Heat exchangers

Scout intake sheet

4
Challenge description

Within the heat integration cluster of the Institute for Sustainable Process Technology (ISPT), the foundation is laid for a nationally supported cross-sectoral Integrated Circular Heat Program, in which innovation and practice are actively linked. Indeed, for a large number of companies in the agro-food, paper, chemical, horticultural and food sectors, heat is the biggest energy consumer. Therefore, heat technologies need to be vastly integrated to reach a carbon neutral heat supply for all temperature levels by 2050. As this knowledge is spread through various industries and discipline, ISPT wants to present to its partners an overview of the existing technologies that are linked with the (re-)use and storage of heat. This specific scouting case will focus on heat exchangers. These technologies can be used for liquid-liquid, gas-gas or gas-liquid heat exchanges. Of interest are the material (ex: corrosion resistance), the efficiency, the capacity, the temperature and the size. The search should focus on integrated and applied systems (i.e. no lab searches on materials).

Scope
Discover Demonstrate Develop Deploy
Current known technique(s)
  • Flat plate
  • shell and tube
  • Heat pipe
  • 3d printing
Ideal outcome

An overview of all the existing heat exchangers with their specification and suppliers

Minimum viable outcome

A list of all the existing heat exchangers

Objective(s)
  • Max (working) Pressure
  • Material
  • Effectiveness
  • Max. design temperature (°C)
  • Sizing of the equipment
Constraint(s)
  • Capacity
Functions
Action = [exchange] OR [is] OR [design] OR [obtain] OR [review] OR [review] OR [know] OR [use]

Object = [heat] OR [heat exchanger] OR [heat exchanger] OR [heat transfer] OR [heat exchanger] OR [heat] OR [boiling heat transfer mechanism] OR [nanofluid]

Environment = [gas gas] OR [heat exchange] OR [tube] OR [shell] OR [flow] OR [process] OR [design] OR [fluid flow] OR [heat transfer] OR [pressure drop] OR [heat exchanger type] OR [heat transfer mechanism] OR [new concept] OR [shell] OR [algorithm] OR [industrial] OR [compact] OR [nanofluid] OR [review]
Terminology
  • HX / HEX
Case Confirmation
Confirmed by
Comments

Preliminary Results

Concept Technology Selection
1 Plate
Plate heat exchangers use the surface of plates (usually stacked) to exchange heat. They are commonly used because of their compactness, ease of production, sensitivity, easy care after set-up and efficiency. Plate type heat exchangers are widely used in process industries for gas/gas applications. Typically, these exchangers prove to be very efficient, especially as air preheaters in process furnaces or in equipment used in environmental protection.
1.1 Brazed plate heat exchanger (BPHE)

0 of 0
1.2 Gasketed plate heat exchanger (GPHE)

0 of 0
1.3 Welded plate heat exchanger (WPHE)

0 of 0
1.4 Spiral plate heat exchangers (SPHE)

0 of 0
1.5 Printed circuit heat exchanger (PCHE)

0 of 0
1.6 Pillow-plate heat exchangers (PPHE)

0 of 0
1.7 Plate and Shell heat exchanger

0 of 0
1.8 Scraped-surface heat exchangers (SSHE)

0 of 0
1.9 Wide-gap plate heat exchanger

0 of 0
1.10 Capsule-type plate heat exchanger

0 of 0
2 Shell and Tube
A shell and tube heat exchanger is a class of heat exchanger designs. It is the most common type of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-pressure applications. As its name implies, this type of heat exchanger consists of a shell (a large pressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids. The set of tubes is called a tube bundle. [Wiki](https://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger) There are different design elements that can be used in a shell and tube: - Baffles: Baffles can be used in the shell to break up or split the flow to increase transfer; some specific types are described in the technologies. - Floating headers: floating headers can be used when thermal expansion is an issue. - Tube design: specific tube design is described in the technologies.
2.1 Shell and Tube Designs (TEMA)

0 of 0
2.2 Flat tubes heat exchanger

0 of 0
2.3 Twisted tube heat exchanger

0 of 0
2.4 Multipass-type heat exchanger

0 of 0
2.5 Falling-film heat exchanger

0 of 0
2.6 Helical baffled heat exchanger

0 of 0
2.7 ROD baffled heat exchanger

0 of 0
3 Other tubular
Next to shell and tube heat exchangers, other tubular heat exchangers are presented.
3.1 Double pipe heat exchanger (DPHE)

0 of 0
3.2 Triple concentric tube heat exchanger (TCTHE)

0 of 0
3.3 Helical coil heat exchanger

0 of 0
3.4 Spiral wound heat exchanger (SWHE)

0 of 0
4 Extended or Enhanced
Extended or enhanced heat exchangers make use of design elements that enhance heat transfer, usually by etending the surface area.
4.1 Plate-fin heat exchanger

0 of 0
4.2 Finned tube heat exchanger

0 of 0
4.3 Plate-fin-and-tube heat exchanger

0 of 0
4.4 Corrugated plate heat exchanger

0 of 0
4.5 Coil wired tube heat exchanger

0 of 0
4.6 Twisted-tape tube heat exchanger

0 of 0
4.7 Rotor enhanced shell and tube

0 of 0
4.8 Metal foam heat exchangers

0 of 0
5 Regenerative
A regenerative heat exchanger, or more commonly a regenerator, is a type of heat exchanger where heat from the hot fluid is intermittently stored in a thermal storage medium before it is transferred to the cold fluid. To accomplish this the hot fluid is brought into contact with the heat storage medium, then the fluid is displaced with the cold fluid, which absorbs the heat.
5.1 Fixed matrix heat exchanger

0 of 0
5.2 Rotary heat exchanger

0 of 0
5.3 Rotating hood regenerator

0 of 0
5.4 Microscale regenerative heat exchanger

0 of 0
6 Direct contact
Direct contact heat exchangers involve heat transfer between hot and cold streams of two phases in the absence of a separating wall. Thus such heat exchangers can be classified as: - Gas – liquid - Immiscible liquid – liquid - Solid-liquid or solid – gas Most direct contact heat exchangers fall under the Gas – Liquid category, where heat is transferred between a gas and liquid in the form of drops, films or sprays.
6.1 Gas-solid heat exchangers

0 of 0
6.2 Spray column

0 of 0
6.3 Tray column

0 of 0
6.4 Bubble column

0 of 0
7 Compact
Compact heat exchangers are becoming increasingly important elements in many industrial processes, both in their original role as contributors to increased energy efficiency, and more recently as the basis for novel ‘intensified' unit operations.
7.1 Microchannel heat exchanger

0 of 0
7.2 Hollow fiber heat exchanger

0 of 0
7.3 Meso heat exchanger

0 of 0
7.4 Microjet heat exchanger

0 of 0
7.5 Marbond heat exchanger

0 of 0
8 Trends
There are some trends in heat exchangers that affect their design or material use.
8.1 3D printed heat exchangers

0 of 0
8.2 Nano fluids-based

0 of 0
8.3 Polymer heat exchangers

0 of 0
8.4 Phase change material heat exchange

0 of 0

Published 07/31/2019

Based on the case described above we have executed the first line of queries in IGOR^AI. The goal was to obtain a broad set of techniques that exchange heat. Heat exchangers can be classified in a number of ways, inclucing transfer mechanisms, type of contact, direction of flow, phases and construction. To give the broadest overview of integrated system the heat exchangers are classified based on design. 8 concepts are distinguished based on the results: 1 Plate heat exchangers 2 Shell and Tube heat exchangers 3 Other tubular heat exchangers 4 Extended or Enhanced heat exchangers 5 Regenerative heat exchangers 6 Direct contact heat exchangers 7 Compact heat exchangers 8 Trends in heat exchangers Every concept comprises multiple design types (46 in total). Within these type there are even more design possibilities for some of the heat exchangers. Below the table, short descriptions, research findings and sources per techniques are listed as well. You can use this information to get a better understanding of the techniques. During the midway meeting, we would like to discuss the techniques and concepts, determine their relevance and select the top selection that needs to be deepened in the second phase of the project. To determine which technologies are relevant to proceed to the next scouting phase you can play the technology selection game by clicking on the button below.

