HEAT EXCHANGER MANUFACTURER AND DESIGNER

1. Email Address water@watermanaustralia.com   DESIGNING A SHELL AND TUBE HEAT EXCHANGER (STHE) Home » Blogs on Water Treatment Plant & Machinery » Designing a Shell and Tube Heat Exchanger (STHE) Designing a Shell and Tube Heat Exchanger (STHE) ADMIN

2. Introduction:  For e몭ective heat transfer between two 몭uids while maintaining their separation, STHE are widely utilised in a variety of industries. They are appropriate for high-temperature and high-pressure applications because they are durable and adaptable. To ensure maximum performance and safety, STHE design entails a number of crucial processes. We’ll look at the key components of STHE design. Understanding the Basics Before commencing the design process, it is crucial to have a 몭rm grasp of the foundations of shell and tube heat exchangers. These devices feature a cylindrical casing with many tubes inside. A tube-side 몭uid is one that 몭ows inside the tubes, whereas a shell-side 몭uid is one that 몭ows around the tubes. The heat of one 몭uid is transferred to the other through the tube walls. A shell and tube heat exchanger is de몭ned by many factors, including the tube diameter, tube length, shell diameter, tube arrangement, and many more.

3. Design Steps

4. Design Steps 1. Determine the Heat Exchanger’s Purpose Establishing the goal of the heat exchanger is the 몭rst stage in constructing a STHE. What particular heat transfer requirements does your application have? Is a 몭uid being heated or cooled? What are the required temperatures and pressures for the 몭uids on the shell side and the tube side? A good design depends on your ability to comprehend the objectives and limitations of your heat exchanger. 2. Selection of Materials Choosing the appropriate materials for the heat exchanger’s shell, tubes, and other parts is essential. Materials are chosen based on a variety of criteria, including corrosion resistance, temperature and pressure requirements, and the characteristics of the 몭uids being handled. STHE are often made of carbon steel, stainless steel, or an assortment of alloys. 3. Determine Heat Transfer Area In order to determine how much heat transfer area a heat exchanger will need, it is necessary to know both the heat transfer rate and the temperature di몭erence between the two 몭uids. The area of heat transmission can be calculated with the help of the following formula: Q = U * A * ΔTlm Q = rate of heat exchange (in watts or British thermal units per hour). U = total heat transfer coe몭cient (in W/m²·K or BTU/hr·ft²·°F). A = area of heat exchange (in square metres or square feet). ΔTlm = average temperature gradient as a logarithm (in Kelvin or Fahrenheit). 4. Tube Layout and Geometry The heat exchanger’s e몭ciency is tremendously a몭ected by the tubes’ geometry and layout. There are a lot of options to consider while designing a tube, including the tube’s diameter, length, pitch, and number of passes. While longer tubes with smaller diameters can improve heat transfer e몭ciency, they may also result in larger pressure drops. The shell-side 몭uid 몭ow is in몭uenced by the tube pitch, or the distance between the tubes. 5. Calculate the Required Number of Tubes The intended heat transfer rate and the tube-side 몭uid 몭ow rate determine how many tubes are needed in the heat exchanger. You can use the following formula to determine how many tubes are needed: N = Q / U A ΔTlm N = the number of tubes. Q = heat – transfer rate. U = heat transfer coe몭cient. A = area of heat exchange. ΔTlm = logarithmic mean temperature di몭erence 6. Sizing the Shell A number of variables, including the size and quantity of tubes, 몭uid 몭ow rates at the shell’s side, and the required pressure drop, a몭ect the shell’s dimensions, including its length and diameter. The diameter of the shell ought to permit su몭cient 몭uid movement while leaving su몭cient room for the tubes. 7. Estimation of Pressure Drop Appropriate design requires an estimation of the pressure drop on the shell-side as well as the tube-side. Pressure drop has an impact on the heat exchanger’s e몭ectiveness and performance. Calculations of pressure decreases consider variables such as 몭uid characteristics, tube con몭guration, and 몭ow rates. 8. Ba몭e Design Ba몭es are installed inside the shell to provide better heat transfer and direct 몭uid 몭ow. The spacing and design of ba몭es is critical to achieving the desired heat transfer e몭ciency while minimising pressure and drop. Depending on the purpose, di몭erent ba몭e con몭gurations, including segmental or helical ba몭es, might be employed. 9. Determining the Overall Heat Transfer Coe몭cient The overall heat transfer coe몭cient plays a signi몭cant role in heat exchanger design (U). Heat-transfer resistance on both the shell and tube sides is calculated. Empirical correlations can be used to determine U, a variable that is

