CHEMICAL ENGINEERING

3rd YEAR [6th SEMESTER]

[2020]

GOVT.POLYTECHNIC MANKENDA [AGRA]

 ]

HEAT EXCHANGER
 Group members
Rohit Yadav

Shubham Kumar

Shreya Gupta
 Introduction
What is Heat exchanger?
A heat exchanger is a device which transfers heat from one
medium to another, a Hydraulic Oil Cooler or example will
remove heat from hot oil by using cold water or air. Alternatively
a Swimming Pool Heat Exchanger uses hot water from a boiler
or solar heated water circuit to heat the pool water. Heat is
transferred by conduction through the exchanger materials
which separate the mediums being used. A shell and tube heat
exchanger passes fluids through and over tubes, where as an
air cooled heat exchanger passes cool air through a core of fins
to cool a liquid...
 Types of Heat Exchanger

There are many different types of heat exchanger available,

But these are mostly used in industry...

1. Shell & Tube heat exchanger

2. Plate type heat exchanger
3. Air cooled
4. Double pipe heat exchangers
5. Finned tube heat exchanger
6. Condensers, evaporators, and boilers
Shell & Tube heat exchanger

 Shelland Tube Heat Exchangers consist of a large number of

small tubes which are located within a cylindrical shell. The
tubes are positioned into the cylinder using a tube bundle or
"tube stack" which can either have fixed tube plates
(permanently fixed to the body) or, in the case of Thermex Heat
Exchangers a floating tube stack which allows the tube bundle
to expand and contract with varying heat conditions as well as
allowing the tube bundle to be easily removed for servicing and
maintenance...
[image]
Shell & Tube heat exchanger design

There can be many variations on the shell and tube design.

Typically, the ends of each tube are connected
to plenums (sometimes called water boxes) through holes
in tubesheets. The tubes may be straight or bent in the shape
of a U, called U-tubes
[Image]

In nuclear power plants called pressurized water reactors, large

heat exchangers called steam generators are two-phase, shell-
and-tube heat exchangers which typically have U-tubes. They
are used to boil water recycled from a surface condenser into
steam to drive a turbine to produce power. Most shell-and-tube
heat exchangers are either 1, 2, or 4 pass designs on the tube
side. This refers to the number of times the fluid in the tubes
passes through the fluid in the shell. In a single pass heat
exchanger, the fluid goes in one end of each tube and out the
other
 [Image]

Surface condensers in power plants are often 1-pass straight-

tube heat exchangers (see surface condenser for diagram).
Two and four pass designs are common because the fluid can
enter and exit on the same side. This makes construction much
simple
 [Image]

There are often baffles directing flow through the shell side so

the fluid does not take a short cut through the shell side leaving
ineffective low flow volumes. These are generally attached to
the tube bundle rather than the shell in order that the bundle is
still removable for maintenance.
Counter current heat exchangers are most efficient because
they allow the highest log mean temperature
difference between the hot and cold streams. Many companies
however do not use two pass heat exchangers with a u-tube
because they can break easily in addition to being more
expensive to build. Often multiple heat exchangers can be used
to simulate the counter current flow of a single large exchanger.
Plate heat exchanger

Plate Heat Exchangers operate in very much the same way as

a shell and tube heat exchanger, using a series of stacked
plates rather than tubes. Plate heat exchangers are usually
brazed or gasketed depending on the application and fluids
being used. Their compact stainless steel construction makes
them an ideal choice for use with refrigerants or in food and
beverage processing...
[Image]
Desing plate and frame heat exchanger
[Image]

