BUILDING SUPERIOR

STEAM AIR HEATERS

COMPACT, LIGHTWEIGHT AND EFFICIENT SOLUTIONS.

CONCEPT ENGINEERING
INTERNATIONAL
 Saturated steam condensing in tubes has a very high heattransfer coefficient. To harness
its true potential you need a very efficient fin tube as the airside is the limiting factor.
Our PIN Fin tube fits the bill. It consists of wire loops fastened to the tube with a flattened
wire soldered to the tube. The soldering(lead free solder is an option) gives 100% bondingand
strength and the wire loops provide very high airside turbulence. The result is an extremely high
airside coefficient enhancing significantly the overall heat transfer coefficient.
These fin tubes can be provided with carbon steel, stainless steel or copper wire fins on
steel, stainless steel or copper/copper alloy tubes. To demonstrate the performance of these
tubes against helical fin tubes we have done the following:
 1. Designed a 1 meter by 1 meter 3 row panel using ¾” OD steel tubes with 10 FPI L type
Aluminum fins. We have used 57 tubes in this panel. (19 tubes/row) The fin thickness
was 0.5 mm and the fin height was 13 mm giving a heat transfer area of 3.51 ft2/ft. The
transverse pitch was 50.8 mm and the longitudinal pitch was 38 mmv

2. Using HTRI software, we calculated the heat transfer and pressure drop of this panel under
different air flow rate conditions, 25 deg C ambient air temperature and saturatedsteam
at 3 kg/cm2g pressure in the tubes. We calculated all the parameters like air outlet
temperature, LMTD, linear heat transfer coefficient, heat load and airsidepressure drop.
We also isolated the airside heat transfer coefficient.

3. We then repeated this exercise using the same tube size but substituting the L type fins
with our Pin fins in 5 different wire-winding configurations. The design was done using our
in house design data proven over 2 decades of use. Since Aluminum cannot be used in
wire wound fin tubes, we have considered stainless steel wire fins.

4. We also used panels with the same 1 meter by one meter 3 row configuration but changed
the tube OD. We have adjusted the number of tubes to fit this configuration. We have
selected the most commonly used winding configuration for each tube OD selected. We
thus had panels with 1” OD at 51 tubes per panel, 5/8” tubes at 60 tubes per panel and
3/8” tubes at 77 tubes per panel.

5. We thus arrived at 9 panels, One of ¾” L type fin tubes, five of different windings of ¾”
wire wound fin tubes and one each of 3/8”, 5/8” & 1” tubes. The idea of comparing one
meter by one-meter panels was to be able to compare the performance of similarly sized
heat exchangers across the tube options.

6. When comparing coefficients we have decided to use a linear coefficient (Per length
of tube) instead of the generally used surface area. This gives a more straightforward
comparison between tubes and is easier to use.One must keep in mind that with lower
OD tubes a larger number of tubes can be fitted in a panel which will gives a higher panel
coefficient. (Linear coefficient x length of tube in panel).

7. Due to its fin geometry and efficiency the weight of the wire fin tube is very low both
in absolute per meter terms andmore so when the total length is adjusted for higher
performance. To compare, S1 and the higher efficiency S2 and S3 stainless steel fin
tubes are lower in weight than the 10 FPI Aluminum fin steel tube combination. The S4 &
S5 are only slightly higher. When comparing against the stainless steel L fin tube, the S1
is 40% of the weight. The S5 stainless steel is only 2.9 kgsvs. 4.7 kgs for the stainless
steel fin L tube. When you consider that the S1 is 30% more efficient and the S5 is 3 times
the efficiencyof the L tube great new possibilities open up. The weight chart that follows
is worth studying.

