Heat Exchangers

Heat Exchangers
B K Kumbhar
Saturday, August 8, 2009 1

Presentation points
 Importance & Classification
 Types of Heat Exchangers in Dairy & Food
Industry
 Selection of Heat Exchangers
 Indirect Contact Type Heat
 Direct Contact Type Heat

Heat Exchanger
 Heating and/or cooling of the process streams
during processing
 Heat transfer between two fluids through a
separating wall or by direct contact with each
other
 Classification based on
Degree of heat transfer surface compactness
Construction features
Flow arrangements
Number of fluids
Heat transfer mechanisms

In Dairy and Food Industries
Direct Contact
Steam Injection
Steam infusion
Indirect Contact
Tubular
Plate
Jacketed Kettle

Selection of Heat Exchangers
 Flow Rate of Both the Fluids

 Heat Sensitivity
 Terminal Temperatures
 Types of Fluids
 Properties of Both Fluids
 Flow Arrangement
 Operating Pressure and Temperature
 Pressure Drop

Contd
Selection of Heat Exchangers ----contd
 Heat Recovery
 Fouling
 Ease of Inspection, Cleaning, Repair &
Maintenance
 Materials of Construction
 Cost of Heat Exchanger

Flow Rate of Both the Fluids
Size
Length
Width
Height
Weight
Site Requirement
Lifting and Servicing capabilities
Inventory Considerations
Sizing of the Heat Exchanger

Minimum Pressure Drop
Flow Ratio

Heat Sensitivity
 Low Hold-up Volume

 Low Residence Time
 Low Surface Temperature
Requirements
 Good Flow Distribution
 High Heat Transfer Coefficient
 Small Channel Volume

Terminal Temperatures
 Performance of Heat Exchanger depends on terminal
temperatures
 Heat Transfer Units (HTU) defined as

Ratio of
* Temperature of one fluid
* Mean temperature difference between the fluids
 Plate heat exchanger > Tubular Heat Exchanger

 Up to 4 HTU in case of Plate heat exchanger

Types of Fluids
 Liquids
 Gases
Tubular heat exchanger suitable for condensable

gases (steam)
Plate heat exchanger suitable for liquids with less
than 50000 cP

Properties of Both Fluids
 Heat Transfer Calculations

 Pumping Calculations
 Viscosity
Low viscosity- Plate heat exchanger
High viscosity- Scraped surface heat exchanger
 Thermal conductivity
 Density
 Specific heat
 Thermal diffusivity
Flow Arrangement
Concurrent – Flow in same direction
 Thermodynamically poor
 High thermal stresses since large temperature difference at inlet
 Heat sensitive materials
Counter current- flow opposite to each other
 Thermodynamically superior
 Minimum thermal stresses
 Maximum heat recovery
 Least heat transfer area
Cross flow- Flow perpendicular to each other
 In between the above
 Design of headers require less space
 Space is important

Operating Pressure and Temperature
Mechanical Design
 Operating Pressure
 Operating Temperature
Problems of high operating temperature and pressure

 Vibration
 Fatigue
 Thermal stresses, etc.
Plate heat exchanger free from such problems however plate

thickness and gasket material limit its application

Maximum Operating Conditions
Heat Exchanger T, 0C P, kg/cm² Q, l/h

 Plate heat exchanger 260 21 50,00,00
 Double pipe 540 70 no limit
 Shell and tube 540 105 no limit
 Scraped surface 250 35 27,00
 Kettle 260 5 -

Pressure Drop
Important for
 Pumping Cost - proportional to pressure drop
 Heat Transfer Rate - proportional to pressure drop
 Specific pressure drop defined as

 Pressure drop per unit HTU
 Used to compare the performance of different heat exchangers

Heat Recovery
 Conservation of energy- very important

 Recovery of heat from used/waste process streams
 Less than 50% in tubular heat exchangers

 Up to 95% in plate heat exchanger

Fouling
Deposition of solid material- poor conductor of heat
* Decreases heat transfer
* Decreases flow rate
* Lead to corrosion
* Loss of valuable materials
* Affects the design and size of the unit
* Affects the production runs
Factors affecting fouling
 Velocity- High velocity less fouling
* Shearing force * Turbulence
* Laminar layer thickness * Residence time
 Surface temperature – important for heat sensitive liquids
- small temperature difference required
 Bulk fluid temperature – more fouling in less bulk temperature
 Composition
Ease of Inspection, Cleaning, Repair & Maintenance
Requirement PHE DP ST SS Kettle
Inspection for fouling
 Product side a b a a a
 Media side a b b/d d c/d
Inspection for leakage

