Heat Exchanger

Heat exchanger slide Applied
Research International
Index
Heat exchange theory...................................................2
Importance of turbulance............................................2
Disadvantage................................................................2
Heat exchangers...........................................................3
Heat exchangers are of three types:............................4
Section:.........................................................................4
Materials used are as follows:......................................5
Advantages are:............................................................5
Central cooling system have advantages as follows.....6
Maintenance and trouble shooting:.............................6
Requirements of a shell-tube type heat exchanger......6
Factors affecting tube to tube plate joining.................7
Methods of joining tube to tube plate-........................7
Expansion arrangement...............................................8
Material selection for tubular heat exchanger............8
Desirable properties in a tube plate............................9
Types of corrosion attacks..........................................10
Methods of protection aginst corrosion and wastage:
....................................................................................11
Plate types heat exchanger........................................12
Advantages are:..........................................................13
Advantages of titanium:.............................................13
Disadvantages of plate type:......................................13
Materials....................................................................14
/conversion/tmp/scratch/367920419.doc 1
Heat exchange theory

Heat exchange depends upon
1 Temperature difference between two
2 The ability of material of the tube or plate to conduct
3 The area and thickness of the materials.
S.W. velocity should be 2.5 m/s (upper limit) and lower limit
1m/sec (per al brass)
Importance of turbulance
1. It rotates particles of the liquid so that they tend to
break up the boundary layer and remove heat by direct
contact with the heat transfer surfaces.
2. The scouring action tends to keep cooler surface clean.
Disadvantage
1. It cause impingement corrosion/erosion occurs at the
entry of the tubes where turbulance is more.
AQ= h1(th-thw) SA= (k/y) (thw-tcw)SA= h2(tcw-tc)Sa

H1= co-eff. Of heat transfer on the hot fluid side.
H2=
K= thermal conductivity of the wall material
Y= thickness of the wall.
Overall co-eff. Of heat transfer from hot to cold liquid
SQ
U=----------------
(th-tc)SA
Thermal performance of a heat exchanger. Q=UA
= logarithmic means of the temperature different at the
inlet and outlet of the heat exchanger, it is maximum in
reverse flow. (counter)
Heat exchangers
Heat is transferred by condition, convection or radiation
and it from higher to lower temperature.
Conduction is the transfer of heat from one part of a
substance to another part of the same substance or another
substance that is in physical contact with it.
Convection is the transfer of heat with a fluid by mixing of
one portion with another. The movement may caused by the
difference in densities resulting from the temperature
difference as in natural convection or the motion of the
liquid by mechanical means as in forced convection.
Radiation is because of all matter emitting electro-magnetic
radiation at temperature above absolute zero. Higher the
temperature greater the energy radiated. Radiant energy
being electro-magnetic requires no medium and will pass
through vacuum also. Certain gases emit radiations of some
wavelength whereas most solids emit radiations over wide
range of wavelengths.
Fouriers law of conduction states that flow of heat through
single homogeneous solid directly proportional to area A of
the section at right angles to the flow of heat and to the
change of temp wrt length of the path of heat flow.
Q=-K X A x dt/dx
K-thermal conductivity
Newtons law of cooling states that the heat transfer from
solid of surface area A and temperature Ts to liquid to
fluid of temperature t is given by
Q=h x A x (Ts-t)
H= heat transfer coefficient
Q= UA(th-Tc)
Th-temperature of hot fluid and Tc-temperature of cold liquid
U-overall heat transfer coefficient
Heat exchangers are of three types:

(a) Recuperator type in which the flowing
liquids exchanging heat on the either side of a
dividing wall. Recuperator types are of parallel
type, counter-flow type cross-flow type and mixed
flow type. They may be also single pass or multi-
pass. Multi-pass types give an advantage of
reduced space and even reduced pump capacity
of the coolant.
(b) Regenerator type in which the hot and cold
fluids pass alternately through a space. The fluids
in general are gaseous.
(c) Evaporative type is cooled evaporatively and
continuous in the same space as the coolant as in
a cooling tower.
Section:
(a) Quantity of maximum and minimum fluid to be
cooled.
(b) Range of inlet and outlet temperature for coolant
and fluid to be cooled.
(c) Specific heat of the medium
(d) Type of medium-corrosive or non-corrosive.
(e) Safety
(f) Operating pressures
(g) Maintenance, fouling, cleaning and access
(h) Position is the system and associated pipe work
(i) Cost, materials,
(j) Stream line or turbulent flow
Velocity of flow x pipe dia
(Reynolds number= ---------------------------------------
Kinematic viscosity
Keeping the above points in view the heat exchangers
that are used on board are broadly divided into shell and
tube type and plate type.
Shell type
Materials used are as follows:

End covers-cast iron, tube plates-naval bras and tube-
aluminium brass, baffles-brass.
Sometimes are radial fins are fitted integral with the
tubes. The fins give following advantages: (a) greater
surface area, (b) better heat transfer (c) lower metal
surface temperature (d) in case of oil heaters reduce the
risk of cracking and hence fouling.
Plate type: material used are plates of titanium, stainless
steel or aluminium bras. Corrugations are provided for
strength and additional heat transfer area. gaskets are of
nitrile rubber.
Advantages are:
(a) Space saving
(b) Easy inspection and cleaning and pipes do not
have to be disconnected for cleaning
(c) Variable capacity and plate numbers can be
altered to increase capacity
(d) Net heat transfer surface area can be reduced
due to turbulent flow
(e) Titanium plates have virtually no corrosion or
erosion and so no sacrificial anodes are required.
Central cooling system have advantages

as follows
(a) Reduced maintenance due fresh water having clean
and treated water. Cleaning of the system and
component replacement is simpler.
(b) Fewer speed may be higher on fw pipes and size and
installation cost can reduced.
(c) Water speed may be higher on fw pipes and size and
installation cost can reduced.
(d) Better stability with even temperature of coolant
which is fresh, water.
Maintenance and trouble shooting:
Requirements of a shell-tube type heat

exchanger
Water boxes are designed so that it will not be
necessary to dis-assemble piping.
The tube bundle is usually of removable type for ease
of cleaning.
Water boxes or heat to be designed so that there is a
smooth flow of water sharp corner to be avoided.
Cooling water velocities should not be more than
recommended.
Tube are normally 1/8 inch more in length than
distance between tube plates. Tube plate thickness
should not be less than inch.
When external fins are provided, the dia of hole on one
side of the tube plate should be more than dia of the
fin.
Holes in the tube plates are flared so that when the
tubes re belled, they remain flush with the tube plate
face.
Holes are on the tube plates are provided at least with
one groove.
Distance between the baffle plates should not be more
than 36 inches.
Adequate air vents must be provided to avoid
collection of air in the upper region of water box. Such
air pockets affect heat transfer area and cause
expansion ;of tubes and their failure.
In feed water heaters and condensers means must be
provided for prevention of entry of steam at high
velocity.
Factors affecting tube to tube plate
joining
Tube hole finish
Tube wall thickness reduction
Length of expanded joint
Tube plate ligament width (i.e. minimum distance
between tube holes)
Tube wall thickness.
Relative yield strength between tube and tube plate.
Methods of joining tube to tube plate-

Mechanical roller expansion simple type consists of 3
parts ie rollers, cage and a mandrel.
Hydraulic expansion is achieved by fluid (usually
water) pressure. A pressure of about 2000 to 3000
bars is needed
Explosion expansion is carried out by detonating an
explosive charge.
Welded joint are used when factors such temp,
pressures fatigue and corrosive fluids and the
consequences of leakage dictate joints to be welded.
For welded joints the surfaces must be free of
protective coatings, lubricants, rust, pits, scratches
etc. depending on the thickness various types of
welded joints are used.
Expansion arrangement
Simple U-tube arrangement.
Bayonet type
Packed tube joints
Floating tube nest
Shell expansion joints are used to lessen the stresses
caused by the differential expansion (where the
differential expansion is not more than 1.5mm for a 5 ft
tube expansion arrangements are used).
When the shell of heat exchanger operates at an
elevated temperatures, one foot of the shell is
anchored and the other is designed to permit free
expansion along the axial direction.
Material selection for tubular heat

