An ACHE is a device for rejecting heat from a fluid directly to ambient air.

This is in contrast to
rejecting heat to water and then rejecting it to air, as with a shell and tube heat exchanger and a wet
cooling tower system.

The obvious advantage of an ACHE is that it does not require water, which means that plants
requiring large cooling capacities need not be located near a supply of cooling water.

An ACHE may be as small as an automobile radiator or large enough to reject the heat of turbine
exhaust steam condensation from a 1,200 MW power plant — which would require 42 modules, each
90 feet wide by 180 feet long and served by two 60-foot diameter fans driven by 500-horsepower
motors.

Components
An ACHE consists of the following components:

 One or more bundles of heat transfer surface.

 An air-moving device, such as a fan, blower, or stack.
 Unless it is natural draft, a driver and power transmission to mechanically rotate the fan or
blower.
 A plenum between the bundle or bundles and the air-moving device.
 A support structure high enough to allow air to enter beneath the ACHE at a reasonable rate.
 Optional header and fan maintenance walkways with ladders to grade.
 Optional louvers for process outlet temperature control.
 Optional recirculation ducts and chambers for protection against freezing or solidification of
high pour point fluids in cold weather.
 Optional variable pitch fan hub for temperature control and power savings.

Process Coolers / Condensers Gas Coolers

Cooling Tower Fans Gas Compressor Inter / After

Coolers
Cooling Water Coolers
Air Cooler Fans
Air Cooler Fans

Cooling Tower Fans Process Coolers

Steam Condensers Cooling Tower Fans

Seal / Lube Oil Cooler Steam Condensers

Closed-Loop Cooling Water Air Cooler Fans

Coolers

Geothermal Plant Condensers

Air Cooler Fans

LNG Plants Compressor Inter / After Cooler

Process Coolers Jacket Water Coolers

Amine Re-boilers Air Cooler Fans

Air Cooler Fans

Cooling Tower Fans

High velocity

Reduces hot air recirculation

Plenums protect exchanger

bundle from elements

Better air distribution across the

bundle

Better process control and

stability because the plenum
covers 60% of bundle area

Increased capacity in the fan-

off or fan failure condition

Slightly lower horsepower

requirements

Maintenance personnel
protected from high exit-air
temperatures

Well suited for high-

temperature service
 Freeze protection

Process temperature control

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Typical components of an air-cooled heat exchanger

Tube Bundle
A tube bundle is an assembly of tubes, headers, side frames, and tube supports as shown in figure
below. Usually the tube surface exposed to the passage of air has extended surface in the form of
fins to compensate for the low heat transfer rate of air at atmospheric pressure and at a low enough
velocity for reasonable fan power consumption.

Typical construction of tube bundles with plug and cover plate headers

The prime tube is usually round and of any metal suitable for the process, due consideration being
given to corrosion, pressure, and temperature limitations. Fins are helical or plate type, and are
usually of aluminum for reasons of good thermal conductivity and economy of fabrication. Steel fins
are used for very high temperature applications.

Fins are attached to the tubes in a number of ways:

 An extrusion process in which the fins are extruded from the wall of an aluminum tube that is
integrally bonded to the base tube for the full length.
 Helically wrapping a strip of aluminum to embed it in a pre-cut helical groove and then
peening back the edges of the groove against the base of the fin to tightly secure it.
  Wrapping on an aluminum strip that is footed at
the base as it is wrapped on the tube.

Sometimes serrations are cut in the fins. This causes an

interruption of the air boundary layer, which increases
turbulence which in turn increases the airside heat
transfer coefficient with a modest increase in the air-side
pressure drop and the fan horsepower.

The choice of fin types is critical. This choice is influenced

by cost, operating temperatures, and the atmospheric
conditions. Each type has different heat transfer and
pressure drop characteristics. The extruded finned tube
affords the best protection of the liner tube from atmospheric corrosion as well as consistent heat
transfer from the initial installation and throughout the life of the cooler. This is the preferred tube for
operating temperatures up to 600°F. The embedded fin also affords a continued predictable heat
transfer and should be used for all coolers operating above 600°F and below 750°F. The wrap-on
footed fin tube can be used below 250°F; however, the bond between the fin and the tube will loosen
in time and the heat transfer is not predictable with certainty over the life of the cooler. It is advisable
to derate the effectiveness of the wrap-on tube to allow for this probability.

There are many configurations of finned tubes, but manufacturers find it economically practical to limit
production to a few standard designs. Tubes are manufactured in lengths from 6 to 60 feet and in
diameters ranging from 5/8 inch to 6 inches, the most common being I inch. Fins are commonly
helical, 7 to 11 fins per inch, 5/16 to I inch high, and 0.010 to 0.035 inch thick. The ratio of extended to
prime surface varies from 7:1 to 25:1. Bundles are rectangular and typically consist of 2 to 10 rows of
finned tubes arranged on triangular pitch. Bundles may be stacked in depths of up to 30 rows to suit
unusual services. The tube pitch is usually between 2 and 2.5 tube diameters. Net free area for air
flow through bundles is about 50% of face area. Tubes are rolled or welded into the tube sheets of a
pair of box headers.