 Product side a b/c b/d d c/d
 Media side a a a b a
Inspection for corrosion

 Product side a a/b a/d a a
 Media side a b/d a/dc c b/c
a: Very good b: Acceptable c: Poor d: Impossible

PHE-
Saturday,Plate
Augustheat
8, 2009exchanger DP- double pipe ST- shell and tube SS- scraped
19
surface
Ease of Inspection, Cleaning, Repair & Maintenance
------contd
Chemical cleaning
 Product side a a b/c a a
 Media side a a a a a
Manual cleaning
 Product side a b a a a
 Media side a c/d a/d d c/d
Extension a b/d d d d
Repair a b/c b a a
Materials of Construction
Material of construction depends on
 Properties of the fluids such as heat sensitivity, fouling,
corrosivity,
 Operating temperature and pressure
 Welding ease
 Availability
 Conformance to all applicable laws, codes and
insurance requirements
 Cost
Materials
Stainless steel Carbon steel Graphite
Aluminum Titanium Hastalloy
Gaskets
Nitryl rubber
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Butyl rubber 21
Teflon Compressed asbestos fibers
Cost of Heat Exchanger
 Optimization based on cost consideration

 Consider all above factors

Indirect Contact Type Heat Exchangers
 Plate heat exchanger
 Tubular heat exchangers
 Double pipe heat exchanger

 Scraped surface heat exchanger (SSHE)
 Spiral tube heat exchanger
 Shell and tube heat exchanger
 Jacketed kettle

Plate Heat Exchanger
 Consists of rectangular thin corrugated plates
stacked in a frame.
 Plates pressed against each other between the
stationary frame plate and movable pressure plate
with compression bolt to form narrow flow
channels.
 Hot and cold streams flow in alternate channels.
 Corner openings termed as ports
 Flow port
 Transfer port
 Fluid flow may be diagonal or vertical

Plate Heat Exchangers
 Construction
 Ports
 Corrugations
 Flow arrangements
 Advantages
 Limitations

Parts of Plate heat exchanger
 Thin corrugated plates
 Stationary frame plate
 Movable pressure plate
 Plate carrying bar
 Plate guide bar
 Compression bolt
 Connecting plate
 Gasket
 Inlet and outlet nozzles for each stream

Plate Heat Exchanger
Stationary frame plate
Plate carrying bar
Milk out
Hot water in
Movable pressure plate
Milk in
Connecting plate
Hot water out Plate carrying bar
Compression nut & bolt

Flow Path in Plate Heat Exchanger
Four pass of milk

Second pass
Milk Out Milk in
Hot Water in Hot Water out
First pass
Two pass of hot water

Gaskets
 Prevent leakage of liquids
 Eliminate possibility of mixing
 Criteria for gasket materials
 Thermal stability
 Resistance to assuming permanent deformation
 Good ageing characteristics
 Low compression set
 Selection depends on the chemical composition of the
process streams and operating temperature.

Type of Ports
 Flow Port
 Transfer Port

Corrugations
 Inducing turbulence in the process stream
 Providing reinforcement
 Plate support points to maintain interplate
separation and increasing heat transfer surface
area.
 Patterns
 Trough type
 Chevron or herringbone type

Flow arrangement
 Series – low flow rates and large temp. change
 Looped – large flow rates and small
temperature change
 Complex – intermediate cases of flow and
temperature changeLooped flow
Looped f
Series Flow

Looped flo
Series flow
Series Flow

Looped Flow Pattern
Looped

Parts of a Plate
Gasket
Transfer port Flow port
Flow distribution Gasket

triangles
Corrugations
Transfer port
Flow port

Herringbone (Chevron type, 3D)

Flow pattern
Looped flow
Series Flow

ADVANTAGES
 Overall heat transfer coefficient higher
 Effective mean temp difference usually higher
 Less cost
 Occupies less floor and head space – low hold-up
volume gives quicker start up and faster response to

control function changes.
 Less massive foundation
 Less fouling
 Disassembled easily
 Variety of ways for assembling
 Multiple duties like heating, cooling, regeneration etc
 Intermixing prevented by double gasket.