The plate heat exchanger (PHE) is a specialized design well

suited to transferring heat between medium- and low-pressure
fluids. Welded, semi-welded and brazed heat exchangers are
used for heat exchange between high-pressure fluids or where
a more compact product is required. In place of a pipe passing
through a chamber, there are instead two alternating chambers,
usually thin in depth, separated at their largest surface by a
corrugated metal plate. The plates used in a plate and frame
heat exchanger are obtained by one piece pressing of metal
plates. Stainless steel is a commonly used metal for the plates
because of its ability to withstand high temperatures, its
strength, and its corrosion resistance.
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 are
compressed together in a rigid frame to form an arrangement of
parallel flow channels with alternating hot and cold fluids. The
plates produce an extremely large surface area, which allows
for the fastest possible transfer. Making each chamber thin
ensures that the majority of the volume of the liquid contacts
the plate, again aiding exchange. The troughs also create and
maintain a turbulent flow in the liquid to maximize heat transfer
in the exchanger. A high degree of turbulence can be obtained
at low flow rates and high heat transfer coefficient can then be
achieved.
As compared to shell and tube heat exchangers,
the temperature approach in a plate heat exchangers may be
as low as 1 °C whereas shell and tube heat exchangers require
an approach of 5 °C or more. For the same amount of heat
exchanged, the size of the plate heat exchanger is smaller,
because of the large heat transfer area afforded by the plates
(the large area through which heat can travel). Increase and
reduction of the heat transfer area is simple in a plate heat-
exchanger, through the addition or removal of plates from the
stack
Air type

Air Cooled Heat Exchangers are commonly used in vehicles or

other mobile applications where no permanent cool water
source is available. Thermex designs and supplies combination
cooling packs (or combi-coolers) which combine an engine
jacket water cooler, oil cooler and charge air cooler into a single
unit reducing space requirements and improving efficiency.
Cool air is provided either by a fan or by air flow caused by the
movement of the vehicle...
[Image]
Double Pipe heat exchanger

A form of shell and tube heat exchanger, double pipe heat

exchangers employ the simplest heat exchanger design and
configuration which consists of two or more concentric,
cylindrical pipes or tubes (one larger tube and one or more
smaller tubes). As per the design of all shell and tube heat
exchangers, one fluid flows through the smaller tube(s), and the
other fluid flows around the smaller tube(s) within the larger
tube.

The design requirements of double pipe heat exchangers

include characteristics from the recuperative and indirect
contact types mentioned previously as the fluids remain
separated and flow through their own channels throughout the
heat transfer process. However, there is some flexibility in the
design of double pipe heat exchangers, as they can be
designed with cocurrent or countercurrent flow arrangements
and to be used modularly in series, parallel, or series-parallel
configurations within a system. For example, Figure, below,
depicts the transfer of heat within an isolated double pipe heat
exchanger with a cocurrent flow configuration.
[Image]
Finned tube heat exchanger

A plate-fin heat exchanger is a type of heat exchanger design

that uses plates and finned chambers to transfer heat between
fluids. It is often categorized as a compact heat exchanger to
emphasise its relatively high heat transfer surface area to
volume ratio. The plate-fin heat exchanger is widely used in
many industries, including the aerospace industry for its
compact size and lightweight properties, as well as
in cryogenics where its ability to facilitate heat transfer with
small temperature differences is utilized.
Aluminum alloy plate fin heat exchangers, often referred to as
Brazed Aluminum Heat Exchangers, have been used in the
aircraft industry for more than 60 years and adopted into the
cryogenic air separation industry around the time of the second
world war and shortly afterwards into cryogenic processes in
chemical plants such as Natural Gas Processing. They are also
used in railway engines and motor cars. Stainless steel plate
fins have been used in aircraft for 30 years and are now
becoming established in chemical plant
Design of plate-fin heat exchangers

