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Training course on Heat Exchangers available at https://yesyen.com/Product_CBT_YESYEN.php . TEMA classification types explicitly described along with an exhaustive coverage on various types (Plate and Frame, Air cooled, etc.) of Heat Exchangers with Animation. Shell and Tube type intricately covered including Breech Lock Exchangers.
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Double Perforated Impingement Plate in Shell-and-Tube Heat …
This article presents a solution to a chronic problem causing repeated tube failure at shell-and-tube heat exchangers. The problem is related to the fouling …
Source: www.tandfonline.com
Date Published: 10/7/2021
View: 4019
DOUBLE PERFORATED IMPINGEMENT PLATE (DPIP) IN …
This paper presents a solution to a chronic problem causing repeated tube failure at shell-and-tube heat exchangers. The problem is related to fouling …
Source: dc.engconfintl.org
Date Published: 7/23/2022
View: 353
What is use of impinging plate in heat exchanger? – Quora
The impingement plate which is used mainly to protect tubes against shell se inlet flow impingement, it eliminates some stagnant locations and creates …
Source: www.quora.com
Date Published: 5/7/2022
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Heat Exchanger Impingement Plates
Heat Exchanger Designs & Selections • Differential Thermal Expansion … Most frequently used for impact protection is the impingement plate (impact plate).
Source: cmsheattransfer.com
Date Published: 12/27/2022
View: 2282
Impingement plate: – Heat Exchanger Design Handbook …
Multimedia Edition of Heat Exchanger Design Handbook (HEDH) is the standard reference source for heat transfer and heat exchanger design.
Source: hedhme.com
Date Published: 9/6/2021
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What is impingement plate on heat exchanger?
The impingement plate is placed inside the shell facing the shell inlet nozzle and usually attached directly to the bundle by tack welding to the tie rods. It is used mainly to protect tubes portions facing the shell inlet nozzle against potential erosion corrosion phenomenon and vibration impact of high velocity.
What is the purpose of impingement plate in an evaporator?
An impingement plate distributes the fluid to the tubes and prevents fluid-induced erosion, cavitation and vibration.
What is the purpose of plate type heat exchanger?
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.
What is the function of baffle plate?
Baffle plates are long, flat plates mounted to the interior of a mixing tank such that they protrude inward toward the center of the tank to disturb the swirling fluid. They also force the liquid to move upward along the tank wall.
What is tube sheet in heat exchanger?
Tube sheets have holes drilled to accept a series of tubes inside of an enclosed tubular pressure vessel. These pressure vessels, commonly referred to as shell and tube heat exchangers, are the most common heat exchangers used in oil refineries and large chemical plants.
What are heat exchanger baffles?
Baffles are an integral part of the shell and tube heat exchanger design. A baffle is designed to support tube bundles and direct the flow of fluids for maximum efficiency. Baffle design and tolerances for heat exchangers are discussed in the standards of the Tubular Exchanger Manufacturers Association (TEMA).
What is floating head in heat exchanger?
A floating head type heat exchanger is a type of shell and tube heat exchanger in which the tube sheet assembly is free and free to move within the shell or shell cover. These exchangers are widely used for the service where the temperature between the shell and the tube bundle is high, which creates expansion issues.
What is a plate to plate heat exchanger?
A plate exchanger consists of a series of parallel plates that are placed one above the other so as to allow the formation of a series of channels for fluids to flow between them. The space between two adjacent plates forms the channel in which the fluid flows.
Why plate heat exchanger is more efficient?
Plate heat exchangers are extremely energy efficient, because the energy required usually already exists within the system and can then be easily transferred to another system or process instead of just being allowed to cool down or be pumped out and wasted.
Where is a plate heat exchanger used?
You’ll find gasket plate heat exchangers used in many HVAC applications to indirectly connect chillers, boilers and cooling towers to central plant systems. They’re also used for economiser circuits and heat recovery circuits to reduce the cooling load on the chillers.
Is a baffle plate necessary?
Without the baffle plate in the way, stoves wouldn’t be able to produce as much heat because all of the warm air would be rapidly lost up the flue. Heat wouldn’t also be reflected back to above the fire to aid in secondary combustion of gases.
What is an example of baffle?