 Over 90 % heat recovery.
Limitations
 Cannot withstand operating pressures much in
excess of 21 kg/cm2 (300 psi)
 Gaskets should be elastomeric. So, maximum
operating temp. usually limited to 2600C.
 For mild steel construction, plate heat
exchangers are costlier.
 Moderate pressure loss required to produce
economic designs to handle large quantities of
low density fluids such as vapors and gases.
Tubular Heat Exchangers
 Double/triple pipe
 Shell and tube
 Spiral tube
 Scraped surface heat exchangers (SSHE)
• Common factor among former three is that tube of
relatively smaller diameter housed in shell.
• SSHE is basically large double pipe heat
exchanger with scraper inside the inner tube
Double Pipe Heat Exchangers
 Simplest Type of Heat Exchanger
 Pair of single lengths of pipe
 smaller diameter pipe -within another pipe
 from a number of lengths arranged in a vertical row
 Welding of the outer jacket to the inner pipe is done
or
 A packed stuffing box -permit differential
movement - removal of inner pipe for cleaning or
maintenance purpose.
 5-10 cm pipe size shells
 1.9-6.35 cm inner tubes
Application of Double Pipe HE
 Can be used for liquid-liquid or steam/gas-
liquid duties with high μ
 Suitable for low flow rates
 high temp. ranges
 withstand high pressure
 Difficult to inspect for fouling or leakage.

 Low flow rates
 High temperature range
 High pressure because of small diameter pipes
 Space requirement - high as compared to plate
heat exchanger
 Ceiling or wall mounted thereby taking up no floor
space.
 Flow distribution is no problem
 In-place-cleaning - very easily

Most difficult to inspect for fouling or leakage.

 Repair - not difficult
 very close temperature approaches- true
counter current flow
 Sometimes three tubes - concentrically - triple
pipe heat exchanger
 annuals between the innermost and
intermediate tubes
 concurrently or counter currently
 to preheat the liquid food material before
evaporation or spray drying

 Space requirement normally high
 No problem in flow distribution and in-place
cleaning, repair no problem.
 Three tubes mounted concentrically to form triple
pipe heat exchanger.
 Velocity in heater is high and excellent heat
transfer rates possible.
 In double pipe type, heat recovery or regeneration
not possible, while the triple tube arrangement
makes possible the use of efficient and compact
regenerative hook-up.
 Typical application – dairy and food industry

 To preheat the liquid food material before evaporation or
spray drying.
Scraped surface heat exchanger (SSHE)
 Also called votator or swept surface heat
exchanger.
 Two concentric scraper fitted cylinders with two
or more scraper blades.
 Outer cylinder covered with insulating material
 Stainless steel sheet used to cover the insulation to
protect from mechanical damage.
 Inner cylinder made of SS or MS lined with
chrome-nickel plating.
Scraped Surface Heat Exchanger


 Fixed-clearance scrapers
small clearance between the blades and the heat transfer
surface highly abrasive products such as sugar/fat mixtures
 Variable-clearance scraper- floating blades
• Forced toward the wall by, springs, centrifugal force, and hydrodynamic
action of the fluid scrape, sweep, or cut the product film -minimum fouling
and burn on takes place
 Heat transfer rate increases
 mechanically-induced turbulence, film removal, product mixing
 HTC compare very well with those of plate heat exchanger
 Product velocity at the heat transfer surface
speed of the scraper, number of rows of blades. It does not
depend on the product flow rate
 The product requires whipping and aerating - ice-cream
freezers - beaters
Operations
 Liquid-full operation
filled completely with liquid product
sensible heat transfer
 Thin-film operation
does not run full
phase change

 Diameters 7.5-25 cms
 And lengths 120-180 cms
 Viscosity up to 100000 cp
 Solids contents upto 75 per cent
 Temperatures -180 to 30 C

 Ice cream, condensed milk, baby foods, etc. Or for
pasteurization or sterilization
 Space requirement
-high or low depending upon the type of unit.
 Vertical installation
 -less floor area- difficult to inspect for cleaning
 Horizontal installation
 needs double unit size for removal of rotor shaft if floor mounted -easy
to lower down for inspection.
 .

 Costliest among all heat exchangers
 Moving parts, seals and blades -proper
maintenance
 Lubrication -manufacturers instructions.
 Blades - sharpened as they get worn.

Scrapers
• Scrape the film continuously.
• More heat transfer rate.
• Minimum fouling and burning
 Fixed clearance scrapers
 Used for highly abrasive products (sugar/fat
mixtures)
 Variable clearance scrapers
 Floating blades forced towards wall by springs,
centrifugal force, hydrodynamic action of the
fluid or combination of these factors.

