Heat Exchanger

A piece of equipment built for
efficient heat transfer from one

medium to another.
⦿A heat exchanger is a piece of equipment
built for efficient heat transfer from one
medium to another.
⦿ They are widely used in refrigeration, air
conditioning, power plants, chemical plants,
petrochemical plants, petroleum refineries,
natural gas processing and sewage treatment.
Heat Exchangers
A heat exchanger is a device that allows heat from a fluid (a liquid or a gas)
to pass to a second fluid (another liquid or gas) with the two fluids at
different temperatures and in thermal contact.
They are classified according to transfer processes, number of fluids, and
degree of surface compactness, construction features, flow arrangements,
and heat transfer mechanisms.
Applications:
(i) Heating or cooling of a fluid stream.
(ii) Evaporation or condensation of single or multicomponent fluid streams.
(iii) Sterilize, pasteurize, fractionate, distill, concentrate, crystallize, or
control process fluids.
(iv) Chemical and petrochemical plants .
(v) Air conditioning systems.
(vi) Power production.
(vii) Waste heat recovery.
(vii) Automobile radiator.
(ix) Central heating system.
(x) Electronic parts.
⦿ In parallel-flow heat
exchangers, the two fluids enter
the exchanger at the same end,
and travel in parallel to one
another to the other side.
⦿ In counter-flow heat
exchangers the fluids enter the
exchanger from opposite ends.
The counter current design is the
most efficient.
⦿ In a cross-flow heat
exchanger, the fluids travel
roughly perpendicular to one
another through the
exchanger.
⦿ Double pipe heat exchanger
⦿ Shell and tube heat exchanger
⦿ Plate heat exchanger
⦿ Plate and shell heat exchanger
⦿ Adiabatic wheel heat exchanger
⦿ Plate fin heat exchanger
⦿ Pillow plate heat exchanger
⦿ Fluid heat exchangers
⦿ Waste heat recovery units
⦿ Dynamic scraped surface heat exchanger
⦿ Direct contact heat exchangers
⦿ HVAC air coils
⦿ Spiral heat exchangers
⦿ Double pipe heat exchanger
⦿ Shell and tube heat exchanger
⦿ Plate heat exchanger
⦿ Plate and shell heat exchanger
⦿ Adiabatic wheel heat exchanger
⦿ Plate fin heat exchanger
⦿ Pillow plate heat exchanger
⦿ Fluid heat exchangers
⦿ Waste heat recovery units
⦿ Dynamic scraped surface heat exchanger
⦿ Direct contact heat exchangers
⦿ HVAC air coils
⦿ Spiral heat exchangers
⦿ It is also known as concentric tube heat exchanger
⦿ In this heat exchanger the fluid to be cooled or
heated passes through the tube 2(green) and the
other fluid is passed through tube 1 (red)to absorb or
release the heat.
⦿ Advantages: Cheap for both design and maintenance.
⦿ Disadvantages: Low efficiency and requires large

space.
⦿ Pasteurization
⦿ Digester heating
⦿ Heat recovery
⦿ Pre-heating
⦿ Effluent
cooling.
⦿ One set of these tubes contains the fluid that
must be either heated or cooled. The second fluid runs
over the tubes that are being heated or cooled so that
it can either provide the heat or absorb the heat
required.
⦿ They are typically used for high pressure
applications.(above 30 bars)
⦿ Cooling of hydraulic fluid.
⦿ Cooling of engine oils.
⦿ Cool or heat swimming pool water or
charged air.
⦿ It is composed of multiple, thin, slightly separated
plates that have very large surface areas and fluid flow
passages for heat transfer.
⦿ The plates are often spaced by rubber sealing gaskets
which are cemented into a section around the edge of
the plates. The plates are pressed to form troughs at
right angles to the direction of flow of the liquid which
runs through the channels in the heat exchanger.
These troughs are arranged so that they interlink with
the other plates which forms the channel with gaps of
1.3–
1.5 mm between the plates.
⦿ The plates can be replaced after
getting corroded.
⦿ If the temperature difference to be
accquired is to be increased then it can be
done by adding more plates.
⦿ Water heaters
⦿ Cooling tower isolation
⦿ Free cooling
⦿ Waste heat recovery
⦿ Heat pump isolation
⦿ Thermal (ice) storage
systems
⦿A spiral heat exchanger (SHE), may refer to
a helical (coiled) tube configuration
⦿ Efficient use of space.
⦿ They can be easily cleaned.
⦿ A Spiral Heat Exchangers (or SHE) is a coiled tube