To determine which technologies are relevant to proceed to the next scouting phase you can play the technology selection game by clicking on the button below.

Concept Technology Selection
1 Plate
Plate heat exchangers use the surface of plates (usually stacked) to exchange heat. They are commonly used because of their compactness, ease of production, sensitivity, easy care after set-up and efficiency. Plate type heat exchangers are widely used in process industries for gas/gas applications. Typically, these exchangers prove to be very efficient, especially as air preheaters in process furnaces or in equipment used in environmental protection.
1.1 Brazed plate heat exchanger (BPHE)

0 of 0
1.2 Gasketed plate heat exchanger (GPHE)

0 of 0
1.3 Welded plate heat exchanger (WPHE)

0 of 0
1.4 Spiral plate heat exchangers (SPHE)

0 of 0
1.5 Printed circuit heat exchanger (PCHE)

0 of 0
1.6 Pillow-plate heat exchangers (PPHE)

0 of 0
1.7 Plate and Shell heat exchanger

0 of 0
1.8 Scraped-surface heat exchangers (SSHE)

0 of 0
1.9 Wide-gap plate heat exchanger

0 of 0
1.10 Capsule-type plate heat exchanger

0 of 0
2 Shell and Tube
A shell and tube heat exchanger is a class of heat exchanger designs. It is the most common type of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-pressure applications. As its name implies, this type of heat exchanger consists of a shell (a large pressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids. The set of tubes is called a tube bundle. [Wiki](https://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger) There are different design elements that can be used in a shell and tube: - Baffles: Baffles can be used in the shell to break up or split the flow to increase transfer; some specific types are described in the technologies. - Floating headers: floating headers can be used when thermal expansion is an issue. - Tube design: specific tube design is described in the technologies.
2.1 Shell and Tube Designs (TEMA)

0 of 0
2.2 Flat tubes heat exchanger

0 of 0
2.3 Twisted tube heat exchanger

0 of 0
2.4 Multipass-type heat exchanger

0 of 0
2.5 Falling-film heat exchanger

0 of 0
2.6 Helical baffled heat exchanger

0 of 0
2.7 ROD baffled heat exchanger

0 of 0
3 Other tubular
Next to shell and tube heat exchangers, other tubular heat exchangers are presented.
3.1 Double pipe heat exchanger (DPHE)

0 of 0
3.2 Triple concentric tube heat exchanger (TCTHE)

0 of 0
3.3 Helical coil heat exchanger

0 of 0
3.4 Spiral wound heat exchanger (SWHE)

0 of 0
4 Extended or Enhanced
Extended or enhanced heat exchangers make use of design elements that enhance heat transfer, usually by etending the surface area.
4.1 Plate-fin heat exchanger

0 of 0
4.2 Finned tube heat exchanger

0 of 0
4.3 Plate-fin-and-tube heat exchanger

0 of 0
4.4 Corrugated plate heat exchanger

0 of 0
4.5 Coil wired tube heat exchanger

0 of 0
4.6 Twisted-tape tube heat exchanger

0 of 0
4.7 Rotor enhanced shell and tube

0 of 0
4.8 Metal foam heat exchangers

0 of 0
5 Regenerative
A regenerative heat exchanger, or more commonly a regenerator, is a type of heat exchanger where heat from the hot fluid is intermittently stored in a thermal storage medium before it is transferred to the cold fluid. To accomplish this the hot fluid is brought into contact with the heat storage medium, then the fluid is displaced with the cold fluid, which absorbs the heat.
5.1 Fixed matrix heat exchanger

0 of 0
5.2 Rotary heat exchanger

0 of 0
5.3 Rotating hood regenerator

0 of 0
5.4 Microscale regenerative heat exchanger

0 of 0
6 Direct contact
Direct contact heat exchangers involve heat transfer between hot and cold streams of two phases in the absence of a separating wall. Thus such heat exchangers can be classified as: - Gas – liquid - Immiscible liquid – liquid - Solid-liquid or solid – gas Most direct contact heat exchangers fall under the Gas – Liquid category, where heat is transferred between a gas and liquid in the form of drops, films or sprays.
6.1 Gas-solid heat exchangers

0 of 0
6.2 Spray column

0 of 0
6.3 Tray column

0 of 0
6.4 Bubble column

0 of 0
7 Compact
Compact heat exchangers are becoming increasingly important elements in many industrial processes, both in their original role as contributors to increased energy efficiency, and more recently as the basis for novel ‘intensified' unit operations.
7.1 Microchannel heat exchanger

0 of 0
7.2 Hollow fiber heat exchanger

0 of 0
7.3 Meso heat exchanger

0 of 0
7.4 Microjet heat exchanger

0 of 0
7.5 Marbond heat exchanger

0 of 0
8 Trends
There are some trends in heat exchangers that affect their design or material use.
8.1 3D printed heat exchangers

0 of 0
8.2 Nano fluids-based

0 of 0
8.3 Polymer heat exchangers

0 of 0
8.4 Phase change material heat exchange

0 of 0

1 Plate

Back

Plate heat exchangers use the surface of plates (usually stacked) to exchange heat. They are commonly used because of their compactness, ease of production, sensitivity, easy care after set-up and efficiency. Plate type heat exchangers are widely used in process industries for gas/gas applications. Typically, these exchangers prove to be very efficient, especially as air preheaters in process furnaces or in equipment used in environmental protection.