The box header consists of tube sheet, top, bottom, and end plates, and a cover plate that may be
welded or bolted on. If the cover is welded on, holes must be drilled and threaded opposite each tube
for maintenance of the tubes. A plug is screwed into each hole, and the cover is called the plug sheet.
Bolted removable cover plates are used for improved
access to headers in severe fouling services. Partitions
are welded in the headers to establish the tube-side flow
pattern, which generates suitable velocities in as near
countercurrent flow as possible for maximum mean
temperature difference. Partitions and stiffeners
(partitions with flow openings) also act as structural
stays. Horizontally split headers may be required to
accommodate differential tube expansion in services
having high fluid temperature differences per pass. The
figure below illustrates common head types.

Bundles are usually arranged horizontally with the air

entering below and discharging vertically. Occasionally
bundles are arranged vertically with the air passing
across horizontally, such as in a natural draft tower
where the bundles are arranged vertically at the periphery of the tower base. Bundles can also be
arranged in an "A" or "V" configuration, the principal advantage of this being a saving of plot area.
The disadvantages are higher horsepower requirements for a given capacity and decreased
performance when winds on exposed sides inhibit air flow.

Within practical limits, the longer the tubes and the greater the number of rows, the less the heat
transfer surface costs per square foot. One or more bundles of the same or differing service may be
combined in one unit (bay) with one set of fans. All bundles combined in a single unit will have the
same air-side static pressure loss. Consequently, combined bundles having different numbers of rows
must be designed for different face velocities.

Axial Flow Fans

The figure below displays the air moving device for an ACHE which is commonly an axial flow,
propeller type fan that either forces the air across the bundles (forced draft) or pulls it across (induced
draft). To provide redundancy in case a mechanical unit falls and to provide the basic control
achievable by running one fan or two, a bundle or set of bundles is usually provided with two fans.

Axial flow fans

Even distribution of the air across the tube bundle is critical for predictable, uniform heat transfer. This
is achieved by adequate fan coverage and static pressure loss across the bundle. Good practice is to
keep the fan projected area to a minimum of 40% of the projected face area of the tube bundle and
the bundle static pressure loss at least 3.5 times the velocity pressure loss through the fan ring. For a
two fan unit this is generally assured if the ratio of tube length to bundle width is in the range of 3 to
3.5 and the number of tube rows is held to 4 rows minimum with the net free area for air flow at about
50% of the face area of the bundle.

Fans can vary in size from 3 to 60 feet in diameter, and can have from 2 to 20 blades. Blades can be
made of wood, steel, aluminum, or fiberglass-reinforced plastic, and can be solid or hollow. Hollow
plastic blades are by far the most popular. Blades can have straight sides or be contoured. The more
efficient type has a wide chord near the center and tapers to a narrow chord at the tip, with a slight
twist. The twist and taper compensate for the slower velocity of the blade nearer the center to
produce a uniform, efficient air velocity profile.

Fans may have fixed or adjustable pitch blades. Except for small diameters (less than 5 feet) most
ACHEs have adjustable pitch blades. Adjustable pitch fans
are manufactured in two types. One is manually adjustable
(with the fans off) and the other is automatically adjustable
(while running). Most automatically adjustable pitch fans
change their pitch by means of a pneumatically actuated
diaphragm working against large springs inside the hub.

Plenum
The air plenum is an enclosure that provides for the
smooth flow of air between the fan and bundle. Plenums
can be box type or slopesided type. The slopesided type
gives the best distribution of air over the bundles, but is
almost exclusively used with induced draft because
hanging a machinery mount from a slopesided forced draft
plenum presents structural difficulties.

Mechanical Equipment
Fans may be driven by electric motors, steam turbines, gas or gasoline engines, or hydraulic motors.
The overwhelming choice is the electric motor. Hydraulic motors are sometimes used when power
from an electric utility is unavailable. Hydraulic motors also provide variable speed control, but have
low efficiencies.

The most popular speed reducer is the high-torque positive type belt drive, which uses sprockets that
mesh with the timing belt cogs. They are used with motors up to 50 or 60 horsepower, and with fans
up to about 18 feet in diameter. Banded V-belts are still often used in small to medium sized fans, and
gear drives are used with very large motors and fan diameters. Fan speed is set by using a proper
combination of sprocket or sheave sizes with timing belts or V-belts, and by selecting a proper
reduction ratio with gears. Fan tip speed should not be above 12,000 feet per minute for mechanical
reasons, and may be reduced to obtain lower noise levels. Motor and fan speed are sometimes
controlled with variable frequency drives. The figure below provides a breakdown of the mechanical
equipment.