 SSHE can be used for two modes of operations
 Liquid-full operation
 Vessel completely filled with product
 Almost always sensible heat transfer
 Thin-film operation
 Does not run full, but liquid flows in a thin film down
the vessel device
 Sensible + latent heat transfer

Spiral tube heat exchanger
 One or more spirally wound tubes
 Heat transfer higher
 Turbulence induced is more due to higher velocity
 Natural scrubbing of the tube
 Production cycle extended for a longer time.
 Fewer cleaning cycles required.
 Large amount of space accommodated.
 Used for aseptic production of liquid and semi-
solid food products
 @ 75 – 15000 lit/hr
• Diameters 7.5 to 25 cm, lengths 120 to 180 cm
• Continuous heating or freezing (μ = 1,00,000 cP
and solid content up to 75 %)
• Temperature range 1800 to -300C
• Manufacturing of ice cream, condensed milk, baby
foods etc.
• Space requirement high or low depending upon
type of unit
• Costliest among all others
 Considerable amount of surface can be
accommodated in a given space by spiraling.
Thermal expansion -not a problem
 Cleaning of the outer surface of the tube is
difficult.
 Used for aseptic production of liquid and semi-
solid food products

Spiral Tube Heat Exchanger

Shell and Tube Heat Exchangers
Round tubes housed in a cylindrical shell
 One fluid flows inside the tube while the other
fluid flows across and along the tubes
 Major components-
 Tubes
 Shell
 Baffles
 Tube sheets
 Pass divider
 Channel cover
 Tube side and shell side nozzles
The tubes
 Arranged on a square pitch- easily cleaned
 Triangular pitch pattern -more number of tubes

Shell and tube heat exchangers
 Tubes arranged on square or triangular pitch pattern
 Square pattern – easy cleaning
 Triangular pattern – more no. of tubes to a given shell
diameter.
 Material – usually low carbon steel, low alloy steel.
SS, Cu etc.
 Baffles
 Support tubes, prevent vibration and guide shell side
fluid back and forth
 Increase in velocity, turbulences, degree of mixing
andAugust
Saturday, high heat transfer coefficient.
8, 2009 63
 Shell and tube heat exchanger -widely used in process
industries - relatively easy construction -wide range of
duties-mechanically rugged -withstand normal shop
fabrication stresses, shipping and field erection stresses
and normal operating conditions
 Can be reasonably easily cleaned
 Gaskets and tubes, which are most subject to failure, can
be replaced easily
 Low solids content and viscosities normally less than
10000 cps
 Often used for non-food processing steps such as chilling
the brine for refrigeration or as hot water heaters
 Tubular evaporators - shell and tube heat exchanger

Shell and Tube Heat Exchanger

Shell
 Roundness of the shell -important for inserting and
fixing the baffles of maximum diameter impingement
baffle -below the shell-side inlet nozzle- prevent the
impact of fluid on the tubes, which may lead to erosion,
cavitation, and/or vibration of tubes
 Tube bundle- tubes, tube sheets and baffles from the
shell for inspection and cleaning
 Tube-side channels and nozzles control - tube-side fluid
into and out of the tubes
 Channel cover -round plate fitted to the channel flanges
- removed for tube inspection
Baffles
To support the tubes in proper position during assembly
and operation
 To prevent vibration of the tubes caused by flow
induced eddies
 To guide the shell side fluid back and forth across the
tube field
 Increase in velocity, turbulences, degree of mixing and
heat transfer coefficient

Types of Baffles
 Transverse baffles are placed along the length of tubes
 Longitudinal baffles
Minimum spacing between baffles -one-fifth of the shell diameter

A pass divider
 Plate fitted into one or both the channel
 Pass dividers - fitted tightly to prevent the leakage of
fluid from one pass to another
 Tube side passes – may be more
 Shell side passes – restricted to one- two
 Sometimes more than two.

Fluid choice
 Fouling and corrosion characteristics of the fluid,

permissible pressure drop across the heat
exchanger, constructional cost, etc.
 Corrosive and more susceptible for fouling fluids -
tubes
 In shell-side fluid -more pressure drop

 Types of baffles:
• Transverse
• Longitudinal
 Minimum spacing between baffles 1/5 th of shell
diameter, but not less than 5 cm.
 Choice of fluid depends on:

 Fouling and corrosion characteristics
 Permissible pressure drop
 Constructional cost etc.
 Corrosive and fouling producing fluids in tubes