1.1 Brazed plate heat exchanger (BPHE)

0

A brazed plate heat exchanger (BPHE) is built up from a package of corrugated stainless steel plates which are brazed together using materials such as copper and nickel. The plate package is generally sealed by front and rear plate packages to form a self contained unit. Each plate has a characteristic corrugation pattern that governs the degree of thermal efficiency and hydraulic behavior of the BPHE unit. Further, four to six apertures are placed in the corners/edges of these plates. Alternate plates are arranged at 180° to each other resulting in formation of the inlet and outlet port manifolds for the various process fluid circuits. [#ARTNUM](#article-26232-1752739663). Compactness, low volume, scalability, possibility to achieve close temperature approaches, relatively high values of the heat transfer coefficients make brazed plate heat exchangers suitable for a very wide range of applications. Plate heat exchangers are widely used for phase-change heat transfer in refrigeration, residential heating and air-conditioning applications. [#ARTNUM](#article-26232-1752739663). They are also employed in natural gas liquefaction (LNG) plants. [#ARTNUM](#article-26232-2792430176) They are used especially when corrosion can be an issue. In Brazed Plate Heat Exchangers, the brazing process eliminates gasketed joints which allows for higher design pressure and temperatures. [Source](http://www.graham-mfg.com/gasketed-and-brazed-plate-heat-exchanger-advantages)

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1.2 Gasketed plate heat exchanger (GPHE)

0

In Gasketed Plate Heat Exchangers, each heat transfer plate is fitted with an elastomeric gasket, which seals and distributes the process fluids. The heads, normally referred to as channel covers, include connections to permit the entry of the process fluid into the plate pack. [Source](http://www.graham-mfg.com/gasketed-and-brazed-plate-heat-exchanger-advantages) The plates can easily be removed for cleaning, expansion, or replacing purposes, drastically reducing maintenance costs. Gasketed Plate Heat Exchangers are limited in high fluid temperatures, by the temperature limitations of the gasket. [Source](https://www.thermaxxjackets.com/plate-and-frame-heat-exchangers-explained/) GPHE are employed in direct heating and HVAC applications.

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1.3 Welded plate heat exchanger (WPHE)

0

Welded plate heat exchangers are similar to Gasketed plate heat exchangers, but instead the plates are welded together. They are extremely durable, and are ideal for transferring fluids with high temperatures or corrosive materials. The plates are all welded together in one block, they therefore can’t be fully dismantled and the heating/cooling capacity is fixed. However, they do allow higher pressure and temperature fluids to be used so you’ll find these mostly in heavy industrial, power plants and oil refinery applications. [Source](https://theengineeringmindset.com/plate-heat-exchanger-applications/) Typical applications of module welded plate heat exchangers in the chemical industry are acid coolers, thermal oil coolers, or condensers for hydrocarbon mixtures.[#ARTNUM](#article-26241-2062888851)

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1.4 Spiral plate heat exchangers (SPHE)

0

The main advantage of the SHE is its highly efficient use of space. This attribute is often leveraged and partially reallocated to gain other improvements in performance, according to well known tradeoffs in heat exchanger design. (A notable tradeoff is capital cost vs operating cost.) A compact SHE may be used to have a smaller footprint and thus lower all-around capital costs, or an oversized SHE may be used to have less pressure drop, less pumping energy, higher thermal efficiency, and lower energy costs. The Spiral heat exchanger is good for applications such as pasteurization, digester heating, heat recovery, pre-heating (see: recuperator), and effluent cooling. For sludge treatment, SHEs are generally smaller than other types of heat exchangers. [Wiki](https://en.wikipedia.org/wiki/Heat_exchanger#Helical-coil_heat_exchangers) A SPHE consists of two sheets that are rolled around a central rod and therefore two separated concentric channels are made. The ends of the channels are sealed through welding. There are two possibilities to seal the sides of the heat exchanger: using bolts and gaskets to fasten the covering sheets to the heat exchanger or welding the covering sheets to the heat exchanger. [#ARTNUM](#article-26228-2342724403) **Research findings:** - Spiral heat exchanger is a self cleaning equipment with low fouling tendencies, easily accessible for inspection or mechanical cleaning and with minimum space requirements. [#ARTNUM](#article-26228-2065526122)

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1.5 Printed circuit heat exchanger (PCHE)

0

PCHE is a plate-type compact heat exchanger and its core is composed of thin plates (of thickness1.5–3 mm) made of alloys like stainless steel or inconel alloys [3], with flow channels etched on them by chemical etching process. The etched plates are stacked one over the other and are bonded together using diffusion bonding. These blocks are welded together to construct the core of the PCHE and the headers are connected to the core for external connections. Printed Circuit Heat Exchanger (PCHE) is a widely chosen plate type compact heat exchanger for high pressure applications.[#ARTNUM](#article-26243-2767695692) The complete microchannel heat exchangers are highly compact, typically comprising about onefifth the size and weight of conventional heat exchangers for the same thermal duty and pressure drops. PCHEs can be constructed out of a range of materials, including austenitic stainless steels suitable for design temperatures up to 800°C, and nickel alloys such as Incoloy 800HT suitable for design temperatures more than 900°C. Single units ranging from a few grams up to 100 tonnes have been manufactured. [#ARTNUM](#article-26243-1980144440) The field of applications is very varied, including specialised chemicals processing, and PCHEs are even to be found orbiting the Earth in the International Space Station! Due to the inherent flexibility of the etching process, the basic construction may readily be applied to both a wider range, and more complex integration of process unit operations. Chemical reaction, rectification, stripping, mixing, and absorption, as well as boiling and condensation, can be incorporated into compact integrated process modules.[#ARTNUM](#article-26243-1980144440)

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1.6 Pillow-plate heat exchangers (PPHE)

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The pillow plate is constructed using a thin sheet of metal spot-welded to the surface of another thicker sheet of metal. The thin plate is welded in a regular pattern of dots or with a serpentine pattern of weld lines. After welding the enclosed space is pressurised with sufficient force to cause the thin metal to bulge out around the welds, providing a space for heat exchanger liquids to flow, and creating a characteristic appearance of a swelled pillow formed out of metal. A pillow plate exchanger is commonly used in the dairy industry for cooling milk in large direct-expansion stainless steel bulk tanks. The pillow plate allows for cooling across nearly the entire surface area of the tank, without gaps that would occur between pipes welded to the exterior of the tank. [Wiki](https://en.wikipedia.org/wiki/Heat_exchanger#Helical-coil_heat_exchangers) Pillowplate heat exchangers (PPHE) are a novel heat exchanger type based on wavy pillowlike plate geometry. Typically, they are composed of parallel plates arranged as a stack. In this way, inner channels within the pillowplates alternate with outer channels between the adjacent plates, and thus, a structure with alternating inner and outer channels is arranged for the heat transfer media. In heat exchanger applications, several pillow-plates are arranged vertically as a stack, parallel to each other, with alternating channels within and between the pillow-plates. The medium inside the pillow-plates is being continuously redirected by the welding point pattern. This leads to thin boundary layers and good heat transfer performance, and hence, to lower required heat transfer area and lower investment. On the other hand, internal pressure loss also increases, leading to high operating costs for pumps and compressors. [#ARTNUM](#article-26310-2779667980)

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1.7 Plate and Shell heat exchanger

0

The plate and shell heat exchanger combines the plate heat exchanger with shell and tube heat exchanger technologies. The heart of the heat exchanger contains a fully welded circular plate pack made by pressing and cutting round plates and welding them together. Nozzles carry flow in and out of the platepack (the 'Plate side' flowpath). The fully welded platepack is assembled into an outer shell that creates a second flowpath ( the 'Shell side'). Plate and shell technology offers high heat transfer, high pressure, high operating temperature, uling and close approach temperature. In particular, it does completely without gaskets, which provides security against leakage at high pressures and temperatures. [Wiki](https://en.wikipedia.org/wiki/Heat_exchanger#Plate_and_shell_heat_exchanger) Plate-and-shell exchangers combine the pressure and temperature capabilities of a cylindrical shell with the excellent heat transfer performance of a plate heat exchanger. The round plates ensure an even distribution of mechanical loads, without the stress concentrations that occur in the corners of rectangular plates.

