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BAOJI CHENGYUN TITANIUM INDUSTRY CO., LTD.
ADDRESS: Gaoya Industrial Park, High-Tech Development Zone, BaoJi City, ShaanXi Province, China.
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Heat Exchanger

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What is Heat Exchanger

A heat exchanger is a device used for transferring heat energy between two fluids at different temperatures. The fluids can be either gases or liquids, and the heat transfer can occur either directly or indirectly. The heat exchanger usually consists of a series of tubes or plates that are designed to provide a large surface area for the heat exchange process. Heat exchangers are commonly used in a variety of applications, ranging from heating and cooling systems to chemical processing and power generation.

Shell and Tube Heat Exchanger

Benefits of Heat Exchanger

Enhanced Energy Efficiency
Heat exchangers play a critical role in increasing energy efficiency in industrial operations. They play an important role in collecting and recycling energy that would otherwise be wasted by enabling the transmission of heat across fluids. This not only decreases total energy consumption but also lowers operational expenses, promoting industrial sustainability and economic feasibility. Because of its capacity to capture and recycle thermal energy, heat exchangers play an important role in fostering resource-efficient and cost-effective industrial practices.

Temperature Control
Accurate temperature control is critical in a wide range of industrial applications, and heat exchangers have emerged as important instruments for attaining this aim. These devices provide precise temperature adjustment by effectively regulating the heat content of fluids. Heat exchangers, whether used in cooling or heating processes, ensure that industrial activities stay within the temperature parameters prescribed. This rigorous control not only optimizes ultimate product quality but also maintains consistency, making heat exchangers indispensable for meeting demanding temperature regulations in a variety of industrial situations.

Reduced Environmental Impact
Efficient energy utilization not only improves financial outcomes but also plays an important role in promoting environmental sustainability. Heat exchangers actively contribute to reducing greenhouse gas emissions by preserving energy and reducing the need for further fuel usage. This is in line with the growing emphasis on environmentally friendly industrial practices and reflects the critical role heat exchangers play in the development of greener, more sustainable industrial processes.

Space and Weight Savings
In comparison to other heat transfer technologies, heat exchangers stand out for their small and lightweight construction. This characteristic is extremely useful in industrial facilities where space is limited, solving the issues of congested or space-constrained situations. Space utilization efficiency not only improves operational flexibility but also has a favorable impact on transportation costs and logistics. Heat exchangers' lower weight simplifies handling and transportation, adding to overall efficiency in industrial operations.

Increased Equipment Lifespan
By successfully regulating and maintaining temperatures, heat exchangers play a critical role in preserving the longevity of industrial equipment and machinery. Their ability to keep critical components working at regular and ideal temperatures saves excessive wear and tear. As a result, maintenance requirements and downtime are decreased, adding considerably to the overall dependability and efficiency of industrial operations. Heat exchangers' accuracy in temperature management acts as a protective measure, extending the life of equipment.

Versatility Across Industries
The significant benefit of heat exchangers is their amazing versatility in a wide range of industrial applications. These adaptable devices are used in a wide range of industries, from chemical processing and power generation to food and beverage manufacturing. This broad usefulness highlights heat exchangers' versatility and dependability, demonstrating their ability to address the particular thermal management demands of many sectors, making them a vital component in the current industrial environment.

What are the Applications of Heat Exchanger

At home

Around the home, they're commonly found in central heating combi boilers and help to heat and cool down the water efficiently and safely. They're also found in your refrigerator, ensuring it stays at a stable, cool temperature.

Public Spaces

You're also likely to have benefited from heat exchangers in public places. Your local swimming pool would be much colder without a heat exchanger helping to keep the water warm.Car engines produce a lot of heat and this needs to be managed effectively to prevent dangers. Cars often use a combination of fans and air flow, with fins to dissipate heat, and the use of a coolant fluid.

Industrial

Heat exchangers are also used widely in different industrial applications. This includes power generation, the manufacture and storage of food, chemical engineering, and even in the running of air and marine transport, for example.

