfer. Additionally, the shell and tube design allows for easy cleaning and
maintenance of the heat exchanger.
2) GAS TURBINE POWER PLANT
An air-cooled heat exchanger (ACHE) is a device used to transfer heat between a
process fluid and ambient air. It consists of a bundle of finned tubes, through which
the process fluid flows, and a fan or fans that circulate the ambient air across the
finned tubes to remove heat. Here is a simplified diagram of an air-cooled heat
exchanger:

In this diagram, the process fluid enters the heat exchanger through an inlet and flows
through the tube bundle. The tube bundle is composed of a series of finned tubes that
increase the surface area available for heat transfer. Ambient air is circulated across
the finned tubes by one or more fans. The heat from the process fluid is transferred to
the ambient air through convection, and the cooled fluid exits through an outlet.
 3) HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

In this diagram, the tube side represents the fluid flow path inside the tubes, while the fin
side represents the fluid flow path over the external surface of the finned tubes. The finned
tubes increase the heat transfer surface area, allowing for improved heat exchange between
the two fluids.
4) INTERNAL COMBUSTION CHAMBER
A radiator tube heat exchanger is a type of heat exchanger commonly used in
automotive cooling systems. It is designed to transfer heat from the engine coolant to
the surrounding air, thereby helping to cool down the engine.

A radiator tube heat exchanger is a type of heat exchanger commonly used in

automotive cooling systems. It is designed to transfer heat from the engine coolant to
the surrounding air, thereby helping to cool down the engine. The basic structure of a
radiator tube heat exchanger consists of a series of tubes or channels through which
the coolant flows. These tubes are typically made of metal, such as aluminum or
copper, that has good thermal conductivity. The coolant, heated by the engine, enters
the radiator and passes through these tubes. Attached to the tubes are thin, flattened
fins that increase the surface area available for heat transfer. These fins help in
dissipating the heat from the coolant to the surrounding air. As the hot coolant flows
through the tubes, the heat is conducted through the tube walls and transferred to the
fins. At the same time, a fan or airflow is directed over the fins to facilitate the
transfer of heat to the air. The movement of air helps in carrying away the heat from
the fins, cooling them down in the process. As a result, the coolant temperature
decreases, allowing it to circulate back to the engine and remove more heat.
5) OIL REFINERY AND PETROCHEMICAL
A shell and tube heat exchanger is a common type of heat exchanger used in
various industries for transferring heat between two fluids. It consists of a shell (a
cylindrical vessel) and a bundle of tubes inside it. The shell is usually made of metal
and has inlet and outlet ports for the hot and cold fluids.

Here's a textual representation of a shell and tube heat exchanger:

In the above representation, the hot fluid enters through Inlet1 and flows through the tube
bundle. The tube bundle consists of a series of tubes that are connected to the shell on one
end and open on the other end. The cold fluid enters through Inlet2 and flows around the
outside of the tubes inside the shell. As the fluids pass through the heat exchanger, heat is
transferred from the hot fluid to the cold fluid through the tube walls. The hot fluid exits
through Outlet1, and the cold fluid exits through Outlet2.

This arrangement allows for efficient heat transfer between the fluids while keeping them
separated. The larger surface area provided by the numerous tubes enhances heat transfer.
Additionally, the shell and tube design allows for easy cleaning and maintenance of the
heat exchanger.
Question 3: Explain the new and latest technology for heat exchangers used in the
industry?

Here are a few notable advancements in heat exchanger technology:

I. Microchannel Heat Exchangers: Microchannel heat exchangers utilize small

channels with dimensions typically less than 1 mm to enhance heat transfer
efficiency. These heat exchangers offer compactness, high heat transfer rates, and
reduced material usage compared to traditional designs. They find applications in
various industries, including automotive, HVAC, and electronics cooling.
II. Nanofluids: Nanofluids involve suspensions of nanoparticles in conventional heat
transfer fluids, such as water or oil. The addition of nanoparticles, such as carbon
nanotubes or metallic nanoparticles, can significantly enhance the thermal
conductivity of the fluid. Using nanofluids in heat exchangers can result in
improved heat transfer rates and reduced size and weight of the exchanger,
making them attractive for various applications.
III. Phase Change Materials (PCMs): Phase change materials are substances that can
store and release large amounts of thermal energy during phase transitions (e.g.,
solid to liquid or liquid to gas). Integrating PCMs into heat exchangers allows for
thermal energy storage and retrieval, enabling more efficient heat transfer and
temperature regulation. This technology finds applications in renewable energy
systems, waste heat recovery, and thermal management of electronic devices.
 REFERENCE

1) Understanding Heat Exchangers - Types, Designs, Applications and Selection

Guide. (n.d.).
https://www.thomasnet.com/articles/process-equipment/understanding-heat-
exchangers/
2) Brogan, R. (2008). HEAT EXCHANGERS. In Begellhouse eBooks.
https://doi.org/10.1615/atoz.h.heat_exchangers
3) Micro channel heat exchangers. (n.d.).
https://www.danfoss.com/en/products/dcs/heat-exchangers/micro-channel-heat-
exchangers/
 MECHANICAL ENGINEERING DEPARTMENT

DJL50033 – POWER PLANT ENGINEERING 3

CASE STUDY

NAME MATRIX NO
NUR QASDINA BATRISYA BINTI 10DJL20F1002
MOHD KAMAH
IZATUL RIANA BINTI DARUSOMIN 10DJL20F20071
NUR AQILAH IRDINA BINTI ISHAK @ 10DJL20F2002
TALHA

LECTURER: PN. NORAZLINA BINTI MAT NAYAN