Structure
The structure consists of the columns, braces, and cross beams that support the exchanger at a
sufficient elevation above grade to allow the necessary volume of air to enter below at an approach
velocity low enough to allow unimpeded fan performance and to prevent unwanted recirculation of hot
air. To conserve ground space in oil refineries and chemical plants, ACHEs are usually mounted
above, and supported by, pipe racks, with other equipment occupying the space underneath the pipe
rack. ACHE structures are designed for appropriate wind, snow, seismic, piping, dead, and live loads.

Comparison of Induced and Forced Draft Units

Induced Draft

Advantages

 Better distribution of air across the bundle.

 Less possibility of hot effluent air recirculating into the intake. The hot air is discharged
upward at approximately 2.5 times the intake velocity, or about 1,500 feet per minute.
 Better process control and stability because the plenum covers 60% of the bundle face area,
reducing the effects of sun, rain, and hall.
 Increased capacity in the fan-off or fan failure condition, since the natural draft stack effect is
much greater.

Disadvantages and limitations

 Possibly higher horsepower requirements if the effluent air is very hot.

 Effluent air temperature should be limited to 220°F to prevent damage to fan blades,
bearings, or other mechanical equipment in the hot air stream. When the process inlet
temperature exceeds 350°F, forced draft design should be considered because high effluent
air temperatures may occur during fan-off or low air flow operation.
 Fans are less accessible for maintenance, and maintenance may have to be done in the hot
air generated by natural convection.
 Plenums must be removed to replace bundles.

Forced Draft

Advantages

 Possibly lower horsepower requirements if the effluent air is very hot. (Horsepower varies
inversely with the absolute temperature.)
 Better accessibility of fans and upper bearings for maintenance.
 Better accessibility of bundles for replacement.
 Accommodates higher process inlet temperatures.

Disadvantages

 Less uniform distribution of air over the bundle.

 Increased possibility of hot air recirculation, resulting from low discharge velocity from the
bundles, high intake velocity to the fan ring, and no stack.
  Low natural draft capability on fan failure.
 Complete exposure of the finned tubes to sun, rain, and hail, which results in poor process
control and stability.

In most cases the advantages of induced draft design outweigh the disadvantages.

Thermal Design
There are more parameters to be considered in the thermal design of ACHEs than for shell and tube
exchangers (see figure below). ACHEs are subject to a wide variety of constantly changing climatic
conditions which pose problems of control not encountered with shell and tube exchangers.
Designers must achieve an economic balance between the cost of electrical power for the fans and
the initial capital expenditure for the equipment. A decision must be made as to what ambient air
temperature should be used for design. Air flow rate and exhaust temperature are initially unknown
and can be varied in the design stage by varying the number of tube rows and thus varying the face
area.
 Because the number of tube rows, the face area, the air
face velocity, and the geometry of the surface can all be
varied, it is possible to generate many solutions to a given
thermal problem. However, there is obviously an optimum
solution in terms of capital and operating costs.

The basic heat transfer relationships that apply to shell and

tube exchangers also apply to ACHEs. The fundamental
relation is the Fourier equation:

Where

F is a factor that corrects the log mean temperature difference for any deviation from true counter-
current flow. In ACHEs the air flows substantially unmixed upward across the bundles and the
process fluid can flow back and forth and downward as directed by the pass arrangement. With four
or more downward passes, the flow is considered counter-current and so the factor "F" is 1.0.

As is apparent, initially neither the area nor the overall heat transfer rate nor the effluent air
temperatures are known. The traditional approach in the design of ACHEs entailed an iterative trial
and error procedure both on the CMTD and the transfer rate until the area satisfied both. Specifically,
an air rise was assumed, the CMTD was calculated, an overall heat transfer coefficient was assumed,
and an exchanger size was selected with the expected necessary area. An appropriate face velocity
was then used to calculate an effluent air temperature, and the process was repeated until the
assumed effluent air temperature matched the calculated value. The individual coefficients and the
overall coefficient were then calculated, and the whole process was repeated until the calculated "U"
and CMTD were sufficiently close to the assumed values.

However, there is another method that eliminates trial and error on the CMTD, and leaves only the
trial and error on the tube-side film coefficient. The following discussion presents the Ntu Method
described by Kays and London in Compact Heat Exchangers, as applied to ACHEs.