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1.8 Scraped-surface heat exchangers (SSHE)

0

An SSHE basically consists of a cylindrical rotating shaft (the “rotor”) within a concentric hollow stationary cylinder (the “stator”) so as to form an annular region along which the process fluid is pumped. The stator acts as the heat-transfer surface, and it is normally enclosed within another cylindrical tube which provides a gap through which a heating or cooling service fluid (for example, steam or ammonia) passes. Attached to the rotor are a number of pivoted blades, each of which scrapes the heat-transfer surface, removing processed fluid and hence allowing unprocessed fluid to come closer to the stator. A cut-away schematic of a typical SSHE is shown in the figure. Scraped-surface heat exchangers (SSHEs) are extensively used in a wide variety of industrial settings where the continuous processing of fluids and fluid-like materials is involved. They are often used in the pharmaceutical and chemical industries (for example, in dewaxing oils and producing paints); however, they are most commonly found within the food-manufacturing sector, where they are used for mixing and heating or cooling foodstuffs during processes such as sterilisation, crystallisation and gelatinisation. Unlike the simpler plate heat exchangers which are commonly used for low-viscosity process fluids, SSHEs are designed to deal with the problems that arise when processing very viscous products.[#ARTNUM](#article-26537-2014080855)

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1.9 Wide-gap plate heat exchanger

0

The wide gap heat exchanger is similar to a gasketed heat exchangers, accept that one or more of the channels are wider. It has excellent heat transfer and a compact structure with deeper corrugation, therefore,it is especially suitable for heat exchanging between fibrous and viscous materials/fluids and solid particle containing fluids.[#ARTNUM](#article-26309-2377641195).

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1.10 Capsule-type plate heat exchanger

0

The capsule-type plate heat exchanger is proposed to address high viscosity fluid which has concave and convex ellipsoidal embossing similar to half capsules[#ARTNUM](#article-26138-2503965242) and has the advantages of low pressure drop and less deposition due to the straight passages in the channels. [#ARTNUM](#article-26138-2914453957)

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2 Shell and Tube

Back

A shell and tube heat exchanger is a class of heat exchanger designs. It is the most common type of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-pressure applications. As its name implies, this type of heat exchanger consists of a shell (a large pressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids. The set of tubes is called a tube bundle. [Wiki](https://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger) There are different design elements that can be used in a shell and tube: - Baffles: Baffles can be used in the shell to break up or split the flow to increase transfer; some specific types are described in the technologies. - Floating headers: floating headers can be used when thermal expansion is an issue. - Tube design: specific tube design is described in the technologies.


2.1 Shell and Tube Designs (TEMA)

0

A shell and tube heat exchanger is a class of heat exchanger designs. It is the most common type of heat exchanger in oil refineries and other large chemical processes, and is suited for higher-pressure applications. [Wiki](https://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger) There are different design elements that can be used in a shell and tube, the Tubular Exchanger Manufacturer’s Association (TEMA) has provided standard nomenclature for describing different configurations of common shell & tube heat exchangers, as can be seen in the figure. [Source](https://www.engineeringpage.com/heat_exchangers/tema.html)

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2.2 Flat tubes heat exchanger

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Flat tube heat exchangers use flat tubes. This can result in better heat transfer, especially when other design elements, like fins or vortex generators are used. Flat tubes are often used in cooling applications. **Research findings:** The heat exchanger element with flat tubes and vortex generators gives nearly twice as much heat transfer and only half as much pressure loss as the corresponding heat exchanger element with round tubes.

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2.3 Twisted tube heat exchanger

0

A twisted (oval) tube heat exchanger is a type of heat exchanger that aims at improving the heat transfer coefficient of the tube side and also decreasing the pressure drop of the shell side. Tubes that play an important role in this heat transfer enhancement technique are made from normal round tubes. They are formed into an oval section with a superimposed twist by some special techniques. Two ends of the tubes remain round on the consideration of assembling them with the tube sheet. [#ARTNUM](#article-26126-2049240625) **Research findings:** The analyzing result shows that the twisted oval tube heat exchangers is preferred to work at low tube side flow rate and high shell side flow rate.

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2.4 Multipass-type heat exchanger

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In a multipass type heat exchanger one fluid moves through the shell multiple times, usually through the use of U-tubes. Multiple-pass shell-and-tube heat exchangers allow thermal expansion and easy mechanical cleaning, as well as longer flowpaths for a given exchanger length. In addition, the high velocities achieved for the tube fluid help increase heat transfer coefficients and reduce surface fouling. [#ARTNUM](#article-26148-1985475579) Using multipass systems, gives more flexibilty in optimising fluid velocity, pressure drop and heat transfer. Industries: - Industrial waste heat recovery solutions - Energy - Oil and gas industry - Chemical industry

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2.5 Falling-film heat exchanger

0

A falling-film heat exchanger is characterized by one fluid forming a film on the inside of a tube, while being cooled or heated from the shell side. Usually the film is facilitated by gravity (vertically), although other types do exist. It is often used as an evaporator in industry, to concentrate solutions. [Wiki](https://en.wikipedia.org/wiki/Falling_film_evaporator)

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2.6 Helical baffled heat exchanger

0

The efforts to improve the shell side flow characteristics are made using the spiral baffle plates instead of vertical baffle plates. In this type of heat exchanger, fluid contacts with tubes flowing rotationally in the shell. It could improve heat exchanger performance considerably because stagnation portions in the shell could be removed. It is proved that the shell-and-tube heat exchanger with spiral baffle plates is superior to the conventional heat exchanger in terms of heat transfer.[#ARTNUM](#article-26213-1536994987)

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2.7 ROD baffled heat exchanger

0

The ROD baffle heat exchanger can slightly enhance the shell side heat transfer coefficient with the significant reduction of pressure loss due to the shell side fluid flowing longitudinally through tube bundle, which leads to the reduction of the manufacture and running cost and in some cases to the dimensions reduction of the heat exchangers. [#ARTNUM](#article-26129-2047878495) The RODbaffle exchanger offers a solution to the vexing problem of tube failures in shell-and-tube exchangers resulting from tube vibration.

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3 Other tubular

Back

Next to shell and tube heat exchangers, other tubular heat exchangers are presented.