Originally conceived by an Italian mechanic, Paolo Fruncillo. A

plate-fin heat exchanger is made of layers of corrugated sheets
separated by flat metal plates, typically aluminium, to create a
series of finned chambers. Separate hot and cold fluid streams
flow through alternating layers of the heat exchanger and are
enclosed at the edges by side bars
Heat is transferred from one stream through the fin interface to
the separator plate and through the next set of fins into the
adjacent fluid. The fins also serve to increase the structural
integrity of the heat exchanger and allow it to withstand high
pressures while providing an extended surface area for heat
transfer.
A high degree of flexibility is present in plate-fin heat exchanger
design as they can operate with any combination of gas, liquid,
and two-phase fluids. Heat transfer between multiple process
streams is also accommodated with a variety of fin heights and
types as different entry and exit points available for each
stream.
The main four type of fins are: plain, which refer to simple
straight-finned triangular or rectangular designs; herringbone,
where the fins are placed sideways to provide a zig-zag path;
and serrated and perforated which refer to cuts and
perforations in the fins to augment flow distribution and improve
heat transfer. A disadvantage of plate-fin heat exchangers is
that they are prone to fouling due to their small flow channels.
They also cannot be mechanically cleaned and require other
cleaning procedures and proper filtration for operation with
potentially-fouling streams
[Image]
Condensers, Evaporators, and Boilers

Boilers, condensers, and evaporators are heat exchangers

which employ a two-phase heat transfer mechanism. As
mentioned previously, in two-phase heat exchangers one or
more fluids undergo a phase change during the heat transfer
process, either changing from a liquid to a gas or a gas to a
liquid.

Condensers are heat exchanging devices that take heated gas

or vapor and cool it to the point of condensation, changing the
gas or vapor into a liquid. On the other hand,
in evaporators and boilers, the heat transfer process changes
the fluids from liquid form to gas or vapor form.
[Image]
 Heat Exchanger Selection
While there are a wide variety of heat exchangers available, the
suitability of each type (and its design) in transferring heat
between fluids is dependent on the specifications and
requirements of the application. Those factors largely
determine the optimal design of the desired heat exchanger
and influence the corresponding rating and sizing calculations.

Some of the factors that industry professionals should keep in

mind when designing and choosing a heat exchanger include:

 The type of fluids, the fluid stream, and their properties

 The desired thermal outputs
 Size limitations
 Costs
Fluid Type, Stream, and Properties

The specific type of fluids—e.g., air, water, oil, etc.—involved

and their physical, chemical, and thermal properties—e.g.,
phase, temperature, acidity or alkalinity, pressure and flow rate,
etc.—help determine the flow configuration and construction
best suited for that particular heat transfer application.

For example, if corrosive, high temperature, or high pressure

fluids are involved, the heat exchanger design must be able to
withstand the high stress conditions throughout the heating or
cooling process. One method of fulfilling these requirements is
by choosing construction materials which hold the desired
properties: graphite heat exchangers exhibit high thermal
conductivity and corrosion resistance, ceramic heat
exchangers can handle temperatures higher than many
commonly used metals’ melting points, and plastic heat
exchangers offer a low-cost alternative which maintains a
moderate degree of corrosion resistance and thermal
conductivity. Another method is by choosing a design suited for
the fluid properties: plate heat exchangers are capable of
handling low to medium pressure fluids but at higher flow rates
than other types of heat exchangers, and two-phase heat
exchangers are necessary when handling fluids which require a
phase change throughout the heat transfer process. Other fluid
and fluid stream properties that industry professionals may
keep in mind when choosing a heat exchanger include fluid
viscosity, fouling characteristics, particulate matter content, and
presence of water-soluble compounds.
Thermal Outputs

The thermal output of a heat exchanger refers to the amount of

heat transferred between fluids and the corresponding
temperature change at the end of the heat transfer process.
The transference of heat within the heat exchanger leads to a
change of temperature in both fluids, lowering the temperature
of one fluid as heat is removed and raising the temperature of
the other fluid as heat is added. The desired thermal output and
rate of heat transfer help determine the optimal type and design
of heat exchanger as some heat exchanger designs offer
greater heater transfer rates and can handle higher
temperatures than other designs, albeit at a higher cost
Size Limitations