The following are definitions based on Compact Heat Exchangers:

 Hot fluid heat capacity rate =

 Cold fluid heat capacity rate =

  Number of heat transfer units = Ntu =

 Heat capacity rate ratio = R =

 ACHE heat transfer effectiveness = E

Typical Heat Transfer Coefficients for

Air-Cooled Heat Exchangers

Condensing service
U
Amine reactivator 100 - 120
Ammonia 105 - 125
Refrigerant 12 75 - 90
Heavy naphtha 70 - 90
Light gasoline 95
Light hydrocarbons 95 - 105
Light naphtha 80 -100
Reactor effluent Platformers, Hydroformers, 80-100
Rexformers
Steam (0 - 20 psig) 135 - 200

Gas cooling service

Air or flue gas @ 50 psig (P = 1 psi) 10
Air or flue gas @ 100 psig (P = 2 psi) 20
Air or flue gas @ 100 psig (P = 5 psi) 30
Ammonia reactor stream 90 - 110
Hydrocarbon gasses @ 15 - 50 psig (P = 1 psi) 30 - 40
Hydrocarbon gasses @ 50 - 250 psig (P = 3 psi) 50 - 60
Hydrocarbon gasses @ 250 - 1500 psig (P = 5 70 - 90
psi)

Liquid cooling service

Engine jacket water 130 - 155
Fuel oil 20 - 30
Hydroformer and Platformer liquids 85
Light gas oil 70 - 90
Light hydrocarbons 90 -120
Light naphtha 90
Process water 120 -145
Residuum 10 - 20
Tar 5 - 10

Coefficients are based on outside bare tube surface for 1-inch OD tubes with 10 plain extruded
aluminum fins per inch, 5/8 inch high, 21.2:1 surface ratio.

Fan Selection - Horsepower Requirements

The fan diameter must assure that the area occupied by the fan is at least 40 percent of the bundle
face area. The fan diameter must be 6 inches less than the bundle width. Fan performance curves
are used to select the optimum number of blades and pitch angle as well as the horsepower.

To calculate the required horsepower for the fan driver:

Motor Shaft Horsepower =

Actual ft3/min (at fan) - Total Pressure Loss (inches water)
6356 - Fan (System) Efficiency - Speed Reducer Efficiency

The actual volume at the fan is calculated by multiplying the standard volume of air (scfm) by the
density of standard air (0.075 lb/ft) divided by the density of air at the fan. From this relationship it can
be seen that the ratio of the fan horsepower required for a forced draft unit to that required for an
induced draft unit is approximately equal to the ratio of the exit air density to the inlet air density,
which is in turn equal to the ratio of absolute air temperatures (t1 + 460) / t2 + 460). The total
pressure difference across the fan is equal to the sum of the velocity pressure for the selected fan
diameter, the static pressure loss through the bundle, (which is deten-nined from the equipment
manufacturer's test data for a given fin type and tube spacing), and other losses in the aerodynamic
system. Fan diameters are selected to give good air distribution and usually result in velocity
pressures of approximately 0.1 inch of water.

The design of the fan, the air plenum chamber, and the fan housing, (in particular fan tip clearance),
can materially affect system efficiency, which is always lower than shown on fan curves based on
idealized wind tunnel tests. Industrial axial flow fans in properly designed ACHEs have fan (system)
efficiencies of approximately 75%, based on total pressure. Poorly designed ACHEs may have
system efficiencies as low as 40%. Speed reducers usually have about 95% mechanical efficiency.
The value of driver output horsepower from the equation above must be divided by the motor
efficiency to determine input power.

For estimating purposes refer to the figure below to approximate the horsepower requirement. This
chart plots bare tube surface divided by horsepower versus tube bundle depth for the normal range of
velocities. Applying the above criteria to our sample problem, we detennine that we must use two 10-
foot diameter fans to have 40% of the bundle face area. We find that for a 6-row bundle, the
area/horsepower is between 68 and 92 square feet of bare tube surface. If we use an average value
of 80, the horsepower requirement for each fan is (336 ·.2618 · 32) (2 · 80) = 17.5 horsepower at
maximum design ambient temperature. Power consumption must be calculated for the coldest
expected ambient temperature, since at a fixed fan blade angle, fan horsepower consumption is
inversely proportional to the absolute temperature. The power required for this minimum ambient
temperature will set the required motor size.

Performance Control of ACHEs

In addition to the fact that the process flow rate, composition, and inlet temperature of the fluid may
vary from the design conditions, the ambient air temperature varies throughout a 24-hour day and
from day to day. Since air coolers are designed for maximum conditions, some form of control is
necessary when overcooling of the process fluid is detrimental, or when saving fan power is desired.
Although control could be accomplished using by-passing of process fluid, this is rarely done, and the
usual method is air flow control.

Varying Air Flow

Varying air flow can be accomplished by: (see figure below)

 Adjustable louvers on top of the bundles.

 Two-speed fan motors.
 Fan shut-off in sequence for multifan units.
 AUTO-VARIABLE® fans.
 Variable frequency fan motor control
Louvers operate by creating an adjustable restriction to air flow and therefore do not save energy
when air flow is reduced. In fact, louvers impose a permanent energy loss, even in the open position.