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 Weight of different fin configurations of fintubes
Total
Winding Code Tube OD Weight per meter (kg/mtr)
weight
Tube Fins Tension wire Solder wire Kg/mtr
S1 A ¾” 1.01 0.91 0.062 0.09 2.072
S2 B ¾” 1.01 1.1 0.07 0.093 2.273
S3 C ¾” 1.01 1.25 0.08 0.11 2.45
S4 D ¾” 1.01 1.38 0.083 0.12 2.593
S5 E ¾” 1.01 1.68 0.083 0.12 2.893
P4 F 3/8” 0.16 0.45 0.05 0.06 0.72
R2 G 5/8” 0.34 0.88 0.08 0.09 1.39
T5 H 1” 0.75 1.63 0.12 0.14 2.64
L fins SS L 10 FPI ¾” 1.01 3.71 - - 4.72
L fins AL L 10 FPI ¾” 1.01 1.41 - - 2.42

Design Parameter
L 10,
Model No Units S1,S2,S3,S4,S5 T5 R2 P4
Air inlet temperature deg C 25 25 25 25
Steam Pressure kg/cm^2g 3 3 3 3
Dirt factor outside (Rdo) hr. ft2 F/btu 0.002 0.002 0.002 0.002
Dirt factor inside (Rdi) hr. ft2 F/btu 0.0005 0.0005 0.0005 0.0005
Face Area M^2 1 1 1 1

Heat Transfer Coefficient

Tube side (hi) btu/hr. ft^2 F 1500 1500 1500 1500
When referred to tube ID/OD
(hio) btu/hr. ft^2 F 1180 - - -
with dirt factor (hiod) btu/hr. ft^2 F 742 742 742 742
linear heat transfer coefficient btu/hr. ft F 145.64 202.27 122.20 70.29

Tube
OD in 0.75 1 0.625 0.375
thk in 0.08 0.08 0.064 0.048
ID in 0.59 0.84 0.497 0.279
No.of rows 3 3 3 3
No. of tubes 57 51 60 77
Pitch in row (pir) mm 50.8 57.2 48 38
row pitch (Rp) mm 38 44 36 28
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Air sup Udlinear Air coefficient
velocity btu/hr. ft
fpm btu/hr. ft F deg C
P4 R2 L fin S1 S2 S3 S4 S5 T5 P4 R2 L fin S1 S2 S3 S4 S5 T5
200 12.61 16.69 16.80 19.76 24.43 28.86 32.19 39.79 31.92 15.68 19.75 22.32 23.48 30.21 37.05 42.61 56.70 38.76
300 16.47 21.30 20.40 23.91 29.33 34.38 38.13 46.53 39.82 22.13 26.55 27.86 29.58 38.07 46.68 53.69 71.44 51.06
400 19.65 25.11 22.67 27.24 33.20 38.68 42.71 51.61 46.22 28.26 32.75 31.22 34.85 44.85 55.00 63.26 84.17 62.09
500 21.73 28.38 24.20 30.04 36.42 42.21 46.45 55.68 51.64 32.79 38.55 33.63 39.59 50.93 62.45 71.83 95.55 72.27
600 23.63 31.25 25.71 32.48 39.18 45.24 49.62 59.11 56.33 37.32 44.04 36.04 43.90 56.51 69.31 79.73 106.12 81.81
700 24.70 34.01 27.17 34.63 41.61 47.86 52.35 62.01 60.47 40.06 49.73 38.45 47.95 61.70 75.67 87.04 115.82 90.85
800 25.85 35.62 28.53 36.57 43.77 50.17 54.76 64.53 64.18 43.17 53.25 40.85 51.74 66.58 81.65 93.91 124.94 99.48
900 26.88 37.07 29.82 38.33 45.72 52.26 56.92 66.77 66.74 46.12 56.55 43.23 55.33 71.20 87.32 100.44 133.64 105.78
1000 27.81 38.38 31.09 39.94 47.50 54.15 58.86 68.79 69.11 48.92 59.67 45.56 58.75 75.61 92.73 106.68 141.96 111.85
1100 28.65 39.59 32.23 41.43 49.13 55.86 60.62 70.58 71.28 51.60 62.64 47.78 62.04 79.83 97.89 112.60 149.81 117.65
1200 29.43 40.71 33.29 42.81 50.64 57.45 62.24 72.23 73.28 54.18 65.48 49.89 65.20 83.89 102.87 118.32 157.42 123.20
1300 30.15 41.75 34.28 44.10 52.04 58.91 63.74 73.75 75.14 56.66 68.21 51.90 68.23 87.81 107.68 123.86 164.81 128.54
1400 30.82 42.72 35.20 45.31 53.35 60.27 65.12 75.13 76.87 59.06 70.84 53.82 71.18 91.60 112.32 129.20 171.90 133.69
1500 31.44 43.63 36.09 46.45 54.58 61.55 66.41 76.43 78.49 61.39 73.38 55.65 74.02 95.27 116.84 134.41 178.86 138.67