3.1 Double pipe heat exchanger (DPHE)

0

One of the most simple and applicable heat exchangers is double pipe heat exchanger (DPHE), also called the concentric tube heat exchanger. This kind of heat exchanger is widely used in chemical, food, oil and gas industries. Upon having a relatively small diameter, many precise researches have also hold firmly the belief that this type of heat exchanger is used in high-pressure applications. They are also of great importance where a wide range of temperature is needed. [#ARTNUM](#article-26215-2519485646) - The performance of the heat exchanger and the pressure drop are in a close interaction with the geometry. [#ARTNUM](#article-26215-2771080156)

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3.2 Triple concentric tube heat exchanger (TCTHE)

0

In the TCTHE, there are three sections: central tube, inner annular space and outer annular space. Heat transfer mediums are passed through the central tube and outer annularspace and a thermal fluid is passed through an inner annular space. The triple tube heat exchanger contributes higher heat exchanger effectiveness and more energy saving compared with double tube heat exchanger per unit length.[#ARTNUM](#article-26134-2245358019)

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3.3 Helical coil heat exchanger

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Helical coil heat exchangers contain a helical tube. They are a simpler version of a spiral wound heat exchanger. Helical coils are very alluring for various processes such as heat exchangers and reactors because they can accommodate a large heat transfer area in a small space, with high heat transfer coefficients and narrow residence time distributions. The modification of the flow in the helically coiled tubes is due to the centrifugal forces. The curvature of the tube produces a secondary flow field with a circulatory motion, which pushing the fluid particles toward the core region of the tube. Thus the application of curved tubes in heat exchange process can be highly beneficial in comparison with the straight tube. These applications can arise in the food processing industry for heating and cooling of highly viscous liquid food, such as pastes, or for products that are sensitive to high shear stresses. **Advantages:** - Heat transfer rate in helical coil are higher as compared to a straight tube heat exchanger. Compact structure. - It requires small amount of floor area compared to other heat exchangers. - Larger heat transfer surface area. **Applications:** - Heat exchangers with helical coils are widely used in industries. The most common industries where heat exchangers are used a lot are power generation plants, nuclear plants, process plants, refrigeration, heat recovery systems, food processing industries, etc. - Helical coil heat exchanger is used for residual heat removal system in islanded or barge mounted nuclear reactor system, where nuclear energy is used for desalination of sea water. - In cryogenic applications including LNG plant. [#ARTNUM](#article-26208-2593188271)

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3.4 Spiral wound heat exchanger (SWHE)

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A spiral wound heat exchanger is very compact heat exchanger composed of spiralled coils. It can be used in a shell and tube type of exchanger. They can also be used for multi-phase and multi stream applications. **Research findings:** - Spiral wound heat exchanger (SWHE) has been used as the main cryogenic heat exchanger in 90% of land-based liquefied natural gas (LNG) plants, due to the advantages of compact structure, high pressure resistance, large scaleunit, good thermal compensation performance and multi-stream heat transfer capability. [#ARTNUM](#article-26124-2748655173) - A spiral-wound heat exchanger (SWHE) has many significant advantages over other heat exchangers, such as high robustness, high effectiveness and large exchanger area per volume. As such, it has been widely used in liquefied natural gas (LNG) plants, air separation plants, petroleum plants and nuclear reactor plants. Especially in the large-scale land-based LNG plants and offshore floating LNG plants, the SWHE is the preferred choice of the main cryogenic heat exchanger. [#ARTNUM](#article-26124-2774313722)

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4 Extended or Enhanced

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Extended or enhanced heat exchangers make use of design elements that enhance heat transfer, usually by etending the surface area.


4.1 Plate-fin heat exchanger

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A plate-fin heat exchanger is a form of compact heat exchanger consisting of a block of alternating layers of corrugated fins and flat separators known as parting sheets. These heat exchangers can be made in a variety of materials such as aluminium, stainless steels, nickel, copper, etc. depending upon the operating temperatures and pressures. They are widely used in aerospace, automobile and cryogenic industries due to its compactness (i.e., high heat transfer surface area-to-volume ratio) for desired thermal performance, resulting in reduced space, weight, support structure, footprint, energy requirement and cost. Depending on the application, various types of augmented heat transfer surfaces such as plain fins, wavy fins, offset strip fins, louvered fins and perforated fins are used. They have a high degree of surface compactness and substantial heat transfer enhancement obtained as a result of the periodic starting and development of laminar boundary layers over interrupted channels formed by the fins and their dissipation in the fin wakes. [#ARTNUM](#article-26207-2013946548)

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4.2 Finned tube heat exchanger

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Finned tube heat exchangers have tubes with extended outer surface area or fins to enhance the heat transfer rate from the additional area of fins. Finned tubes or tubes with extended outer surface area enhance the heat transfer rate by increasing the effective heat transfer area between the tubes and surrounding fluid. There are several types of fins. [Source](https://www.enggcyclopedia.com/2012/03/finned-tube-heat-exchangers/) Fin and tube heat exchangers are most widely used due to the extended surface for heat transfer in many industrial applications such as waste heat recovery units, heating, ventilation, and air conditioning and refrigeration systems [#ARTNUM](#article-26132-2470079271) Several designs exist for the fins. New heat exchange tube types with higher performance have been designed, such as the 3-D finned tube, spiral finned tube, serrated finned tube, H-type finned tube, slotted finned tube and so on. [#ARTNUM](#article-26132-2900762659)

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4.3 Plate-fin-and-tube heat exchanger

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The plate fin-and-tube heat exchangers are widely used in variety of industrial applications, particularly in the heating, airconditioning and refrigeration, HVAC industries. There are many different types of geometry for heat exchangers available. Commonly they are composed of tubes, with plates perpedicular, resulting in a cross flow profile as seen in the figure. There are different types of plate-fin geometry, the most common being the plain fin, where the fins are parallel plates attached to a hot element in the form of tubes or some other shape. These fins act as a sink, absorbing the heat out of the hot element with the help of conductive heat transfer. And then dissipating this absorbed heat onto the outside environment which is at a lower temperature. [#ARTNUM](#article-26206-840680848)

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4.4 Corrugated plate heat exchanger

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The corrugated plate heat exchanger consists of a number of gasketed plates constrained between an upper carrying bar and a lower guide bar. The plates are compressed between the fixed frame and the movable frame by using many tie bolts. In addition to the plate efficiency, corrugation patterns that produce turbulent flows, it is not only cause's unmatched efficiency; it also produces a heat exchanger self-cleaning nature, which in turn reducing the fouling effect. There are several patterns possible on corrugated plates. [#ARTNUM](#article-26205-2561023270)

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4.5 Coil wired tube heat exchanger

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To enhance the mixing in a tube, and therefore improve heat transfer a wired coil helical structure can be added to the tube. [#ARTNUM](#article-26751-2519485646)

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4.6 Twisted-tape tube heat exchanger

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A twisted tape insert is one of the most efficient heat transfer enhancement methods which has a wide range ofusages due to simplicity, low cost, easy installment and routinemaintenance[79]. Generally, twisted tape performs as a continuous swirl generator which causes turbulence on flow. This leads to a better mixing of the fluid which eventually results in a higher heat transfer rate. [#ARTNUM](#article-26311-2519485646)

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4.7 Rotor enhanced shell and tube

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In order to improve heat transfer efficiency and solve the fouling problem, a new type heat exchanger whose tube inserted with plastics rotors was designed in the study. [#ARTNUM](#article-26249-2141855446)

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4.8 Metal foam heat exchangers

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Opencell porous metal foams have received attention for use in compact heat exchangers due to their increasing availability and improved thermal performance. In recent years, considerable research has been conducted on use of metallic and nonmetallic foams to further improve performance of stateoftheart heat exchangers.[#ARTNUM](#article-27304-2070465275). They can be used as an enhancement in plate or tube heat exchangers, as shell-filling material or plate material (see pictures). **Research findings:** - In this paper, open-cell aluminum foam is considered as a highly compact replacement for conventional louver fins in brazed aluminum heat exchangers.[#ARTNUM](#article-27304-1996174950) - The heat exchanger performance is one of the main contributors to the thermodynamic and cost effectiveness of the entire LNG regasification system. Within the paper, the authors discuss a new concept for a compact heat exchanger with a micro-cellular structure medium to minimize volume and mass and to increase thermal efficiency. Numerical calculations have been conducted to design a metal-foam filled plate heat exchanger and a shell-and-tube heat exchanger using published experimental correlations. The results show that the metal-foam plate heat exchanger has the best performance at different channel heights and mass flow rates of fluid. In the optimized configurations, the metal-foam plate heat exchanger has a higher heat transfer rate and lower pressure drop than the shell-and-tube heat exchanger as the mass flow rate of natural gas is increased. [#ARTNUM](#article-27304-2196335867)

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5 Regenerative

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A regenerative heat exchanger, or more commonly a regenerator, is a type of heat exchanger where heat from the hot fluid is intermittently stored in a thermal storage medium before it is transferred to the cold fluid. To accomplish this the hot fluid is brought into contact with the heat storage medium, then the fluid is displaced with the cold fluid, which absorbs the heat.