Defence

Even in the defence sector, we find heat exchangers. They are installed, for example, on the navy surface and auxiliary ships as well as on submarines. They cool nuclear submarine propulsion motors.

Types of Heat Exchanger

Double Tube Heat Exchangers

Double tube heat exchangers use what is known as a tube within a tube structure. There are two pipes where one is built inside the other. Just like the example above, one fluid flows through the inner pipe while the second fluid flows around the first fluid in the outer pipe. This type of heat exchanger is known for being the most basic and affordable of all. Its size makes it ideal for tight spaces, allowing for some extra flexibility in the layout of the manufacturing process.

Shell and Tube Heat Exchangers

Out of all the types of heat exchangers, shell and tube heat exchangers are the most versatile. A shell and tube heat exchanger is designed with a number of tubes placed inside a cylindrical shell. The popular design of this type of heat exchanger allows for a wide range of pressures and temperatures. If you need to cool or heat a large amount of fluids or gases, the application of the shell and tube heat exchanger is an option to consider. While smaller in size compared to some of the other types, a shell and tube heat exchanger can be easily broken-down, making cleaning and repairs easy.

Tube in Tube Heat Exchangers

Similar to the other types of heat exchangers, a tube in tube heat exchanger is comprised of two tubes, one for each fluid. However, the tubes are coiled together to form an outside and inside pattern. The application for a tube in tube design can get fairly creative. Since the tubes are coiled together, most designs for this type are compact. Applications for a tube in tube heat exchanger center around high temperature and high pressure. Since it runs at a higher output, a tube in tube heat exchanger tends to have greater efficiency.

Plate Heat Exchangers

While all of the types of heat exchangers discussed so far have a similar design, the plate heat exchanger is the exception. Metal plates are used to transfer heat between two fluids. The plate is a metal shell, with spaces inside each plate that act as hallways for fluids to travel through. With a plate heat exchanger, there is a greater surface area in contact with the fluids, so it has better rates of heat transfer compared to all other types. Although plate heat exchangers can be more expensive, the efficiency gained by the design is a big plus. This type of heat exchanger is best used in places like power plants because of its durability and low repair rates.

Components of Heat Exchanger

Tubes
Tubes are the most important component of a heat exchanger, as they provide the pathways for the fluid to flow through. They are typically made of metal alloys, such as copper, stainless steel, or titanium.

Shell
The shell of a heat exchanger surrounds the tubes and provides a space for the fluid to flow around the tubes. Shells can be made of metal or other materials, such as ceramics or composites.

Baffles
Baffles are plates or sheets that are installed inside the shell to direct the flow of fluid and increase contact with the tubes. They can be arranged in various configurations, such as a cross-flow or parallel-flow design.

End caps
End caps are used to seal the ends of the tubes and prevent fluid from leaking out. They are typically made of the same material as the tubes and welded or fitted onto the ends.

Headers

Headers are used to distribute and collect the fluid entering and leaving the heat exchanger. They are often designed with multiple inlets and outlets to accommodate different flow rates or fluid types.

Fins

Fins are thin, metallic structures that are attached to the outside of the tubes to increase surface area and improve heat transfer. They are commonly used in air-cooled heat exchangers and can be arranged in different shapes and patterns to optimize performance.

Insulation

Insulation is used to reduce heat loss or gain from the heat exchanger and maintain a consistent temperature inside the shell. Various types of insulation materials, such as fiberglass or foam, can be used depending on the application.

Heat Exchanger Features

Increased efficiency
Heat exchangers can help to improve the efficiency of industrial processes by transferring heat from one fluid to another. This can lead to reduced energy consumption and costs.

Reduced costs
Heat exchangers can also help to reduce costs by reducing the amount of energy needed to heat or cool fluids.

Improved safety
Heat exchangers can help to improve safety by preventing the mixing of hazardous fluids.

Environmental protection
Heat exchangers can help to protect the environment by reducing the emission of pollutants.