Air sup Air outlet Heat load

velocity temp
fpm deg C kcal/hr.
P4 R2 L fin S1 S2 S3 S4 S5 T5 P4 R2 L fin S1 S2 S3 S4 S5 T5
200 107.3 108.8 108.1 113.6 121.9 127.60 130.80 135.80 127.2 89234. 90860. 92400. 96065. 105064 111245 114714 120135 110811
300 101.3 101.9 99.7 104.6 113.3 119.60 123.30 129.70 120.9 5
124093 9
125069 0
124950 4
129460 .7
143610 .0
153856 .6
159874 .9
170282 .3
155970
400 96.5 96.6 92.3 97.8 106.4 112.90 116.80 123.90 115.6 .5
155049 .3
155265 .0
150150 .6
157868 .2
176517 .4
190612 .0
199070 21446
.9 19646
.7
500 91.2 92.2 85.7 92.4 100.8 107.20 111.20 118.50 111.0 .1
179444 .9
182155 .0
169050 .2
182697 .4
205467 22281
.8 23365
.0 6.5
253445 7.8
233115
600 87.1 88.6 80.9 88.0 96.1 102.30 106.30 113.60 106.9 .9
201997 20687
.6 .0
186900 .7
204925 23127
.2 5.3
251439 7.9
264450 28819
.6 26640
.8
700 82.5 85.7 77.3 84.3 92.0 98.10 101.90 109.20 103.4 21820
.5 6.7
230350 20370
.0 22503
.0 2.5
254258 .8
277407 29182
.9 6.1
319531 2.5
29752
800 79.0 82.1 74.1 81.1 88.5 94.30 98.10 105.20 100.2 7.2
234200 .9
247644 0.0
218400 8.0
243307 .8
275401 30055
.8 8.4
317037 34783
.2 0.8
326145
900 76.0 79.0 71.5 78.3 85.4 91.00 94.70 101.60 96.8 .0
248837 26347
.8 .0
233100 .8
260059 29470
.9 6.7
322025 34007
.4 0.4
37374 35032
.2
1000 73.3 76.3 69.3 75.8 82.7 88.10 91.60 98.30 93.7 .5
261848 5.0
278112 .0
246750 .6
275401 1.7
312808 34208
.0 8.0
361058 4.2
397381 4.2
372443
1100 71.0 73.9 67.3 73.7 80.2 85.40 88.80 95.30 91.0 27431
.6 29161
.5 25935
.0 29041
.9 32918
.8 3.8
360191 38046
.4 .1
419228 .1
393586
1200 68.9 71.7 65.5 71.7 78.0 83.00 86.30 92.60 88.4 7.6
285593 1.6
303809 0.0
270900 8.9
303809 1.2
344794 37732
.0 6.6
398790 .9
439775 .2
412452
1300 67.0 69.8 63.9 69.9 76.0 80.80 83.90 90.00 86.1 .9
296002 31573
.5 .0
281400 31644
.5 35943
.5 2.3
393260 .6
415108 .6
458099 .3
430613
1400 65.2 68 62.4 68.3 74.1 78.70 81.80 87.70 84.0 30511
.8 6.3
326362 29190
.0 1.1
328639 2.0
372660 .9
407573 .7
431101 .6
475881 .6
447799
1500 63.7 66.4 61.1 66.8 72.4 76.90 79.80 85.50 82.1 0.6
314706 .1
336662 0.0
301350 33991
.0 .0
385454 .1
422048 .5
445630 .5
491982 .1
464334
.3 .5 .0 5.3 .2 .0 .6 .7 .1
 Air sup LMTD Air side
velocity pr drop
fpm deg C in wc
P4 R2 L fin S1 S2 S3 S4 S5 T5 P4 R2 L fin S1 S2 S3 S4 S5 T5
200 68.71 67.54 65.2 63.63 56.15 50.24 46.46 39.43 50.68 0.055 0.049 0.07 0.038 0.051 0.067 0.081 0.115 0.113
300 73.23 72.79 72.2 70.78 63.88 58.33 54.77 47.81 57.11 0.11 0.11 0.128 0.083 0.112 0.147 0.178 0.25 0.253
400 76.66 76.59 78 75.74 69.41 64.21 60.87 54.17 61.92 0.18 0.194 0.194 0.147 0.196 0.257 0.309 0.432 0.446
500 80.29 79.61 82.3 79.48 73.59 68.79 65.61 59.34 65.78 0.262 0.301 0.273 0.227 0.302 0.394 0.473 0.66 0.692
600 83 82.02 85.8 82.41 76.94 72.5 69.49 63.63 69.02 0.357 0.43 0.368 0.325 0.43 0.56 0.671 0.93 0.99
700 85.95 83.91 88.4 84.81 79.75 75.53 72.79 67.22 71.68 0.463 0.583 0.471 0.44 0.58 0.753 0.9 1.243 1.341
800 88.14 86.21 90.5 86.84 82.08 78.18 75.53 70.33 74.03 0.58 0.758 0.587 0.572 0.751 0.973 1.161 1.598 1.743
900 89.99 88.14 92.1 88.58 84.1 80.42 77.91 73.01 76.45 0.708 0.954 0.711 0.721 0.944 1.22 1.453 1.994 2.195