5.1 Fixed matrix heat exchanger

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In a fixed matrix regenerator, a fluid moves through a fixed bed, storing its heat in one direction. When the flow is reversed, another (or the same) fluid can take up this heat again. Phase transitions can also be used.

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5.2 Rotary heat exchanger

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Rotary heat exchangers or heat wheels are popularly used for heat recovery in many industrial and domestic applications.[#ARTNUM](#article-26250-2790684841). They employ rotary 'heat storing elements' that rotate between cold and hot streams to exchange heat. The rotor consists of large scale of heat transfer plates known as matrix. The matrix can be made of steel, ceramic, glass and plastic. The rotor rotates continuously with a constant fraction of the core in the flue gas stream and the remaining fraction in the cooling air stream. The saturated wet flue gas is cooled by the matrix, and the water vapor is condensed on the wall of the matrix as the decrease in temperature of flue gas. [#ARTNUM](#article-26250-2902036760)

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5.3 Rotating hood regenerator

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In a rotating hood regenerating, the heat storage elements are stationary, while the elements trhough which the fluids flow rotate. In principle it is the opposite from a rotary heat exchanger. **Patent findings:** Regenerative heat exchanger for heating > =2 parallel air or gas streams consists of a rotating hood over a fixed chamber of solid material for heat retention. The hood is one of a pair above and below the chamber and is divided into >=2 sections either side of a central axis. The flow area of each pair of sections is the same. These radiate from the centre where there are several concentric ducts for the various parallel gas or air streams. The hood and the central ducts are sealed from the hot exhaust gas flowing outside the hood by flexible seals. These are held in position by springs the tension of which can be adjusted. Device is of use in recovering heat from an exhaust gas stream where two or more temp. controlled air streams are required e.g. for preheating prim. and sec. air.[#ARTNUM](#article-26253-2875827312)

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5.4 Microscale regenerative heat exchanger

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When a hot fluid flows through the cell, heat from the fluid is transferred to the cell wells, and stored there. When the fluid flow reverses direction, heat is transferred from the cell walls back to the fluid. It has a multilayer grating structure in which each layer is offset from the adjacent layer by half a cell which has an opening along both axes perpendicular to the flow axis. Each layer is a composite structure of two sublayers, one of a high thermal conductivity material and another of a low thermal conductivity material.[Wiki](https://en.wikipedia.org/wiki/Regenerative_heat_exchanger) A micro-scale regenerator has been designed, analytically optimized, and fabricated. The regenerator composed of multiple layers of photoresist-nickel structure in an offset grating pattern. The offset pattern and composite structure minimizes axial conduction losses and disrupts boundary layer formation for improved heat transfer. [#ARTNUM](#article-26764-1997390424)

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6 Direct contact

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Direct contact heat exchangers involve heat transfer between hot and cold streams of two phases in the absence of a separating wall. Thus such heat exchangers can be classified as: - Gas – liquid - Immiscible liquid – liquid - Solid-liquid or solid – gas Most direct contact heat exchangers fall under the Gas – Liquid category, where heat is transferred between a gas and liquid in the form of drops, films or sprays.


6.1 Gas-solid heat exchangers

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Gas-solid heat exchange is facilitated by bed-type heat exchangers, most commonly by solid granules forming a bed.

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6.2 Spray column

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A spray tower (or spray column or spray chamber) is gas-liquid contactor used to achieve mass and heat transfer between a continuous gas phase (that can contain dispersed solid particles) and a dispersed liquid phase. It consists of an empty cylindrical vessel made of steel or plastic, and nozzles that spray liquid into the vessel. The inlet gas stream usually enters at the bottom of the tower and moves upward, while the liquid is sprayed downward from one or more levels. This flow of inlet gas and liquid in opposite directions is called countercurrent flow.[Wiki](https://en.wikipedia.org/wiki/Spray_tower) Cooling towers also use a spray-type system


6.3 Tray column

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A plate column (or tray column) is a chemical equipment used to carry out unit operations where it is necessary to transfer mass between a liquid phase and a gas phase. In other words, it is a particular gas-liquid contactor. The peculiarity of this gas-liquid contactor is that the gas comes in contact with liquid through different stages; each stage is delimited by two plates (except the stage at the top of the column and the stage at the bottom of the column). [Wiki](https://en.wikipedia.org/wiki/Plate_column) Different types of tray columns exists, such as disk and donut, sieve trays etc.


6.4 Bubble column

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A bubble column reactor is an apparatus used to generate and control gas-liquid chemical reactions. It consists of a vertically-arranged cylindrical column filled with liquid, at the bottom of which gas is inserted. [Wiki](https://en.wikipedia.org/wiki/Bubble_column_reactor)


7 Compact

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Compact heat exchangers are becoming increasingly important elements in many industrial processes, both in their original role as contributors to increased energy efficiency, and more recently as the basis for novel ‘intensified' unit operations.


7.1 Microchannel heat exchanger

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Microchannels (broadly ⩽1  mm) represent the next step in heat exchanger development. They are a particular target of research due to their higher heat transfer and reduced weight as well as their space, energy, and materials savings potential over regular tube counterparts.[#ARTNUM](#article-26150-2083412469). Microchannel heat exchangers can be used for many applications including: high-performance aircraft gas turbine engines, heat pumps and air conditioning. Microchannel heat exchangers can be produced in the same wat as printed circuits, through etching and diffusion bonding. [#ARTNUM](#article-26150-2475723589) Machining of thin metal foils with specially contoured diamond cutting tools allows the production of small and very smooth fluid microflow channels for micro heat exchanger applications. Heat exchanger plate wall thickness, as well as fin dimensions, may be carefully controlled and machined to dimensions on the order of tens of micrometers. The plates are stacked and bonded with the vacuum diffusion process to form a crossflow, platetype heat exchanger.[#ARTNUM](#article-26150-2077945856)

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7.2 Hollow fiber heat exchanger

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Hollow fiber heat exchangers are similar to shell and tube heat exchangers, however they are much more compact and have large surface areas. Usually they are formed using polymers. **Research findings:** -Despite polymer materials’ low thermal conductivities (0.1–0.4 W/m K, which is 100–300 times lower than metals), by using hollow polymer fibres with the diameters less than 100 μm, the surface area/volume ratio of polymer hollow fibre heat exchangers can be very high. This makes them extremely efficient with superior thermal performance. [#ARTNUM](#article-26752-2303822880)