Two-speed motors, AUTO-VARIABLE fans, and variable frequency fan motor control do save power
when air flow is reduced. In temperate climates, as much as 67% of the design power may be saved
over the course of a year with AUTO-VARIABLE pitch fans. AUTO-VARIABLE hubs will thus pay
back their additional cost in about one year or less.

Both louvers and AUTO-VARIABLE fans may be operated automatically through an instrument that
senses temperature or pressure in the outlet header. For extreme cases of temperature control, such
as prevention of freezing in cold climates in winter, or prevention of solidification of high pour-point or
high melting point materials, more sophisticated designs are available.

Extreme Case Controls

Internal Recirculation. By using one fixed-pitch fan blowing upward and one AUTO-VARIABLE
pitch fan, which is capable of negative pitch and thus of blowing the air downward, it is possible to
temper the air to the coldest portion of the tubes and thus prevent freezing. Normally forced draft units
have the negative pitch fan at the outlet end, while induced draft units have the positive pitch fan at
the outlet end. In hot weather both fans can blow upward.

External Recirculation. This is a more positive way of tempering coolant air, but is practical only
with forced draft units. Hot exhaust air exits the bundle, and enters a top plenum covered by a louver.
When no recirculation is required, the top louver is wide open, and the heated air exits through it.
When the top louver is partially closed, some of the hot air is diverted to a duct, through which it flows
downward and back into the fan intake, mixing with some cold ambient air. An averaging air
temperature sensor below the bundle controls the amount of recirculated air, and thus the average air
intake temperature, by varying the louver opening.

Co-current Flow. For high pour-point streams it is often advisable to ensure a high tube wall
temperature by arranging the flow co-currently, so that the high inlet temperature process fluid is in
contact with the coldest air and the low temperature outlet process fluid is in contact with wan-ned air.

Auxiliary Heating Coils - Steam or Glycol. Heating coils are placed directly under bundles.
Closing a louver on top of a bundle will allow the heating coil to warm the bundle or keep it warm in
freezing weather, so that on start-up or shut-down the material in the bundle will not freeze or solidify.
Heating coils are also occasionally used to temper very cold air to the bundles while the fan is
operating and the exhaust louver is open.

Noise Control
In recent years concerns about industrial noise have grown. Since ACHEs were not originally one of
the serious sources, it has only been after the abatement of the more serious contributors that
attention has focused on ACHEs.

ACHE noise is mostly generated by fan blade vortex shedding and air turbulence. Other contributors
are the speed reducer (high torque drives or gears) and the motor. The noise is generally broad band,
except for occasional narrow band noise produced by the motor or speed reducer, or by interaction
between these sources and the ACHE structure.

The evidence is that for efficient fans at moderate fan tip speeds, this noise is proportional to the third
power of the fan blade tip speed, and to the first power of the consumed fan horsepower. It is at
present quite practical and usually economical to reduce the sound pressure level at 3 feet below an
ACHE to 85 dB(A), but below 80 dB(A), noise from the drives predominates and special measures
must be taken.

Design of ACHEs for Viscous Liquids

Film coefficients for laminar flow inside tubes are very low and of the same order of magnitude as film
coefficients for air flowing over the outside of bare tubes. Therefore, there is generally no advantage
in using fins on the air side to increase the overall heat transfer rate since the inside laminar flow
coefficient will be controlling. Bare tube bundles with a large number of rows are usual.

For process fluids with outlet viscosities up to 20 centipoises, it is possible by using large diameter
tubes and high velocities (up to 10 ft/sec) to achieve a Reynolds number at the outlet above the 2,000
critical Reynolds number, and to keep the flow in the transition region. However, this usually results in
pressure drops of 30 to 100 psi. In view of the disadvantages of designing for laminar flow, this
increased pressure drop is normally economically justifiable because the increase in the operating
and capital cost of the pump is small compared with the decrease in the cost of the turbulent
exchanger.

The biggest problem with laminar flow in tubes is that the flow in inherently unstable. The reasons for
this can be demonstrated by a comparison of pressure drop and heat transfer coefficient for turbulent
versus laminar flow, as functions of viscosity () and mass velocity (G):

Heat Transfer
Flow Type Delta P Function
Turbulent 0.2, G1.8 -0.47, G0.8
Laminar 1.0, G1.0 0.0, G0.33

In an air-cooled heat exchanger, because of imperfect air-side flow distribution due to wind, or
because of multiple tube rows per pass, it is likely that the flow through some of the tubes in a given
pass is cooled more than that through other tubes.

With turbulent flow, pressure drop is such a weak function of viscosity (0.2 power) and such a strong
function of mass velocity (1.8 power), that the flow in the colder tubes must decrease only slightly in
order for the pressure drop to be the same as that in the hotter tubes. Also, as the flow slows and the
viscosity increases, the heat transfer coefficient drops significantly, (-0.47 power of viscosity, 0.8
power of G), so the over-cooling is self-correcting.