5. material- and design-speci몭c to heat exchangers. 10. Consideration of Fouling and Maintenance Over time, fouling the buildup of deposits on the heat exchanger’s surfaces can cause it to lose e몭ciency. When choosing materials and calculating the heat transfer area, designers must take fouling into consideration. The heat exchanger should also be made with simple maintenance in mind, which could entail the use of detachable tube bundles. 11. Thermal Expansion When constructing a shell and tube heat exchanger, take thermal expansion into account. Temperature variations may cause the materials to expand or contract at di몭erent rates. The heat exchanger structure may experience stress as a result, which needs to be controlled to prolong the life of the system. Computer-Aided Design (CAD) and Simulation Simulation tools and computer-aided design (CAD) software can be very helpful in the design process. By modelling and analysing the heat exchanger’s performance under various scenarios, engineers can use these techniques to optimise the heat exchanger’s design for both economy and e몭ciency. Safety and Regulatory Compliance Ensuring adherence to safety norms and regulations is a crucial aspect of designing a STHE. The industry and application may cause these standards to change. For the heat exchanger to operate safely, it is imperative that it is made to endure the pressure, temperature, and climatic conditions that are stipulated. Summary A thorough understanding of 몭uid dynamics, engineering, materials science, and heat transfer concepts is necessary for the intricate process of designing a STHE. An e몭ective heat exchanger is an essential part of many industrial processes because it can have a big impact on system performance and energy e몭ciency. At Waterman Engineers Australia, we serve a variety of sectors with our expertise in the design, manufacture, and installation of STHE. We can help you whether you work in the oil and gas, petrochemical, fertiliser, speciality chemical, compressor, or FPSO (Floating Production Storage and O몭oading) industries. Our experience encompasses both tiny units, under 5 m², and large heat exchangers, up to 7500 m². From 6″ pipes to about 2.5 metres, we provide a wide range of shell diameters and tube lengths up to 13.5 metres. Among the TEMA

6. about 2.5 metres, we provide a wide range of shell diameters and tube lengths up to 13.5 metres. Among the TEMA types that we are familiar with are BEM, AES, AET, AEU, AEW, BEP, AKU, DEU, CEU, AFU, NEN, BJ21S, BJ12U, CKU, and others. We have several di몭erent types of process exchangers in our portfolio, such as electric heaters, hairpin, falling 몭lm, continuous 몭n, reboilers, condensers, and coolers. With a dedication to quality and in-depth knowledge of heat exchanger design, we are your reliable partner in guaranteeing e몭ective heat transfer for your particular industrial requirements. For all of your shell and tube heat exchanger needs, get in touch with Waterman Engineers Australia, and let us assist you maximise your heat transfer procedures. Yes! I am interested RELATED POSTS Biological Wastewater Treatment Systems -Natural Endogenous Respiration Vessel (NERV) Best Practices for Operation & Maintenance of Tailings Storage Facilities for Wastewater Treatment Pharma-Grade Water Plant Demand in Pharmaceutical Industry Biological Wastewater Treatment Systems Overview Due to rising population needs for clean and safe water supplies, biological wastewater treatment systems... read more  Tailings storage facilities (TSFs) are engineered to serve as depositories of the residual substances generated from industrial operations, speci몭cally... read more  The pharmaceutical industry uses a wide variety of water. This includes potable water, puri몭ed water, highly puri몭ed water and... read more  Search…  RECENT POSTS Containerized Sea Water Desalination Plant / Ultra몭ltration Plant  Soft Drink Manufacturing Plant  Heavy Metal Removal from Mining Dam, Mining Pit Wastewater 

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