After choosing the optimal type and design of a heat

exchanger, a common mistake is purchasing one that is too big
for the given physical space. Oftentimes, it is more prudent to
purchase a heat exchanging device in a size that leaves room
for further expansion or addition, rather than choosing one
which fully encompasses the space. For applications with
limited space, such as in airplanes or automobiles, compact
heat exchangers offer high heat transfer efficiencies in smaller,
more lightweight solutions. Characterized by high heat transfer
surface area to volume ratios, several variants of these heat
exchanging devices are available, including compact plate heat
exchangers. Typically, these devices feature ratios of
≥700 m2/m3 for gas-to-gas applications and ≥400 m2/m3 for
liquid-to-gas applications.
Costs

The cost of a heat exchanger includes not only the initial price
of the equipment, but the installation, operational, and
maintenance costs over the device’s lifespan as well. While it is
necessary to choose a heat exchanger which effectively fulfills
the requirements of the applications, it is also important to keep
in mind the overall costs of the chosen heat exchanger to better
determine whether the device is worth the investment. For
example, an initially expensive, but more durable heat
exchanger may result in lower maintenance costs and,
consequently, less overall spend over the courses of a few
years, while a cheaper heat exchanger may be initially less
expensive, but require several repairs and replacements within
the same period of time.
 Design Optimization
Designing the optimal heat exchanger for a given application
(with particular specifications and requirements as indicated
above) involves determining the temperature change of the
fluids, the heat transfer coefficient, and the construction of the
heat exchanger and relating them to the rate of heat transfer.
The two main problems which arise in pursuing this objective
are calculating the device’s rating and sizing.

The rating refers to the calculation of the thermal effectiveness

(i.e., efficiency) of a heat exchanger of a given design and size,
including the rate of heat transfer, the amount of heat
transferred between fluids and their corresponding temperature
change, and the total pressure drop across the device. The
sizing refers to the calculation of the required total dimensions
of the heat exchanger (i.e., the surface area available for use in
the heat transfer process), including the length, width, height,
thickness, number of components, component geometries and
arrangements, etc., for an application with given process
specifications and requirements. The design characteristics of a
heat exchanger—e.g., flow configuration, material, construction
components and geometry, etc.—affect both the rating and
sizing calculations. Ideally, the optimal heat exchanger design
for an application finds a balance (with factors optimized as
specified by the designer) between the rating and sizing which
satisfies the process specifications and requirements at the
minimum necessary cost.
 Construction Method
Heat exchangers were categorized based on the type of flow
configuration employed, this section categorizes them based on
their construction. The construction characteristics by which
these devices can be classified include:

 Recuperative vs. Regenerative

 Direct vs. Indirect
 Static vs. Dynamic
 Types of components and materials employed
Recuperative vs. Regenerative

Heat exchangers can be classified as recuperative heat

exchangers and regenerative heat exchangers.

The difference between recuperative and regenerative heat

exchanger systems is that in recuperative heat
exchangers (commonly called recuperators), each fluid
simultaneously flows through its own channel within the heat
exchanger. On the other hand, regenerative heat exchangers,
also referred to as capacitive heat exchangers or regenerators,
alternately allow warmer and cooler fluids to flow through the
same channel. Both recuperators and regenerators can be
further separated into different categories of exchangers, such
as direct or indirect and static or dynamic, respectively. Of the
two types indicated, recuperative heat exchangers are more
commonly employed throughout industry.
Direct vs. Indirect

Recuperative heat exchangers employ either direct contact or

indirect contact transfer processes to exchange heat between
fluids.

In direct contact heat exchangers, the fluids are not separated

within the device and heat transfers from one fluid to another
through direct contact. On the other hand, in indirect heat
exchangers, the fluids remain separated from one another by
thermally conductive components, such as tubes or plates,
throughout the heat transfer process. The components first
receive heat from the warmer fluid as it flows through the heat
exchanger, and then transfer the heat to the cooler fluid as it
flows through. Some of the devices which employ direct contact
transfer processes include cooling towers and steam injectors,
while devices that employ indirect contact transfer processes
include tubular or plate heat exchangers.
Static vs. Dynamic

There are two main types of regenerative heat exchangers—

static heat exchangers and dynamic heat exchangers. In static
regenerators (also known as fixed bed regenerators), the heat
exchanger material and components remains stationary as
fluids flow through the device, while in dynamic
regenerators the material and components move throughout
the heat transfer process. Both types are at risk of cross-
contamination between fluid streams, necessitating careful
design considerations during manufacturing.