With laminar flow, pressure drop is a much stronger function of viscosity (1.0 power) and a much
weaker function of mass velocity (1.0 power), so the flow in the colder tubes must decrease much
more to compensate for the higher viscosity. Viscosity of heavy hydrocarbons is usually a very strong
function of temperature, but with laminar flow, the heat transfer coefficient is independent of viscosity,
and only a weak function of mass velocity (0.33 power), so the selfcorrection of turbulent flow is
absent.

The result is that many of the tubes become virtually plugged, and a few tubes carry most of the flow.
Stability is ultimately achieved in the high flow tubes as a result of high mass velocity and increased
turbulence, but because so many tubes carry little flow and contribute little cooling, a concurrent
result is high pressure drop and low performance. The point at which stability is reached depends on
the steepness of the viscosity versus temperature curve. Fluids with high pour points may completely
plug most of an exchanger.

This problem can sometimes be avoided by designing deep bundles to improve air flow distribution.
Bundles should have no more than one row per pass, and should preferably have at least two passes
per row, so that the fluid will be mixed between passes.

When a fluid has both a high viscosity and a high pour point, long cooling ranges should be separated
into stages. The first exchanger should be designed for turbulent flow, with the outlet temperature
high enough to ensure an outlet Reynolds number above 2,000 even with reduced flow. The lower
cooling range can be accomplished in a serpentine coil (a coil consisting of tubes or pipes connected
by 180' return bends, with a single tube per pass). The low temperature serpentine coil should, of
course, be protected from freezing by external warm air recirculation ducts.

Closed loop tempered water systems are often more economical, and are just as effective as a
serpentine coil. A shell and tube heat exchanger cools the viscous liquid over its low temperature
range on the shell side. Inhibited water is recirculated between the tube side of the shell and tube and
an ACHE, where the heat is exhausted to the atmosphere.

For viscous fluids which are reasonably clean, such as lube oil, it is possible to increase the tube side
coefficient between four- and tenfold, with no increase in pressure drop, by inserting turbulence
promoters, and designing for a lower velocity. It is then advantageous to use external fins to increase
the airside coefficient also. In addition to the increase in heat transfer coefficient, turbulence
promoters have the great advantage that the pressure drop is proportional to the 1.3 power of mass
velocity, and only to the 0.5 power of viscosity, so that non-isothermal flows are much more stable.
The simplest and probably the most cost-effective promoters are the swirl strips, a flat strip twisted
into a helix.

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Hudson Products has more than 50 years of experience in the
design of air-cooled heat transfer products. Our engineering
department remains at the forefront of technology and provides
complete three-dimensional design of our heat exchangers. We
offer CFD engineering services to predict site-specific air behavior
minimizing potential hot air recirculation.

Model predictions for flow around an air-cooled steam condenser were used to
reduce hot-air recirculation and increase plant capacity.

To view a sample animated gif (1,340KB) of the CFD analysis, click

the image below.
 Home | About Us | Products / Services
Contacts | News | Links

Hudson Products has more than 50 years of experience in the

design of air-cooled heat transfer products. Our engineering
department remains at the forefront of technology and provides
complete three-dimensional design of our heat exchangers. We
offer CFD engineering services to predict site-specific air behavior
minimizing potential hot air recirculation.
 Model predictions for flow around an air-cooled steam condenser were used to
reduce hot-air recirculation and increase plant capacity.

To view a sample animated gif (1,340KB) of the CFD analysis, click

the image below.

Home | About Us | Products / Services

Contacts | News | Links

Hudson Products Fin-Fan® Air-Cooled Heat Exchanger

"Frequently Asked Questions" :

How do I specify fouling factors for an air cooler?

Usually a fouling factor is only included for the process side of the cooler. The airside is usually
considered clean service, although some customers will specify an airside-fouling factor as a
result of airborne contaminants. The fouling factor is actually a resistance to heat transfer and is
actually added to the other resistances due to the heat transfer coefficients. It is usually
recommended that the resistance due to fouling factor be no more than 33% of the total
resistance to design the heat exchanger, otherwise the heat exchanger ends up being designed
for fouling rather than for heat transfer coefficients. Some customers specify fouling as a "not to
exceed %" of the total area.

How do you select the design air temperature for

your cooler?

The design air temperature is not exactly the maximum air temperature during the year. Many air-
cooled heat exchanger designers recommend that the design air temperature is the one that is
only exceeded 2% of the days of the year.

What is less expensive, air coolers or water coolers?

Plants, in general, never have enough cooling water. Water users at the plant always exceed the
supply. A water cooler will almost always be less expensive and smaller than an air-cooled heat
exchanger. However, there may be cases when, because of the process temperature involved,
the film temperature of the cooling water becomes excessive and water causes excessive fouling
in the water system. In these cases, the use of an air cooler is recommended.

When are belts or gearboxes used in air coolers?