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7.3 Meso heat exchanger

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Meso heat exchangers have a very large surface area density >3000 m2/m3. **Research findings:** The current investigation is concerned with the use of a heat exchanger that has a surface area density (β) of 4000 m2/m3 [#ARTNUM](#article-26534-2792620623)

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7.4 Microjet heat exchanger

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This paper describes the development of heat exchanger with microjet technology, proposed for a waste heat recovery from a range of processes. The article presents a comprehensive study on the heat transfer enhancement in prototype heat exchanger. The heat exchanger is based on multiple jet impingement on the cylindrical heat transfer surface. It comprises four coaxial pipes (a supply channel and a return channel for two fluids). The design of the heat is based on available on the market standardized materials. [#ARTNUM](#article-26216-2571195246) Its essential core is a series of plates. Impinging jets are created by introducing plates with four nozzles of 400 and 600 µm in diameter. The nozzles were created by drilling 1 mm thick plate. These plates are separated by spacers/gaskets made of PTFE. Microjet geometry can be varied by exchanging the nozzle plates and spacers of heat exchanger. [#ARTNUM](#article-26216-2278329116)

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7.5 Marbond heat exchanger

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The Marbond heat exchanger/reactor family of products is the latest truly innovative design to enter the CHE marketplace. Produced by Chart Marston at their UK factory, an ‘opened up' version of the Marbond unit is shown in Fig. 3 (scale — the unit shown is about the size of a lap-top computer with channels about 1 mm hydraulic diameter). It extends the choice of users who are looking for high integrity, highly compact units able to operate over a range of pressures and temperatures not met with more conventional gasketed or welded CHEs. The manufacturing procedures are similar to those of the PCHE (chemical etching and diffusion bonding), but the construction allows the use of small passageways, which significantly increases the porosity of the heat exchanger core. This can result, in appropriate applications, in a substantially higher area density than the PCHE. For example, a doubling of porosity, other factors being equal, results in a halving of the volume for a given surface area. The design is particularly versatile in terms of the number of passes and number of streams, and the type can be used for a wide variety of duties involving single phase liquids and gases or two phase streams, as well as for reactions. [#ARTNUM](#article-26535-1989674565)

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8 Trends

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There are some trends in heat exchangers that affect their design or material use.


8.1 3D printed heat exchangers

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By 3D printing complex structures can be made, usually of the shell and tube type heat exchangers. Common shapes that are employed are Y-type and H-type tubes, as well as spirals, but the possibilities of 3D-printed heat exchangers are almost limitless. Especially for compact heat exchangers they are interesting. **Research findings:** - In the present study, threedimensional (3D) fractaltreelike heat exchangers were designed and manufactured using 3D printing technology.[#ARTNUM](#article-26220-2884496616)

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8.2 Nano fluids-based

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In recent years, adding solid particles to a heat transfer medium has been one of the considerable techniques for increasing heat transfer rate in heat exchangers. Although they have drawn many attentions, they cause some problems such as high pressure drop, abrasion, clogging and sedimentation. But using nanofluids causes a relatively higher increase of heat transfer in comparison to solid particles. In order to tackle above-mentioned problems, nanofluids are used with solid particles which are in very small sizes and low concentrations. [#ARTNUM](#article-26217-2519485646) Adding nanoparticles to heat exchange fluids improves their thermal conductivity and improves convection. [#ARTNUM](#article-26217-2064293455)

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8.3 Polymer heat exchangers

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The conventional heat exchanger manufactured in metal (such as stainless steel, copper and aluminium) has the disadvantages in terms of weight and cost. In addition, specially treated metal heat exchangers are needed if the working fluids are corrosive. Given these considerations, it is desirable to find an alternative material for heat exchangers that can overcome these disadvantages and also acquire comparable heat exchange efficiency and be easily fabricated. This is where the use of polymer heat exchanger comes into play. With the advantages of greater fouling and corrosion resistance, greater geometric flexibility and ease of manufacturing, reduced energy of formation and fabrication, and the ability to handle liquids and gases (i.e, single and two-phase duties), polymer heat exchangers have been widely studied and applied in the field of micro-electronic cooling devices, water desalination systems, solar water heating systems, liquid desiccant cooling systems, etc. Most importantly, the use of polymer materials offers substantial weight, space, and volume savings, which makes it more economically competitive compared with exchangers manufactured from many metallic alloys. [#ARTNUM](#article-26457-2303822880)

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8.4 Phase change material heat exchange

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A phase change material (PCM) is a substance with a high heat of fusion which, melting and solidifying at a certain temperature, is capable of storing and releasing large amounts of energy. Heat is absorbed or released when the material changes from solid to liquid and vice versa; thus, PCMs are classified as latent heat storage (LHS) units. [Wiki](https://en.wikipedia.org/wiki/Phase-change_material) Phase change materials are commonly studied for storage applications, however they are also interesting for heat exchangers. Art. [#ARTNUM](#article-29666-953775078) **Research findings:** - The heat exchanger used in this work is a modular type which is similar to the shell and tube heat exchanger. The shell side is filled with Phase Change Materials (PCM) and air flow is through the tubes in the module. The modules of the heat exchanger are arranged one over other with air spacers in between each module. The air space provided in between the module increases the retention time of the air for better heat transfer. Transient Computational Fluid Dynamics modeling is carried out for single air passage in a modular heat exchanger. It shows that the PCM phase transition time in the module in which different shape of fins is adopted. The module with rectangular fins has 17.2 % reduction in solidification compared with the plain module. Then steady state numerical analysis is accomplished to the whole module having the fin of high heat transfer, so that pressure drop, flow and thermal characteristics across the module and the air spacers are determined for various air inlet velocities of 0.4 to 1.6 m/s. Art. [#ARTNUM](#article-29666-2075619204)

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Final Results

Published 09/16/2019

After the midway results meeting, 46 heat exchangers have been reviewed and deepened. The results are organised based on the concept and presented per heat exchanger comprising a description, findings, application (areas), suppliers (if applicable), images, videos, useful links and a reference list. The technology requirements are measured and shown in the [requirements table](#requirements-table). When the heat exchangers were well established in industry the limits (max pressure and temperatures) are given. When this is not the case and specific information was lacking, any values found for that technology were used to give an indication of their applicability range. Capacities of heat exchangers are not easily found, since different sizes are possible as well as parallel systems. By using the concept links below, you can quickly navigate to the concepts and their Heat exchanger descriptions.

Table of concepts:

  1. 1. Plate
  2. 2. Shell and Tube
  3. 3. Other tubular
  4. 4. Extended or Enhanced
  5. 5. Regenerative
  6. 6. Direct contact
  7. 7. Compact
  8. 8. Trends

Technology Radar
Requirements Table

1. Plate

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Plate heat exchangers use the surface of plates (usually stacked) to exchange heat. They are commonly used because of their compactness, ease of production, sensitivity, easy care after set-up and efficiency. Plate type heat exchangers are widely used in process industries for gas/gas applications. Typically, these exchangers prove to be very efficient, especially as air preheaters in process furnaces or in equipment used in environmental protection.