The definition of baffle is confuse. An example of baffle is when a teacher confuses a student with a complicated math problem.
How do plate evaporators work?
During the plate evaporation process, liquid is pumped between thin plates with the heating medium on the mating surfaces. The product is then evaporated with the vapor generated forming a high velocity core.
What is the purpose of entrainment separator in climbing film evaporator?
Finally, the mixture of liquid concentrate and vapour eject at a high velocity from the top of the tubes. The entrainment separator not only prevents entrainment but also acts as a foam breaker. The vapor leaves from the top, while the concentrate is collected from the bottom.
What is the function of a climbing film evaporator?
The climbing/falling film plate evaporator is specifically designed to produce a thin film during both the climbing and falling phases. For the climbing film evaporators, the feed is introduced at the bottom of the tubes. Evaporation causes the vapor to expand thus causing a thin film of liquid to rise along the tubes.
What is plate evaporator?
Plate Evaporator is a type of evaporator in which a thin film of liquid is passed and flows between the plates for the process of evaporation. The Plate Evaporators are also known as the gasketed plate and frame evaporators.
Construction Basics of Shell and Tube Heat Exchangers
Tubes
Tubes are either drawn and seamless, or welded. High quality electroresistance welded tubes exhibit good grain structure at the weld. Extruded tube with low fins and interior rifling is specified for certain applications. Surface enhancements are used to increase the available metal surface or aid in fluid turbulence, thereby increasing the effective heat transfer rate. Finned tubing is recommended when the shell-side fluid has a substantially lower heat transfer coefficient than the tube-side fluid. Finned tubing is not finned in its landing areas, where it contacts the tube sheets. Also, the outside diameter of the finned portions of this tube design is slightly smaller than the unfinned areas. These features allow the tubes to be slid easily through the baffles and tube supports during assembly while still minimizing fluid bypass.
U-tube designs are specified when the thermal difference between the fluids and flows would result in excessive thermal expansion of the tubes. U-tube bundles do not have as much tube surface as straight tube bundles due to the bending radius, and the curved ends cannot be easily cleaned. Additionally, interior tubes are difficult to replace and often requiring the removal of outer layers or simply plugging the tubes. To ease manufacturing and service, it is common to use a removable tube bundle design when specifying U-tubes.
Tube Sheets
The tube sheet is in contact with both fluids, so it must have corrosion resistance allowances and metallurgical and electrochemical properties appropriate for the fluids and velocities. Low carbon steel tube sheets can include a layer of a higher alloy metal bonded to the surface to provide more effective corrosion resistance without the expense of using the solid alloy.
The tube hole pattern, or “pitch,” varies the distance from one tube to the other as well as the angle of the tubes relative to each other and to the direction of flow. This allows the fluid velocities and pressure drop to be manipulated to provide the maximum amount of turbulence and tube surface contact for effective heat transfer.
Where the tube and tube sheet materials are joinable weldable metals, the tube joint can be further strengthened by applying a seal weld or strength weld to the joint. In a strength weld, a tube is slightly recessed inside the tube hole or slightly extended beyond the tube sheet. The weld adds metal to the resulting lip. A seal weld is specified to help prevent the shell and tube liquids from intermixing. In this treatment, the tube is flush with the tube sheet surface. The weld does not add metal but rather fuses the two materials. In cases where it is critical to avoid fluid intermixing, a double tube sheet can be provided. In this design, the outer tube sheet is outside the shell circuit, virtually eliminating the chance of fluid intermixing. The inner tube sheet is vented to atmosphere, so any fluid leak is detected easily.
Shell Assembly
In applications where the fluid velocity for the nozzle diameter is high, an impingement plate is specified to distribute the fluid evenly to the tubes and prevent fluid-induced erosion, cavitation and vibration. An impingement plate can be installed inside the shell, eliminating the need to install a full tube bundle, which would provide less available surface. Alternatively, the impingement plate can be installed in a domed area (either be reducing coupling or a fabricated dome) above the shell. This style allows a full tube count and therefore maximizes utilization of shell space (figure 2).