Belts are usually used in drives up to 50 HP motors. Gearboxes are recommended for motors in
excess of 50HP.

How do I specify the pressure drop for an air cooler

process side?

For gas coolers or condensers, the pressure drop is usually limited to 2 psi. For liquid coolers, the
pressure drop is usually limited to 10 psi for an economical design. If the process fluid has a high
viscosity, then the allowable pressured drop may be specified up to 20 psi or greater depending
on pumping capacity and power consumption.

What is a guideline for the maximum design pressure

of an air cooler?

Air coolers can be designed for up to 15000psi or more.

What is the limit on the width of the air cooler?

There is no limit on the total size. However, there is a limit on the width of one bay and height
during transportation as restricted by roads and bridge heights. Most manufacturers limit the
width of one bay to 16 ft., which often coincides with the maximum 50HP belt drive system.

What is the limit on the length of an air cooler bay?

The maximum length of the tubes available limits its. Mills usually limit tube size to 60 ft.

What is the difference between seal weld and strength

weld of tubes in an air cooler?

Seal weld is usually performed to avoid leaks of process fluids to the atmosphere. Strength weld
is usually specified for high-pressure units and it is controlled by ASME.

What is the maximum number of rows that air coolers

can be designed with?

Air coolers can be designed with up to 16 tube rows finned and in bare tube cases designs have
utilized over 20 rows.

How is the tube thickness specified for an air cooler?

The design of an air cooler is dictated by API 661, which specifies minimum thickness for tubes
depending on the tube material.

What is the limit on the outlet air temperature for an air cooler?

The fan blade material usually limits this air temperature, grease system or bearing. 220 F is a
conservative guideline.

What is the maximum number of passes on an air cooler?

There is no limit. Air coolers can be designed with up to 10 or more passes.

 What tests can be specified to make sure that a new air cooler does not leak?

Submerged bundle air tests, halide testing, hydro testing, and soap testing.

When is the use of a split header recommended?

A split header is recommended when the difference between the inlet and outlet process
temperature is such that the tubes in the tube bundle are subject to different thermal expansion
that may cause a tube to loose contact with the tube sheet.

When are extruded serrated fins recommended?

Extruded serrated fins are recommended to improve the heat transfer coefficient on the airside by
causing turbulence. This is beneficial when a compact (small) unit is needed because of available
plot plan. Extruded fins are an excellent option when alloys (tubes and headers) are specified, in
order minimize the cost of the unit.

What standards govern the design of air-cooled heat exchangers?

API-661, ASME Section VIII notably appendix 13 for header design, ISO 13706

What constitutes the most economical cooler design?

Usually the longest narrowest design possible meeting API - 661requirements for fan coverage

What component contributes the most to the noise

generated by a fin-fan cooler?

Fan speed.

Are multi-blade fan designs the solution to noise problems?

Not necessarily, since the most efficient fan system utilizes the least number of blades. It is
therefore preferable to have a minimum of wide cord airfoil blades versus a number of
narrower blades.

For the average air-cooled exchanger, what is the largest practical fan diameter to be
considered?

As a rule of thumb, 16' usually is the limit allowing the usage of economical drive systems
under 50HP.

Are their designs of fin tube that will help reduce the overall size of the cooler plot layout?

Using extruded serrated fins on airside sensitive designs can greatly reduce cooler bank
sizing.

What standards are available for guidelines for performance testing?

ASME PTC-30.
What are differences between induced and forced
draft fans?

- cost about the same

Induced:
- better air distribution across the bundle
- less like to suffer from hot air recirculation

Forced:
- marginally less power consumption
- easier to maintain and to install over the side recirculation systems

Can I use the top louvers to control the process and the
inlet and recirculation louvers to control the plenum temperature on a winterized unit?

This creates an unstable system. It is better to let the louvers control the plenum temperature
only with a VFD or auto-variable fan controlling the process temperature.

Is a one-pass design recommended for a low-pressure

steam or process condensing service?

Single pass condensers are subject to vapor locking and corrosion in the bottom (coolest)
row due to the temperature and hence pressure gradient created as the air passes through
the bundle. This causes condensate backup in the bottom row and should definitely not be
used.

What is the lowest delta T attainable with an air-cooled exchanger?

As the outlet process temperature approaches the inlet air temperature the unit size
increases disproportionately. The is dependent upon the thermal conditions but approaches
less than 15 F should raise a flag.

The API-661 allowable piping loads are not adequate to

meet my piping design. Can they be increased?

It is not uncommon to design coolers to support piping loads of 2 - 3 times the API
allowables.

What governs the design of the structural steel

supporting the cooler?

This is commonly the most under designed portion of the cooler when it should be the most
conservative. Local building codes usually are specified to ensure member sizing meets local
structural requirements along with the stipulation that the design be authorized by a certified
registered structural engineer.

What is the best system to clean an air-cooled

exchanger on the fin side?