In one example of the static type, warmer fluid is run through

one channel while cooler fluid runs through another for a fixed
period of time at the end of which, through the use of quick-
operating valves, flow is reversed such that the two fluids
switch channels. An example of the dynamic type typically
employs a rotating, thermally conductive component (e.g., a
drum) through which warmer and cooler fluids continuously flow
—albeit in separate, sealed-off sections. As the component
rotates, any given section alternately passes through the
warmer steam and cooler streams, allowing for the component
to absorb heat from the warmer fluid and transfer the heat to
the cooler fluid as it passes through. Figure 2, below, depicts
the heat transfer process within a rotary-type regenerator with a
countercurrent flow configuration.
 Flow Configuration
The flow configuration, also referred to as the flow
arrangement, of a heat exchanger refers to the direction of
movement of the fluids within the heat exchanger in relation to
each other. There are four principal flow configurations
employed by heat exchangers

 Cocurrent flow

 Countercurrent flow

 Crossflow

 Hybrid flow
Cocurrent Flow

Cocurrent flow heat exchangers, also referred to as parallel

flow heat exchangers, are heat exchanging devices in which
the fluids move parallel to and in the same direction as each
other. Although this configuration typically results in lower
efficiencies than a counter flow arrangement, it also allows for
the greatest thermal uniformity across the walls of the heat
exchanger
[Image]
Countercurrent Flow

Countercurrent flow heat exchangers, also known as counter

flow heat exchangers, are designed such that the fluids move
antiparallel (i.e., parallel but in opposite directions) to each
other within the heat exchanger. The most commonly employed
of the flow configurations, a counter flow arrangement typically
exhibits the highest efficiencies as it allows for the greatest
amount of heat transference between fluids and, consequently,
the greatest change in temperature.
[Image]
Crossflow

In crossflow heat exchangers, fluids flow perpendicularly to one

another. The efficiencies of heat exchangers which employ this
flow configuration fall between that of countercurrent and
cocurrent heat exchangers.
[Image]
Hybrid Flow

Hybrid flow heat exchangers exhibit some combination of the

characteristics of the previously mentioned flow configurations.
For example, heat exchanger designs can employ multiple flow
passes and arrangements (e.g., both counter flow and
crossflow arrangements) within a single heat exchanger. These
types of heat exchangers are typically used to accommodate
the limitations of an application, such as space, budget costs,
or temperature and pressure requirements.
[image]
 Exchanger ‘Pass’

What is a heat exchanger Pass

A Heat Exchanger Pass refers to the movement of a fluid from

one end of the heat exchanger to the other. For example, when
referring to the "through tubes" circuit (usually the coolant); ·
Single Pass – Fluid enters one end of the heat exchanger, and
exits at the other end. · Double Pass – Fluid enters and exists
the heat exchanger at the same end. · Triple Pass – Fluid
travels the length of the heat exchanger body three times
before exiting.
[By diagram]

 A greater number of passes increases the amount of heat transfer

available, but can also lead to high pressure loss and high velocity.
 With a full set of operational data, Thermex can select the most
efficient heat exchanger possible whilst working within the pressure
loss and velocity limits.
 The number of passes on the primary circuit can also be adjusted
to optimise thermal performance and efficiency by changing the baffle
quantity and pitch.
 The lifetime of a Heat Exchanger

How to increase the lifetime of a Heat

Exchanger

Heat exchangers are manufactured from robust materials, have

no moving parts and operate at a variety of different pressures
and temperatures, therefore if a heat exchanger is used in the
correct way then there is no reason why it shouldn't be able to
remain operational for many years. To help increase the
operational lifetime of a heat exchanger there are several steps
that should be taken.
Make sure the design data is accurate