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1000 91.62 89.81 93.5 90.11 85.83 82.35 80.02 75.39 78.6 0.846 1.173 0.847 0.887 1.158 1.493 1.775 2.429 2.697
1100 93 91.26 94.8 91.38 87.4 84.1 81.88 77.49 80.42 0.994 1.414 0.996 1.07 1.393 1.792 2.128 2.904 3.25
1200 94.24 92.58 95.9 92.58 88.76 85.64 83.52 79.34 82.15 1.152 1.678 1.153 1.269 1.649 2.118 2.511 3.419 3.853
1300 95.35 93.71 96.9 93.65 89.99 87.02 85.06 81.09 83.65 1.319 1.963 1.323 1.485 1.927 2.47 2.926 3.974 4.506
1400 96.39 94.76 97.8 94.59 91.14 88.33 86.4 82.61 85 1.495 2.27 1.505 1.718 2.225 2.847 3.368 4.565 5.209
1500 97.25 95.7 98.6 95.46 92.16 89.44 87.65 84.04 86.21 1.681 2.6 1.695 1.968 2.544 3.25 3.842 5.196 5.963

Air sup ud/panel Air Coefficient

Velocity
fpm btu/hr panel F btu/hr paneldeg C
P4 R2 L fin S1 S2 S3 S4 S5 T5 P4 R2 L fin S1 S2 S3 S4 S5 T5
200 3185 3284 3141 3694 4568 5396 6019 7438 5339 3960 3886 4173 4390 5648 6926 7967 10600 6483
300 4161 4191 3814 4470 5483 6427 7129 8699 6661 5590 5225 5208 5531 7117 8728 10039 13357 8541
400 4962 4942 4239 5093 6207 7231 7985 9649 7732 7138 6446 5837 6516 8385 10283 11827 15737 10387
500 5489 5585 4524 5617 6808 7892 8684 10410 8638 8282 7586 6288 7401 9522 11676 13429 17864 12089
600 5969 6150 4806 6072 7325 8457 9278 11051 9423 9426 8666 6738 8208 10565 12958 14907 19839 13685
700 6239 6693 5080 6475 7779 8947 9788 11592 10116 10118 9787 7189 8964 11536 14147 16273 21653 15197
800 6529 7010 5333 6836 8184 9381 10238 12064 10736 10904 10480 7638 9674 12448 15264 17557 23360 16641
900 6789 7295 5575 7165 8548 9770 10641 12484 11165 11647 11129 8082 10345 13312 16325 18778 24986 17694
1000 7023 7554 5812 7467 8881 10123 11005 12861 11561 12355 11743 8518 10984 14136 17338 19944 26541 18711
1100 7237 7792 6026 7745 9186 10444 11333 13196 11924 13033 12328 8933 11599 14925 18302 21051 28008 19680
1200 7433 8012 6225 8004 9468 10740 11636 13504 12258 13683 12887 9327 12189 15684 19233 22121 29430 20609
1300 7614 8216 6409 8245 9730 11014 11916 13788 12569 14311 13424 9704 12757 16417 20132 23158 30814 21502
1400 7783 8407 6581 8472 9974 11269 12175 14047 12859 14917 13941 10061 13308 17125 21000 24155 32139 22363
1500 7940 8586 6748 8685 10204 11507 12417 14290 13130 15505 14441 10404 13840 17812 21845 25129 33440 23196
 Tables giving maximum air velocity and performance for various tubes at different
pressure drop points. (Measured in inches of water column.)
We have after analysis generated the following tables where we have generated the maximum
airflow rate possible for every panel given a pressure drop limit. We have set the limit at .5”, 1”, 1.5”
and 2” of water column. For this maximum airflow, we have given the corresponding heat transfer
parameters. These tables allow us to optimize the tubes and airflow rates to get the desired results.