exchanger
Tubes are the most critical part of heat exchanger following
qualities are the most important in a tube materials
1. High thermal conductivity for better heat transfer
2. Ductility for fabrication and cold working
3. Galvanic compatibility with material used for tube
plates and water boxes.
4. Resistant to corrosion, high water velocity erosion
5. Resistant to chemical attack by vapor and
condensate
6. Resistant to attack under loosely held deposits.
7. Resistant to selective corrosion such as
dezincification graphitisation etc.
8. Above qualities are found in the Cu alloys.
Aluminium brass is used. Sb is added to prevent
dezincification. It is economical Cupro-Nickel is
used due to its resistance to erosion at high
velocity of water. It is less prone to stress
cracking than Al brass in the presence of
sulphides and NH3.
Desirable properties in a tube plate

1. Resistant to corrosion and compatible with tube
material
2. Resistant to erosion and impingement attack by SW
flow.
3. Soft enough to allow tubes to expand and from a seal.
4. It should have machinability.
They are normally made of Muntz material (60%

Cu,40%,Zn), naval brass(60% cu, 39%Zn and 1%Mn). Latter
is less susceptible to dezincification. Tube plates are made
thick enough to make allowance for dezincification. They
are made anodic to tube plates.
Cupro-nickel or Monel metal (68%Cu, 32%Ni) tube plates
with titanium tubes for extreme sulphide protection.
Types of corrosion attacks

1. Deposit attack-caused by a layer of non-adherent
matter, which usually lies on the lower half of the tubes
where these are in a horizontal position. It can cause
the metal under the layer to become anodic and get
washed.
Prevention-use of vertical heat exchangers so that
deposits do not lie in the tubes. Regular cleaning of
tubes, ICCP, chlorination prevents deposits.
2. Impingement attack- it removes protective layer thus
exposing fresh metal to attack by corrosion. This effect
is increased by further air entrained in the system.
Prevention- even velocity within the tubes, correct
size of water boxes to avoid eddies and uneven water
distribution, provision for release of air. If there is no
iron or steel in the water system, steel protector plates
or rods should be provided. In gunmetal water boxes
Iron can be provided by steel spraying the surface.
Injection of FESO4 in the MSW system should be
carried out to aid formation of protective oxide film
layer (hydrated solution of FESO4 5PPM conc. for 1
Hr/day)
3. Pitting-it is caused by the breakdown of protective film.
Prevention use of steel protector rods or plates,
FeSO4 injection and avoiding excessive velocity of flow.
4. Dezincification- usual cause is high temperature of SW.
Prevention addition of arsenic, avoiding high
temperature, avoiding stagnation of water, use of
Sacrificial anodes and chlorination (to avoid fouling)
Methods of protection aginst corrosion

and wastage:
1. Design aspects-by providing ample water, shaped
water boxes, smooth tube inlets to prevent
impingements and turbulence.
2. Sacrificial anodes- when dissimilar metals are
connected together and immersed in an electrolyte a
galvanic cell is set up. The more electro-positive metal
becomes anode and the other cathode. The current
flows from anode and will tend to suffer. Corrosion.
Sacrificial anodes, which are more electro-positive
than the other materials are placed on the water boxes
making good electrical contact with it. They undergo
preferential wastage. These should be placed so that
water flow is not affected.
Normally zinc is used. other metals like Al, soft iron for
sw and magnesium for FW sides are used.
ICCP- by using this m the materials to be protected
are made more cathodic wrt another part which is
made anodic on which a small amount of current is
impressed. This provides protection to S.W. pipes, thus
protecting HE from rust, marine growth etc., which
may get dislodged from the tubes. In this case the
anodes do not waste away as the electric current is
impressed upon it from the ships supply. Anodes made
of lead-silver have current passed to them. Platinum
electrodes are used as reference electrodes and the PD
between RE and the surrounding SW is sensed by an
external electric circuit. This determines the amount of
current to be impressed on the lead-silver anode.
Supply is DC. If current is too little corrosion will
ensure. If current is too much damage of paint layers
will occur. Not commonly used for heat exchangers.
FESO4 solution-presence of iron compound or iron
oxides has a beneficial effect on the Hex tubes as they
can provide further protection. Total breakdown of
protective layer may occur due to turbulence. To aid
formation of protective layer FESO4 solution is
injected in the SW system. Standard size of injection
system consists of PVC tk, PVC, metering pump etc.
Chlorination- sodium hypo-chlorite solution is added
to the SW system to prevent fouling by marine growth
and bacteria. (Fouling can cause partial blockage, local
impingement, tube perforation, complete blockage.
Overheating due to blockage can cause accelerated
corrosion.
Coating-bituminous or epoxy coating, rubber lining
etc may be used. They are electrically insulated from
SW which are in contact with other parts of Hex.
Binding strips-connecting the water boxes and the
shell so as to provide electrical contacts between
various parts of the heat exchangers. This protects
aginst electrochemical corrosion.
Prevention of air entry and regular cleaning are also
the means for protection.
Plate types heat exchanger