Jacketed Kettle
 Semispherical container and a jacket
 cylindrical container with jacket - jacketed vat.
 The steam or hot water may be used as a heating medium
 Hot water- spray- more efficient- rapidly moving thin film
 Flooded into the heating/cooling medium passage
 40 percent saving in heating time by spray method
 agitator or scraper- uniform heating and increase rate of heat

transfer
 small capacity plant
 production of small quantities of material in large capacity plants
 not efficient as compared to other types of heat exchangers
 the initial cost of the exchanger is low.
 Operation and maintenance are easy
 No skilled worker is needed.
 energy consumption of the heat exchanger is more

JACKETED KETTLE
 Spray or flooded type
 40 % saving in heating time in spray
 Agitator for uniform heating
 Scraper when concentration of liquid done
 Operation and maintenance easier.
 Not efficient as compared to others
 Initial cost is low
 Volume /heat transfer area high
 Area/volume low
 Agitator or scraper- uniform heating and increase rate of
heat transfer
 Cylindrical container with jacket - jacketed vat.
 Small capacity plant
 Production of small quantities of material in large capacity
plants
 Not efficient as compared to other types of heat exchangers
 The initial cost of the exchanger is low
 Operation and maintenance are easy
 Energy consumption of the heat exchanger is more

DIRECT CONTACT TYPE HEAT
EXCHANGERS
 Steam injection
 Steam into process fluid
 Steam infusion
 Process fluid spread into vessel with steam
atmosphere
 Employed in dairy industry for UHT processing
 Temp. rises very rapidly to 135-1500C.
 Heat transfer mainly due to condensation of
steam resulting in 10 % dilution of the product.75

Saturday, August 8, 2009
Advantages of Direct contact HE
 Very rapid heating and cooling

 Less scaling permits longer production runs
 Low oxygen content of final product

Limitations/disadvantages of Direct Contact
HE
 Direct heating more complex
 Requires
 more plant components,
 additional controls and
 high quality steam (culinary steam)
 Relatively expensive in
 initial and
 operating cost
 No regenerative heating above the temperature at
which steam is mixed
Direct Contact Type
 Steam injection - steam -suitable nozzle -liquid
 Steam infusion heat exchangers - spread into a
vessel with steam atmosphere
 Raises the temperature very rapidly to 135 - 150.
 Heat transfer - condensation of steam
 10% dilution of the product
 Vacuum chamber- evaporatively cooled and the
condensed water is flushed off. Adjustment of the
vacuum - necessary removal of water and
simultaneously controls the dry matter content of
the final produce.

Advantages of Direct Contact HE
 Very rapid heating and cooling and consequently a low
total temperature load on the product.
 Less scaling in the equipment as compared to indirect
heating which also permits longer production runs
because of less frequent cleaning cycles.
 Low oxygen content of the final product. Expansion
cooling does not only remove water but also dissolved
air (02) resulting in an oxygen content of the final
product (milk) of about or less than 0.1 ppm.

 It is not possible to use regenerative heating
above the temperature at which steam is
mixed with the product.

Steam Injection System
 Injection requires steam pressures higher
than those of the product in the infuser.

Steam Infusion System
 With infuser, any pool of product in the
bottom of heating vessel contributes much
of the holding period needed for sterilizing
effect.
 Very close control of product level at this
point is necessary if the process is not to be
variable

Temperature-Time Profile in
UHT Process

Temperature-Time Profile

Heat Exchangers

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 Flow Rate of Both the Fluids

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Sizing of the Heat Exchanger

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 Low Hold-up Volume

 High Heat Transfer Coefficient

 Small Channel Volume

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 Heat Transfer Units (HTU) defined as

 Plate heat exchanger > Tubular Heat Exchanger

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Tubular heat exchanger suitable for condensable

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 Heat Transfer Calculations

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Problems of high operating temperature and pressure

Plate heat exchanger free from such problems however plate

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Heat Exchanger T, 0C P, kg/cm² Q, l/h

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 Specific pressure drop defined as

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 Conservation of energy- very important

 Less than 50% in tubular heat exchangers

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Inspection for leakage

Inspection for corrosion

a: Very good b: Acceptable c: Poor d: Impossible

 Optimization based on cost consideration

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 Double pipe heat exchanger

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 Fluid flow may be diagonal or vertical

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Movable pressure plate

Hot water out Plate carrying bar

Compression nut & bolt

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Four pass of milk

Hot Water in Hot Water out

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Transfer port Flow port

Flow distribution Gasket

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 Occupies less floor and head space – low hold-up

volume gives quicker start up and faster response to

 Variety of ways for assembling

 Multiple duties like heating, cooling, regeneration etc