0.5” Water Column

Air Air side Air Udlinear LMTD Heat Load Outlet
Tube Velocity Pr Drop Co efficient temp

P4 700 0.463 40.06 24.70 85.95 218207.2 82.5

R2 600 0.430 44.04 31.25 82.02 206876.7 88.6
L fin 700 0.471 38.45 27.17 88.40 203700.0 77.3
S1 700 0.440 47.95 34.63 84.81 225038.0 84.3
S2 600 0.430 56.51 39.18 76.94 231272.5 96.1
S3 500 0.394 62.45 42.21 68.79 222815.3 107.20
S4 500 0.473 71.83 46.45 65.61 233657.9 111.20
S5 400 0.432 84.17 51.61 54.17 214466.5 123.90
T5 400 0.446 62.09 46.22 61.92 196467.8 115.60
1” Water Column
Air Air side Air Udlinear LMTD Heat Load Outlet
Tube Velocity Pr Drop Co efficient temp

P4 1100 0.994 51.60 28.65 93.00 274317.6 71.0

R2 900 0.954 56.55 37.07 88.14 263475.0 79.0
L fin 1100 0.996 47.78 32.23 94.80 259350.0 67.3
S1 1100 1.070 62.04 41.43 91.38 290418.9 73.7
S2 900 0.944 71.20 45.72 84.10 294701.7 85.4
S3 800 0.973 81.65 50.17 78.18 300556.7 94.30
S4 700 0.900 87.04 52.35 72.79 291828.4 101.90
S5 600 0.930 106.12 59.11 63.63 288196.1 113.60
T5 600 0.990 81.81 56.33 69.02 266402.5 106.90
1.5” Water Column
Air Air side Air Udlinear LMTD Heat Load Outlet
Tube Velocity Pr Drop Co efficient temp

P4 1400 1.495 59.06 30.82 96.39 305110.6 65.2

R2 1100 1.414 62.64 39.59 91.26 291611.6 73.9
L fin 1400 1.505 53.82 35.20 97.80 291900.0 62.4
S1 1300 1.485 68.23 44.10 93.65 316441.1 69.9
S2 1100 1.393 79.83 49.13 87.40 329181.2 80.2
S3 1000 1.493 92.73 54.15 82.35 342083.8 88.10
S4 900 1.453 100.44 56.92 77.91 340078.0 94.70
S5 800 1.598 124.94 64.53 70.33 347830.4 105.20
T5 700 1.341 90.85 60.47 71.68 297520.8 103.40
2” Water Column
Air Air side Air Udlinear LMTD Heat Load Outlet
Tube Velocity Pr Drop Co efficient temp

P4 1500 1.681 61.39 31.44 97.25 314706.3 63.7

R2 1300 1.963 68.21 41.75 93.71 315736.3 69.8
L fin 1500 1.695 55.65 36.09 98.60 301350.0 61.1
S1 1500 1.968 74.02 46.45 95.46 339915.3 66.8
S2 1300 1.927 87.81 52.04 89.99 359432.0 76.0
S3 1200 2.118 102.87 57.45 85.64 377322.3 83.0
S4 1100 2.128 112.60 60.62 81.88 380466.6 88.80
S5 900 1.994 133.64 66.77 73.01 373744.2 101.60
T5 900 2.195 105.78 66.74 76.45 350324.2 96.80

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Analysis of the Data generated:

Performance of any Fin tube cooler is a combination of its Air side Coefficient and tubeside coefficient
as given by the general formula:

Ud = h’fi*h’i/h’fi+h’i

Where:
Ud = overall heat transfer Coefficient
h’fi = Heat transfer coefficient on fin side of the tube.
h’i = Heat transfer coefficient inside the tube

From this formula we can see that any increase of the coefficient on one side (Air or tube) will lead to
a less than proportional increase in the overall coefficient.