1.1 Brazed plate heat exchanger (BPHE)

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A brazed plate heat exchanger (BPHE) is built up from a package of (corrugated) stainless steel plates which are brazed together using materials such as copper and nickel. The plate package is generally sealed by front and rear plate packages to form a self-contained unit. Each plate has a characteristic corrugation pattern that governs the degree of thermal efficiency and hydraulic behavior of the BPHE unit. Four to six apertures are placed in the corners/edges of these plates. Alternate plates are arranged at 180° to each other resulting in the formation of the inlet and outlet port manifolds for the various process fluid circuits. Art. [#ARTNUM](#article-26232-1752739663). Compactness, low volume, scalability, possibility to achieve close temperature approaches, relatively high values of the heat transfer coefficients make brazed plate heat exchangers suitable for a very wide range of applications. They are used especially when corrosion can be an issue since the plates are available in a wide range of materials (copper, copper+, SS brazing materials). In Brazed Plate Heat Exchangers, the brazing process eliminates gasketed joints which allow for higher design pressure and temperatures. [\[Source\]](http://www.graham-mfg.com/gasketed-and-brazed-plate-heat-exchanger-advantages) They can be used with multiple phases. High turbulent flows at low flow rates can be reached due to the patterns on the plates. This also reduces the fouling within the plates. However, fouling can still occur. The brazed plate heat exchanger is permanently sealed. Due to this backflushing is required for cleaning purposes. Soft debris will be removed, weak acids can be used to enhance the cleaning. **Applications:** Art. [#ARTNUM](#article-26232-1752739663); [#ARTNUM](#article-26232-2792430176) * Refridgeration * Residential heating * HVAC * LNG plants * Dairy/food/beverage industry

1.1.1 Brazed plate heat exchanger (BPHE)
Brazed plate heat exchanger
A brazed plate heat exchanger is characterized by comprising a plurality of heat exchanger sheets and a heat exchanger frame, wherein the heat exchanger frame comprises an end plate and a bottom plate, the heat exchanger sheets are connected with the heat exchanger frame in a brazed mode, a first medium inflow hole is formed in the upper right of the end plate, a first medium outflow hole is formed in the lower left of the bottom plate, a second medium inflow hole is formed in the right lower of the bottom plate, and a second medium outflow hole is formed in the upper right of the bottom plate. After the inlet and outlet direction of the heat exchanger is improved, the flow direction of an industrial low-temperature refrigerating unit provided with the novel heat exchanger is more reasonable; after the improved heat exchanger is used, a heat exchanger pipeline is shorter and simpler. Quite a part of copper pipe materials are saved, heat exchange media flow in copper pipes, and the cost of the whole industrial low-temperature refrigerating unit is reduced.
04/15/2015 00:00:00
Link to Article
1.1.2 Brazed plate heat exchanger (BPHE)
Estimation of Thermal and Hydraulic Characteristics of Compact Brazed Plate Heat Exchangers
This thesis work presents various performance estimation methods of compact brazed plate heat exchangers (BPHE) operating in single phase, condenser, evaporator, cascaded and transcritical applications. Such methods play a vital role in development of heat exchanger selection software and during geometry parameter estimation in the new product development process. The suitability of employing commercial computational fluid dynamics (CFD) codes for estimating single phase thermal and hydraulic performance is investigated. Parametric studies are conducted on geometries of single phase fluid sections to isolate and quantify the influence of individual geometric parameters. The influence of mesh characteristics, choice of boundary conditions and turbulent flow modeling on the accuracy of the thermal and hydraulic predictions is presented. Benefits of simulation of fluid flow in entire channels and characteristics of channel flow for different geometric patterns are also presented. A computationally light, general, robust and continuous rating calculation method is developed for implementation in BPHE selection software. The pressure-enthalpy based method provides a generic rating core for various types of applications and provides extensive post processing information of the heat transfer process. General single phase thermal and hydraulic empirical correlations are developed as functions of plate geometric parameters. For facilitating better integration of the developed calculation method with other refrigeration system simulation software, first or higher order continuity is maintained in the sub-routines used for calculating local heat transfer coefficients and refrigerant properties. A new finite grid interpolation method is developed for fast and accurate retrieval of refrigerant properties. The developed method is currently implemented in SSPG7 (BPHE selection software of SWEP International AB) for supporting transcritical CO2 calculations and cascaded heat exchanger calculations. Additionally, the methods developed for single phase and two phase test data evaluation based on meta-heuristic optimization routines is also presented. The application and results of using the developed rating models for various types of calculations is summarized. Other topics such as influence of variable fluid properties on BPHE rating calculations, influence of multi-pass flow arrangement on lumped BPHE rating calculations are briefly presented.
01/01/2013 00:00:00
Link to Article
1.1.3 Brazed plate heat exchanger (BPHE)
Experimental study on CO2 frosting and clogging in a brazed plate heat exchanger for natural gas liquefaction process
Abstract The plate-fin heat exchanger (PFHE), which has been widely used in natural gas liquefaction (LNG) industry at present, has some disadvantages such as being sensitive to the impurities in the feed gas, such as water, CO 2 and H 2 S. Compared with the PFHE, the brazed plate heat exchanger (BPHE), which has been applied in some boil off gas (BOG) recycling LNG plants of small to middle size, has simpler inherent structure and higher impurity tolerance. In this study the BPHE is suggested to replace the PFHE to simplify or even omit the massive CO 2 purification equipment for the LNG process. A set of experimental apparatus is designed and constructed to investigate the influence of the CO 2 concentration of the natural gas on solid precipitation inside a typical BPHE meanly by considering the flow resistance throughout the LNG process. The results show that the maximum allowable CO 2 concentration of the natural gas liquefied in the BPHE is two orders of magnitude higher than that in the PFHE under the same condition. In addition, the solid-liquid separation for the CO 2 impurity is studied and the reasonable separating temperature is obtained. The solid CO2 should be separated below 135 K under the pressure of 3 MPa.
04/01/2018 00:00:00
Link to Article

1.2 Gasketed plate heat exchanger (GPHE)

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In Gasketed Plate Heat Exchangers, each heat transfer plate is fitted with an elastomeric gasket, which seals and distributes the process fluids. The heads, normally referred to as channel covers, include connections to permit the entry of the process fluid into the plate pack. [\[Source\]](http://www.graham-mfg.com/gasketed-and-brazed-plate-heat-exchanger-advantages) The plates can easily be removed for cleaning, expansion, or replacing purposes, drastically reducing maintenance costs. Gasketed Plate Heat Exchangers are limited in high fluid temperatures, by the temperature limitations of the gasket. [\[Source\]](https://www.thermaxxjackets.com/plate-and-frame-heat-exchangers-explained/) [\[Hestia GPHE\]](https://www.neimagazine.com/features/featurepossibilities-for-gasketed-plate-heat-exchangers-4633881/) The GPHE can handle flows rates up to 2000 m³/hr with a duty up to 30000 kW. Suspensions with a concentration of less than 10 mg/L can be handled. Particles size smaller than 0.6 mm however, cause a rapid increase in pressure drop. Often the system is unsuitable for gas two-phase flow. The main benefit of using GPHE is the ability to easily dismantle the system. This allows for easy cleaning of the system and the flexibility to increase the heater duty of the heat exchanger during usage. Furthermore, the system is normally the most economical if applicable. **Applications:** * District heating * HVAC * Nuclear power plants