End Channels and Bonnets
The head may have pass ribs that dictate whether the tube fluid makes one or more passes through the tube bundle sections (figure 3). Front and rear head pass ribs and gaskets are matched to provide effective fluid velocities by forcing the flow through various numbers of tubes at a time. Generally, passes are designed to provide roughly equal tube-number access and to ensure even fluid velocity and pressure drop throughout the bundle. Even fluid velocities also affect the film coefficients and heat transfer rate so that accurate prediction of performance can be readily made.
Designs for up to six tube passes are common. Pass ribs for cast heads are integrally cast, then machined flat while pass ribs for fabricated heads are welded into place. The tube sheets and tube layout in multipass heat exchangers must have provision for the pass ribs. This requires either removing tubes to allow a low cost straight pass rib, or machining the pass rib with curves around the tubes, which is more costly to manufacture. Where a full bundle tube count is required to satisfy the thermal requirements, the machined pass rib approach may prevent having to consider the next larger shell diameter.
Cast head materials typically are used in smaller diameters to around 14″ and are made from iron, ductile iron, steel, bronze or stainless steel. Typically, they have pipe-thread connections. Cast heads and tube side piping must be removed to service tubes. Fabricated heads can be made in a range of configurations, including metal cover designs that allow servicing the tubes without disturbing the shell or tube piping. Heads can have axially or tangentially oriented nozzles, which typically are ANSI flanges.
Baffles
A baffle must have a slightly smaller inside diameter than the shell’s inside diameter to allow assembly, but it must be close enough to avoid the substantial performance penalty caused by fluid bypass around the baffles. Shell roundness is important to achieve effective sealing against excessive bypass. Baffles can be punched or machined from any common heat exchanger material compatible with the shell side fluid. Some punched baffle designs have a lip around the tube hole to provide more surface against the tube and eliminate tube wall cutting from the baffle edge. The tube holes must be precise enough to allow easy assembly and field tube replacement yet minimize the chance of fluid flowing between the tube wall and baffle hole.
Baffles do not extend edge to edge but have a cut that allows shell-side fluid to flow to the next baffled chamber (figure 4). For most liquid applications, the cuts areas represent 20 to 25% of the shell diameter. For gases, where a lower pressure drop is desirable, baffle cuts of 40 to 45% are common. Baffles must overlap at least one tube row in order to provide adequate tube support. They are spaced somewhat evenly throughout the tube bundle to provide even fluid velocity and pressure drop in each baffled tube section.
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Plate heat exchanger
A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer heat between two fluids. This has a major advantage over a conventional heat exchanger in that the fluids are exposed to a much larger surface area because the fluids are spread out over the plates. This facilitates the transfer of heat, and greatly increases the speed of the temperature change. Plate heat exchangers are now common and very small brazed versions are used in the hot-water sections of millions of combination boilers. The high heat transfer efficiency for such a small physical size has increased the domestic hot water (DHW) flowrate of combination boilers. The small plate heat exchanger has made a great impact in domestic heating and hot-water. Larger commercial versions use gaskets between the plates, whereas smaller versions tend to be brazed.
The concept behind a heat exchanger is the use of pipes or other containment vessels to heat or cool one fluid by transferring heat between it and another fluid. In most cases, the exchanger consists of a coiled pipe containing one fluid that passes through a chamber containing another fluid. The walls of the pipe are usually made of metal, or another substance with a high thermal conductivity, to facilitate the interchange, whereas the outer casing of the larger chamber is made of a plastic or coated with thermal insulation, to discourage heat from escaping from the exchanger.
The world’s first commercially viable plate heat exchanger (PHE) was invented by Dr Richard Seligman in 1923 and revolutionised methods of indirect heating and cooling of fluids. Dr Richard Seligman founded APV in 1910 as the Aluminium Plant & Vessel Company Limited, a specialist fabricating firm supplying welded vessels to the brewery and vegetable oil trades. Also, it set the norm for today’s computer-designed thin metal plate Heat Exchangers that are used all over the world.[1]
Design of plate and frame heat exchangers [ edit ]
Schematic conceptual diagram of a plate and frame heat exchanger.
An individual plate for a heat exchanger
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.