So to get a fair idea of the performance of a fin tube we have to look at both the Airside performance
as well as the overall performance to see its individual impact as well as composite impact. We have
accordingly in the interest of transparency given both the airside coefficient as well as the overall
coefficient.

The lower material consumption per meter of tube offsets in part its greater labor cost giving a
surprisingly economical tube. When the lower length of tube required in any equipment is factored in
it becomes definitely very cost effective.
Now the findings:

1. In the general Airflow velocity range of 800 to 1200 the pressure drop of S1 pin fin tube is almost
identical to the 10 FPI L fin tube. However the airside coefficient is higher by 26-30% similarly the
overall coefficient is higher by 28% in the case of 3-bar steam in the tubes.
2. For S5 the overall coefficient is 220% and airside coefficient is 300% of the coefficient of the 10
FPI L fin tube. This implies a reduction to 40% in panel size for the same performance.
3. The wire fin tube hits the pressure drop limit at a lower airflow rate as compared to the L fin tube.
However at this lower air flow it has a much higher coefficient than the L fin tube operating at the
higher airflow rate giving a higher total heat load. This translates into significant power saving.
4. The outlet Air temperature achieved at different flow rates is higher for the S5 Panel by about 25
degrees centigrade. Again this implies that one can achieve the desired air temperature with a
lower number of fin tube rows.
5. Again with the log mean temperature difference we are able to achieve an improvement of about
18-24 degrees between the 10 FPI L fin tube and S5. A tighter LMTD means a much more efficient
heat exchanger.
6. Notwithstanding the tight LMTD achieved, the heat load for S5 is higher by 60-61% for S5
compared to the 10 FPI L panel.
7. While the difference is very large for S5 and 10 FPI L fin, it is also substantial when compared with
S1, the lowest configuration.
8. Copper fins give a 15% higher airside coefficient and an 8-10% higher overall coefficient as
compared to stainless steel or steel fins.

In a nutshell, we can achieve a reduction in number of rows of the steam air heater, by approximately
50%. We can achieve a further reduction in weight as the wire fin tube is much lighter than the L fin
tube. (If the same metal is used by over 50%, In case the L fin is made of aluminum the weight may
be about the same.) A significant reduction in power consumption is also achieved. We are able to
substitute aluminum fins with stainless steel without an increase in cost or weight.

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Designing your own exchangers

We have made it easy to design your own exchangers by providing extensive data. Also by
presenting the data in the form of 1x1 meter 3 row Panels, and expressing the coefficient in linear
terms we have made it easy to predict performance by scaling up these panels in face area or
number of rows. We have tried to make it intuitive.

For easy reference we have also given a graph comparing the same panel 3 kgs with 10 kgs steam.

By isolating the airside coefficient, we have made it possible for designers to use the data for any
other type of heat exchanger like oil coolers, water coolers or any other air-cooled heat exchangers.

The Data tables have given a color code to values where the typical allowable pressure drops are
reached. (.5, 1, 1.5 & 2) inches of water column. This allows you to select the most appropriate tube
and airflow rate for a given allowable pressure drop. This allows you to easily optimize your tube type
and panel sizing.
Assistance with design

We are willing to work together with you to design your equipment. We charge a very nominal design
fee, which we are willing to rebate at the time of order conclusion. Our design capability covers all
types of heat exchangers and fin tubes. We generally limit ourselves to process design but can also
assist in mechanical design.

Partnership

Concept engineering wishes to work with local companies in all countries. We encourage our local
partners to fabricate the heaters themselves using our fin tubes, turbulators, components and design
capability. This makes it possible for companies with Fabrication capacity but limited heat exchanger
design capability to partner with us to successfully make and market heat exchangers. Of course we
are looking at sustained partnerships with a win win perspective.

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Concept Engineering International Phone: +91-22-4353 3700-99
Turbulator Division, Fax: +91-22-4353 3717
2nd floor, KK Chambers, Sir P.T. Marg, E-mail: [email protected]
Fort, Mumbai 400001. www.conceptengg.com
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