Please see our cleaning page and recommended solutions on this website.
Should I use a VFD for process control?

VFD pricing has come down significantly in the recent past and is an excellent system for
process control and allowing full usage of all available motor power during hot summer
ambients.

What are the basic differences between API -661 and non-API coolers?

Sample differences required for API:

- tube diameter minimum 1"
- geometry with regards to fan proximity to bundle
- temperature limitations for considering split headers
- lateral movement allowance of bundle
- sloping on multi-pass condensers
- header velocity limitations
- minimum header material thickness
- minimum nozzle dimensional tolerances, and maximum allowable nozzle loads
- tube gauge minimums
- restrictions on fan capacity, tip speeds, and motor minimum sizing
- natural frequency, vibration limitations
- minimum specifications on mechanical design of transmission components
- louver minimal construction specifications
- limitations on structural steel design, loads, and construction
- minimum restrictions on welding procedures
- specified noise measurement criteria and guidelines for winterization

What are the most common problems in cooler non-performance?

- poor thermal design, insist on third party check rating, or onsite performance test in
accordance with ASME-PTC-30

- L-Base wrap on fin separation creating gap resistance between fin and tube

- commonly overstated fan efficiencies, insist on air side performance tests

- hot air recirculation off the top to the inlet of same or neighboring cooler

- request computational fluid dynamics analysis when laying out the plant, watch high intake
velocities

- under estimating the air side fouling factor due to airborne contaminant

- excessive tip clearances between fan in fan ring

- the absence of inlet bells to the fan ring for efficient air entry to the fan

- system freezing of process fluid

- insist on maximum side recirculation duct face velocities and adequate instrumentation

How do I control sub-cooling in a condenser?

 In order for an air cooled liquid cooler to function properly, the inlet and outlet piping must be
arranged in a way that ensures the flooding of the entire volume of the tubes. If the outlet
piping is connected to a tank whose liquid level is below the level of the exchanger, and no
loop seal is used to trap the liquid, the liquid will not fill the tubes, and will run out before the
expected cooling takes place. Also if no provision is made for venting gasses from a high
point of the exchanger or piping, it will be difficult or impossible to purge gasses from the
exchanger, and again the expected cooling will not be achieved.

Both of these problems are aggravated when one attempts to use a single tube bundle for
both condensing and sub-cooling. In theory, any tube pass consisting of only one row of
tubes which is sloped in the direction of flow could be wholly or partially flooded with a
properly designed liquid level control, but this may not be practical. Airflow control is normally
used to maintain a constant condensing pressure and temperature. Therefore, as tubeside
flow and ambient air temperature change, the liquid level and the extent of flooding would
have to be adjustable in order to maintain a constant amount of sub-cooling.

Air cooler passes are seldom sloped more than 0.125" per foot. For an average sized
exchanger, say 10' wide by 30' long, if it were determined that an acceptable range of sub-
cooling would be achieved by flooding between 10' and 14' of the bottom row, then the range
of variation in the liquid level would have to be 0.5" or less. This would be difficult to
accomplish in an exchanger of this size. Increasing the slope of the tubes would add to the
cost because the tube bundle gets deeper, and supporting the tubes becomes more difficult.
If automatic variation of the flooding were required to compensate for changes in tubeside
flow and ambient temperature, the cost of such a control system might be higher than the
cost of simply using a second tube bundle for the sub-cooling, in which case separate air flow
controls could be use for the condensing and for the sub-cooling tube bundles.

Problems with venting further complicate the design and operation of a condenser / subcooler
tube bundle. Even in highly pure, single component processes, some small amount of non-
condensable gas is usually present. And when this is not the case, the exchanger will still be
filled with air or nitrogen at startup. If a whole row is flooded, gas can be vented at the
header entrance to that row, but the degree of sub-cooling will not be controllable. And if
over cooling of the condensate is acceptable, then increasing the vertical separation between
the bottom row of tubes and the next row up would make the liquid level less critical.
However, in the above example, the last 16' of the bottom row would be wasted. If only part
of a row is flooded, it is impossible to vent gas from the middle of the tubes.

For the above reasons, Hudson Products recommends that separate tube bundles be used
for condensing and for sub-cooling, and that their piping be arranged so that none the
condensing bundle and the entire sub-cooling bundle is flooded. The system can be vented
at the condenser's outlet, at the sub-cooler's inlet, or at both places. The bundles may be
combined in a common bay, and share fans, plenum and substructure. If a single bundle is
used, Hudson cannot guarantee that the desired amount of sub-cooling will be achieved.

What are the rivets for on the Hudson Tuf-lite II blades?

They are only used to secure the blade while the epoxy cement is permanently bonding the blade
to the hub section. They are not necessary for any strength requirements. However, they
should not be intentionally removed as this would create a hole for moisture entrance. In
addition, it could affect the balance of the blade.