Evaluating plate heat exchangers [ edit ]
Partially dismantled exchanger, with visible plates and gaskets
All plate heat exchangers look similar on the outside. The difference lies on the inside, in the details of the plate design and the sealing technologies used. Hence, when evaluating a plate heat exchanger, it is very important not only to explore the details of the product being supplied but also to analyze the level of research and development carried out by the manufacturer and the post-commissioning service and spare parts availability.
An important aspect to take into account when evaluating a heat exchanger are the forms of corrugation within the heat exchanger. There are two types: intermating and chevron corrugations. In general, greater heat transfer enhancement is produced from chevrons for a given increase in pressure drop and are more commonly used than intermating corrugations.[2] There are so many different ways of modifications to increase heat exchangers efficiency that it is extremely doubtful that any of them will be supported by a commercial simulator. In addition, some proprietary data can never be released from the heat transfer enhancement manufacturers. However, it does not mean that any of the pre-measurements for emerging technology are not accomplish by the engineers. Context information on several different forms of changes to heat exchangers is given below. The main objective of having a cost benefit heat exchanger compared to the usage of a traditional heat exchanger must always be fulfilled by heat exchanger enhancement. Fouling capacity, reliability and safety are other considerations that should be tackled.
First is Periodic Cleaning. Periodic cleaning (on-site cleaning) is the most efficient method to flush out all the waste and dirt that over time decreases the efficiency of the heat exchanger. This approach requires both sides of the PHE (Plate Heat Exchanger) to be drained, followed by its isolation from the fluid in the system. From both sides, water should be flushed out until it runs completely clear. The flushing should be carried out in the opposite direction to regular operations for the best results. Once it is done, it is then time to use a circular pump and a solution tank to pass on a cleaning agent while ensuring that the agent is compatible with the PHE (Plate Heat Exchanger) gaskets and plates. Lastly, until the discharge stream runs clear, the system should be flushed with water again
Optimization of Plate Heat Exchangers [ edit ]
To achieve improvement in PHE’s, two important factors namely amount of heat transfer and pressure drop have to be considered such that amount of heat transfer needs to be increased and pressure drops need to be decreased. In plate heat exchangers due to presence of corrugated plate, there is a significant resistance to flow with high friction loss. Thus to design plate heat exchangers, one should consider both factors.
For various range of Reynolds numbers, many correlations and chevron angles for plate heat exchangers exist. The plate geometry is one of the most important factor in heat transfer and pressure drop in plate heat exchangers, however such a feature is not accurately prescribed. In the corrugated plate heat exchangers, because of narrow path between the plates, there is a large pressure capacity and the flow becomes turbulent along the path. Therefore, it requires more pumping power than the other types of heat exchangers. Therefore, higher heat transfer and less pressure drop are targeted. The shape of plate heat exchanger is very important for industrial applications that are affected by pressure drop.[citation needed]
Flow distribution and heat transfer equation [ edit ]
Design calculations of a plate heat exchanger include flow distribution and pressure drop and heat transfer. The former is an issue of Flow distribution in manifolds.[3] A layout configuration of plate heat exchanger can be usually simplified into a manifold system with two manifold headers for dividing and combining fluids, which can be categorized into U-type and Z-type arrangement according to flow direction in the headers, as shown in manifold arrangement. Bassiouny and Martin developed the previous theory of design.[4][5] In recent years Wang [6][7] unified all the main existing models and developed a most completed theory and design tool.
The total rate of heat transfer between the hot and cold fluids passing through a plate heat exchanger may be expressed as: Q = UA∆Tm where U is the Overall heat transfer coefficient, A is the total plate area, and ∆Tm is the Log mean temperature difference. U is dependent upon the heat transfer coefficients in the hot and cold streams.[2]
Manifold arrangement for flow distribution
Their cleaning helps to avoid fouling and scaling without the heat exchanger needing to be shut down or operations disrupted. In order to avoid heat exchanger performance to decrease and service life of the tube extension, the OnC (Online Cleaning) can be used as a standalone approach or in conjunction with chemical treatment. The re-circulating ball type system and the brush and basket system are some of OnC techniques. OfC (Offline Cleaning) is another effective cleaning method that effectively increases the performance of heat exchangers and decreases operating expenses. This method, also known as pigging, uses a shape like bullet device that is inserted in each tube and using high air pressure to force down the tube. Chemical washing, hydro-blasting and hydro-lancing are other widely used methods other than OfC. Both these techniques, when used frequently, will restore the exchanger into its optimum efficiency until the fouling and scaling begin to slip slowly and adversely affecting the efficiency of the heat exchanger.