Plate type heat exchangers were originally developed
for the milk industry where daily cleaning is necessary.
They were first used at sea, as coolers, in the nineteen-
fifties.
Plate type: materials used are plates of titanium,
stainless steel or aluminium bras. Corrugations are
provided for strength, creating turbulence and
additional heat transfer area. gaskets are of nitrile
rubber. Plates are about 0.6mm thick. Maximum
working pressure is 16 bar and temperature is 110 deg
celcius. Plate gap is 2-5 mm. by using specialized joints
the operating temperature and pressure can be
increased to 250 deg celcius and 21 bar respectively.
Advantages are:
(a) Space saving
(b) Easy inspection and cleaning and pipes do not
have to be disconnected for cleaning
(c) Variable capacity and plate numbers can be
altered to increase capacity
(d) Net heat transfer surface area can be reduced
due to turbulent flow
(e) Turbulent flow ensures no fouling inside.
Advantages of titanium:
(a) Light weight (density= 4.5kg/1)
(b) Low in the galvanic series. So most noble.
(c) Resistant to corrosion
(d) Resistant to erosion. Titanium in atmosphere of
aerated water forms a very stable oxide and in an
anaerobic atmosphere forms a hydrate, which is also
stable. It can withstand high velocity of water.
(e) Its modulus of rigidity is half of that of steel. It is
therefore sufficiently elastic.
(f) It is malleable and hence can made into thin sheets.
(g) It has a high strength and therefore can withstand
high pressures.
Disadvantages of plate type:

(a) Difficulty in testing for plate perforations.
(b)Possibility of mechanical damage to plates due to
frequent handling.
(c) Difficulty to accommodate vapours due to their large
volume.
(d)Increased possibility of fouling due to small plate gap.
(e) Deterioration of joints and their difficulty in removal
and replacement.
(f) Assembly must be carried out with utmost care
especially with multipass.
The plate corrugations stiffens the thin metal sheet and

increases the surface area, additionally considerable
turbulance is created.
In the washboard type the joints bonded into the grooves
act as spacers. With the chevron type alternate plates have
upright and inverted vee corrugations which give each
other mutual support.
Materials
Frame (not in contact with fluids)- coated mild steel)
Plates and flange connections-titanium, stainless steel, or
aluminium brass.
Joints-nitrile rubber (max temperature 1400C) asbestos
Working pressures up to about 16 bar
Plate gap 2-5mm

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Heat exchanger slide Applied

Heat exchange theory

AQ= h1(th-thw) SA= (k/y) (thw-tcw)SA= h2(tcw-tc)Sa

Heat exchangers are of three types:

Materials used are as follows:

Central cooling system have advantages

Maintenance and trouble shooting:

Requirements of a shell-tube type heat

Methods of joining tube to tube plate-

Material selection for tubular heat

Desirable properties in a tube plate

They are normally made of Muntz material (60%

Types of corrosion attacks

Methods of protection aginst corrosion

Plate types heat exchanger

Disadvantages of plate type:

The plate corrugations stiffens the thin metal sheet and

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