arrangement, with two channels coiled one around
the another. These two channels operate in a
counter-flow arrangement, offering excellent turn
down ratios, while optimising flow patterns which in
turn, enhance heat transfer.
⦿ Pasteurization
⦿ Recuperators (Exhaust and Air
Handling Systems)
⦿ Sludge Treatment
(Thermal
depolymerisation)
⦿ Cost
⦿ High/low pressure limits
⦿ Thermal performance
⦿ Temperature ranges
⦿ Product mix (liquid/liquid, particulates or
high-solids liquid)
⦿ Pressure drops across the exchanger
⦿ Fluid flow capacity
⦿ Cleanability, maintenance and repair
⦿ Materials required for construction
⦿ Ability and ease of future expansion
⦿ Plate heat exchangers must be disassembled and cleaned
periodically. Tubular heat exchangers can be cleaned by
such methods as acid cleaning, sand blasting, high-
pressure water jet, bullet cleaning, or drill rods.
⦿ In large-scale cooling water systems for heat
exchangers, water treatment such as purification, addition
of chemicals, and testing, is used to minimize fouling of
the heat exchange equipment. Other water treatment is
also used in steam systems for power plants, etc. to
minimize fouling and corrosion of the heat exchange and
other equipment.
Heat Interchangers
Heat interchangers are the devices used for transferring heat from one
liquid to another or from one gas to another gas through a metal wall.
Working :
In a heat interchanger, when heat is transferred the film coefficients on both
sides of the tube are of the same order of magnitude. In order to increase
the overall coefficient, along with increase in the coefficient on one side the
fluid velocity on both sides is also increased to enhance both the
coefficients. The fluid velocity and heat transfer coefficient could be
achieved by placing baffles outside the tubes. The baffle arrangement
increases the path length and decrease the cross-section of the path of the
second fluid. Thus, provision of baffles increases the velocity of the liquid
outside the tubes and also makes it to flow at right angles to the tubes. It
leads to additional turbulence which reduces the resistance for heat transfer
outside the tubes
1. Baffles
2. Liquid to liquid interchangers
3. Double pipe heat interchangers
 Baffles:
1) Baffles consists of circular discs of sheet metal with one
side cut away.
2) These are perforated to receive tubes.
3) The baffles are supported by one or more guide rods,
which are fastened between the tube sheets by set-screws.
Working:
1) Baffles are placed outside the tubes.
2) These increase the velocity of liquid outside the tubes.
3) Baffles made the liquid flow more or less right angles to
the tubes, which creates more turbulence.
 Liquid to liquid interchangers:
Construction:
1) Normally tube sheets, spacer rods and baffles are assembled
first and then tubes are installed.
2) The most important part in heat interchanger is baffle.
3) Appropriate type of tube sheets is chosen for the fabrication.
4) One or more guide rods are fixed to the tube sheets by means
of set-screws.
5) Baffles consists of circular disc of metal sheet.
6) Baffles are placed at appropriate places using guide rods.
7) Baffles have perforations through which tubes are inserted.
8) The ends of tubes are expanded into the tube sheets.
9) The above assembly is enclosed in a shell.
10) The shell has a provision for introducing the heating medium,
hot fluid.
11) The outlet for fluid is at the right side top.
Working:
1) The hot fluid (heating medium) is pumped from left side top of the
shell.
2) The fluid flows outside the tubes and moves down directly to the
bottom.
3) Then it changes the direction and rises again. This process is
continued till it leaves the heater.
4) Baffles increases the velocity of the fluid outside the tubes.
Baffles gets heated and provide more surface area for heat transfer.
5) The heated liquid is collected from right hand side of the distribution
chamber.
Adv:
1) In liquid- liquid heat transfer is rapid, as the liquid;
2) Passes at high velocity outside the tubes.
3) Flows more or less at right angles to the tubes.
• Double pipe heat interchanger:
In a liquid to liquid heat interchanger, the fluid to be heated
is passed only once through the tubes before it gets
discharged. i.e. Single pass.
Construction:
1) In this two pipes are used: one is inserted in the other.
2) The inside pipe is used for the pumping of cold liquid to
be heated.
3) The outer pipe acts as a jacket for the circulation of the
hot liquid.
4) All jacketed sections are inter-connected.
5) Normally length of pipe is less.
Working:
1) The hot liquid (heating medium) is pumped into the
jacketed section.
2) The hot fluid is circulated through the annular spaces
between them and carried from one section to the next
section. Finally it leaves the jacket.
3) In this process the pipes get heated, white the hot fluid
losses it temperature.
4) The liquid to be heated is pumped through the inlet
provided at the right side.
5) The liquid gets heated up and flows through the bent
tubes into the next section of the pipe.
6) Finally the liquid leaves the interchanger.

Heat Exchanger

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Heat Exchanger

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A piece of equipment built for

efficient heat transfer from one

⦿ Disadvantages: Low efficiency and requires large

⦿ They can be easily cleaned.

⦿ A Spiral Heat Exchangers (or SHE) is a coiled tube

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