Operation and maintenance cost is necessary for a heat exchanger. But there are different ways to minimize the cost. Firstly, cost can be minimized by reducing fouling formation on heat exchanger that decreases the overall heat transfer coefficient. According to analysis estimated, effect of fouling formation will generate a huge cost of operational losses which more than 4 billion dollars. The total fouling cost including capital cost, energy cost, maintenance cost and cost of profit loss. Chemical fouling inhibitors is one of the fouling control method. For example, acrylic acid/hydroxypropyl acrylate (AA/HPA) and acrylic acid/sulfonic acid (AA/SA) copolymers can be used to inhibit the fouling by deposition of calcium phosphate. Next, deposition of fouling can also be reduced by installing the heat exchanger vertically as the gravitational force pulls any of the particles away from the heat transfer surface in the heat exchanger. Second, operation cost can be minimized when saturated steam is used compared to superheated steam as a fluid. Superheated steam acts as an insulator and poor heat conductor, it is not suitable for heat application such as heat exchanger
See also [ edit ]
References [ edit ]
Bibliography [ edit ]
The Importance of Baffle Plates in Liquid Agitation
Use baffle plates to gain more controlled agitation, extend the life of the agitator and create peace of mind for the operator.
Xylem’s top-entry agitators rotate in a clockwise direction (when looking from above the tank). Without interference, tangential velocities from the impeller(s) would typically cause the entire fluid mass in the tank to spin as a whole, with very little actual mixing taking place. It may look like good mixing, but seeing the fluid vortex all the way down to the impeller is deceiving. The reality is that very little shear is being produced. The particles are actually just spinning around more like in a centrifuge than a mixer (see Figure 1).
How Baffles Work
Baffle plates are long, flat plates mounted to the interior of a mixing tank such that they protrude inward toward the center of the tank to disturb the swirling fluid. They also force the liquid to move upward along the tank wall. Both actions improve mixing, and therefore the agitation process, by creating a “controlled chaos” of turbulences. It is not possible to load a mixer’s impellers properly, especially in low viscosity liquids, without baffles due to the spinning of the liquid and the lack of top-to-bottom movement. Baffle plates control the liquid more, from the top to the bottom of the tank, resulting in better mixing (see Figure 2).
Increased Equipment Life
Without baffle plates sludge, especially with low viscosity fluids, will turn at the same speed as the agitator shaft. The shaft will eventually find the most suitable position using the “law of least resistance”, and begin to turn out of the center line. This will stress the agitator’s support bridge and the shaft will eventually begin making an oval turn. This in turn will fatigue the shaft, risking premature breakdowns.
Sizing, Positioning, and Number
The graph below (Figure 3) shows the relation of the width of the baffle plate to liquid viscosity. The distance from the wall is normally T/72 but not less than 50mm.
In cylindrical tanks the baffles should be evenly spaced. The number of baffles needed depends on liquid characteristics, the degree of agitation (Reynolds number) desired, and the volume of the tank. Typically, four baffle plates are used but the number can vary due to the degree of agitation required.
For a low degree of agitation, such as in a digester chamber, two baffles can be sufficient (see Figure 4). When axial flow down-pumping impellers are used, a cross baffle (comprised of two plates that cross) mounted near the base may be all that is needed (see Figure 5). Note that cross baffles should not be placed at the very bottom of the tank to prevent solids from accumulating there.
Heat Exchanger Impingement Plates
CMS Heat Transfer Division, Inc. 273 Knickerbocker Avenue � Bohemia, NY 11716 USA Tel: 631-968-0084 � Fax: 631-968-0184 � Email: [email protected] CMS Heat Transfer products include shell and tube heat exchangers, fixed tubesheet and u-tube exchangers, oil coolers, pre-heaters, condensers, after-coolers, steam converters, kettles, reboilers and evaporators. CMS engineering include custom heat exchanger, process and mechanical design services to all TEMA and ASME conformance requirements.
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