 If you are sending data to our engineers for heat exchanger
selection, then it is best to make sure that it is as accurate as
possible. Not only will this ensure that your heat exchanger is
thermally efficient but also that it will be able to operate for a
long period of time. If the flow rates are too high then erosion
could be a problem, if the pressures are too high then leaks
could occur and if there are any unusual chemicals in the fluids
(such as acids in coolant water) then please contact us to
check the compatibility. If our standard materials aren't suitable
then we can usually supply an alternative which is.
Commission and Installation 

When installing your heat exchanger, make sure that correct

fittings and pipe work are used. If unsure, please check the
Thermex Installation and Operation Manual for details. For heat
exchangers on applications which use polluted, shallow or
brackish sea water as the coolant and have copper alloy tubes,
it is recommended to run the heat exchanger in clean sea water
for several weeks first, this creates a protective layer over the
tube material which helps to protect against corrosion
Regular Maintenance and Servicing 

All Thermex shell and tube heat exchangers are designed to

allow for easy maintenance and servicing. The end caps can be
removed allowing the internal tube bundle to be removed for
cleaning. New seal kits can also be provided from stock and
are available to purchase on our Web Shop. For information
and tips on servicing your heat exchanger, please see the
Thermex Installation and Operation Manual.
 Heat Exchanger Thermodynamics
The design of a heat exchanger is an exercise in
thermodynamics, which is the science that deals with heat
energy flow, temperature, and the relationships to other forms
of energy. To understand heat exchanger thermodynamics, a
good starting point is to learn about the three ways in which
heat can be transferred  – conduction, convection, and
radiation. In the sections below, a review of each of these heat
transfer modes is presented...,
Conduction

Conduction is the passing of thermal energy between materials

that are in contact with one another. Temperature is a measure
of the average kinetic energy of molecules in a material –
warmer objects (that are at a higher temperature) are exhibiting
more molecular motion. When a warmer object is brought in
contact with a cooler object (one that is at a lower temperature),
there is a thermal energy transfer between the two materials,
with the cooler object becoming more energized and the
warmer object becoming less energized. This process will
continue until thermal equilibrium has been achieved.

The rate at which heat energy is transferred in a material by

thermal conduction is given by the following expression:
 

In this expression, Q represents the amount of heat transferred

through the material in time t, ΔT is the temperature difference
between one side of the material and the other (the thermal
gradient), A is the cross-sectional area of the material, and d is
the thickness of the material.  The constant k is known as the
thermal conductivity of the material and is a function of the
material’s intrinsic properties and its structure. Air and other
gases generally have low thermal conductivities, while non-
metallic solids exhibit higher values and metallic solids
generally showing the highest values.
  Convection

Convection is the transfer of thermal energy from a surface by

way of the motion of a fluid such as air or water that has been
heated. Most fluids expand when heated and therefore will
become less dense and rise relative to other parts of the fluid
that are cooler. So, when the air in a room is heated, it rises to
the ceiling because it is warmer and less dense, and transfers
heat energy as it collides with the cooler air in the room, then
becoming denser and falling again towards the floor. This
process creates a natural or free convection current.
Convection can also occur through what is termed forced or
assisted convection, such as when heated water is pumped
through a pipe such as in a hydronic heating system.

For free convection, the rate of transfer of heat is expressed by

Newton’s law of cooling:
 

Where Q-dot is the rate of transfer of heat, hc is the convective

heat transfer coefficient, A is the surface area over which the
convection process is occurring, and ΔT is the temperature
differential between the surface and the fluid. The convective
heat transfer coefficient hc is a function of the properties of the
fluid, similar to the thermal conductivity of the material
mentioned earlier regarding conduction.
Radiation

Thermal radiation is a mechanism of heat energy transfer that

involves the emission of electromagnetic waves from a heated
surface or object. Unlike conduction and convection, thermal
radiation does not require an intermediate medium to carry the
wave energy. All objects whose temperature is above absolute
zero (-273.15oC) emit thermal radiation in a typically broad
spectral range.

The net rate of radiation heat loss can be expressed using the
Stefan-Boltzmann Law as follow

Where Q is the heat transfer per

unit time, Th is the temperature of the hot object (in absolute
units, oK), Tc is the temperature of the colder surroundings (also
in absolute units, oK), σ is the Stefan-Boltzmann constant
(whose value is 5.6703 x 10-8 W/m2K4). The term represented
by ε is the emissivity coefficient of the material and can have a
value anywhere between 0 to 1, depending on the
characteristics of the material and its ability to reflect, absorb,
or transmit radiation. It is also a function of the temperature of
the material.
 Types of Heat Exchanger in
“INDUSTRIES”
Sometimes, a specific heat exchanger type can be selected
based on the industry it will be used for. Some examples
include

Hydraulics and Industrial  Hydraulic Oil Coolers (Shell and Tube)

Process  Brazed Plate Heat Exchangers
 Air Cooled Oil Coolers

 Marine Oil Coolers

Marine  Header Tank Heat Exchangers
 Manifold Heat Exchangers
 Titanium Heat Exchangers

Food Process Equipment  Stainless Steel Shell and Tube Heat Exchangers
 Brazed Plate Heat Exchangers

Mobile Plant  Air Cooled Heat Exchangers

 Hydraulic Oil Coolers

 Exhaust Gas Heat Exchangers

Power Generation  Manifold Heat Exchangers
 Header Tank Heat Exchangers
 Air Cooled Heat Exchangers

Mining  Stainless Steel Shell and Tube Heat Exchangers

 Carbon Steel Heat Exchangers
Spas and Swimming Pools
 Swimming Pool Heat Exchangers
 Fouling
Fouling occurs when impurities deposit on the heat exchange
surface. Deposition of these impurities can decrease heat
transfer effectiveness significantly over time and are caused by

 Low wall shear stress

 Low fluid velocities
 High fluid velocities
 Reaction product solid precipitation
 Precipitation of dissolved impurities due to elevated wall
temperatures
The rate of heat exchanger fouling is determined by the rate of
particle deposition less re-entrainment/suppression. This model
was originally proposed in 1959 by Kern and Seaton

Crude Oil Exchanger Fouling

In commercial crude oil refining, crude oil is heated from 21 °C

(70 °F) to 343 °C (649 °F) prior to entering the distillation
column. A series of shell and tube heat exchangers typically
exchange heat between crude oil and other oil streams to heat
the crude to 260 °C (500 °F) prior to heating in a furnace.
Fouling occurs on the crude side of these exchangers due to
asphaltene insolubility. The nature of asphaltene solubility in
crude oil was successfully modeled by Wiehe and
Kennedy.The precipitation of insoluble asphaltenes in crude
preheat trains has been successfully modeled as a first order
reaction by Ebert and Panchal who expanded on the work of
Kern and Seaton
[Images]
Cooling Water Fouling

Cooling water systems are susceptible to fouling. Cooling water

typically has a high total dissolved solids content and
suspended colloidal solids. Localized precipitation of dissolved
solids occurs at the heat exchange surface due to wall
temperatures higher than bulk fluid temperature. Low fluid
velocities (less than 3 ft/s) allow suspended solids to settle on
the heat exchange surface. Cooling water is typically on the
tube side of a shell and tube exchanger because it's easy to
clean. To prevent fouling, designers typically ensure that
cooling water velocity is greater than 0.9 m/s and bulk fluid
temperature is maintained less than 60 °C (140 °F). Other
approaches to control fouling control combine the "blind"
application of biocides and anti-scale chemicals with periodic
lab testing
[Images]
Maintenance

Plate and frame heat exchangers can be disassembled and

cleaned periodically. Tubular heat exchangers can be cleaned
by such methods as acid cleaning, sandblasting, 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.
A variety of companies have started using water borne
oscillations technology to prevent biofouling. Without the use of
chemicals, this type of technology has helped in providing a
low-pressure drop in heat exchangers.