How a Heat Exchanger Works

Heat exchangers, metal shells, and tubes work by transferring heat from one place to another. When a furnace burns natural gas or propane fuel, its exhaust/combustion by-products (also known as flue gas) enter and travel through the heat exchanger. The hot flue gas heats the metal as the gas makes its way to the exhaust outlet of the furnace. As this is happening, the hot metal heats the air circulating over the exterior of the heat exchanger.

Primary Heat Exchanger

This part contains the hottest flue gas, found closest to the burners in a furnace. As a result, the flame and heat subject it to the most stress, which can cause cracking and heat stress over time. Furnaces that are 70-80% efficient have one heat exchanger. The more efficient a heat exchanger is, the less energy needs to be spent heating your home. Some furnaces only have a single heat exchanger, but more efficient ones often also have a secondary heat exchanger.

Secondary Heat Exchanger

If you have a furnace that is considered high-efficiency (90%+ efficient), it contains both a primary and secondary heat exchanger. As the combustion exhaust leaves the primary heat exchanger, it travels into a secondary heat exchanger where more heat is released from the flue gas and water vapor begins to form. This change of state from water as a vapor to a liquid releases latent heat in the secondary heat exchanger, bringing the furnace to an even higher level of efficiency. This is why high-efficiency furnaces are sometimes referred to as condensing furnaces. Secondary heat exchangers are generally constructed from stainless steel or a coated steel material capable of withstanding heat, moisture, and acid.

Maintenance Tips for Heat Exchanger

Review the Manufacturer's Guidelines
Examine the heat exchanger user manual and other manufacturer documentation to gather specific instructions and recommendations for maintenance procedures, suitable chemical cleaning agents, and safety precautions. Developing a heat exchanger maintenance checklist based on these steps ensures a consistent chemical cleaning process is always followed and avoids problems such as cracked heat exchangers.

Wear Protection
Follow plant policy for personal protective equipment (PPE) such as safety goggles, gloves, and a respirator mask. Also, check any chemicals and cleaning solvent labeling or machinery for additional PPE needs.

Shut off and Isolate
Make sure all inlet valves are securely fastened and tagged. Close the supply and return water valves. Position a ball valve on the low point of the heat exchanger, which will serve as an entry point for the cleaning agent and will prevent backflow. Shutting off all valves and isolation points to stop the flow of fluids through the system ensures a safe and inactive heat exchanger during the tube cleaning process. And lockout and tagout any electrical.

Perform a Visual Inspection
A heat exchanger risk assessment checks for visible signs of damage, such as corrosion, cracks, or other abnormalities. Check for fouling or corrosion and identify the fouling to determine the optimal cleaning method. This may include chemical or mechanical cleaning or a combination of both: test inlet and outlet temperatures. Inspect tubes for damage and replace them if needed.

Release Pressure and Drain Fluids
Ensure the heat exchanger's pressure goes down using a safety relief device, checking that the pressure relief valve reads zero. Wait until the system cools before doing anything else to minimize exposure to hot fluids. High-pressure cleaning can reduce safety.

Attach Hoses
Using a descaling system, which is chemical safe, attach a circulation hose to pump fluid into the bottom and return fluid from the top. The exit point must be at the exchanger's highest point. This ensures the cleaning agent comes in contact with all interior wetted surfaces and that upper interior areas do not become air-bound with CO2 or foaming.

Our Factory

Baoji ChengYun Titanium Industry Co., Ltd., established in December 2015, is an independent legal person joint-stock private enterprise, The company is located in Baoji City, the hometown of Emperor Yan, the birthplace of Zhou and Qin culture, known as "Chencang" in ancient times, now the sub-center of Guantian Economic Development Zone. Baoji is south of Qinling Mountain, which is known as the dividing line between north and south China, north of the loess plateau in northwest China, Weihe River, a tributary of the Yellow River, passes through the city. Baoji has been the transportation hub fortress leading to northwest China since ancient times. Baoji has a long history and culture, honest folk customs, and is an important town in northwest China and a famous historical and cultural city.

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FAQ

Q: What is a heat exchanger?

A: A heat exchanger is a device used to transfer thermal energy between two or more fluids, often without them mixing.

Q: What types of heat exchangers are there?

A: There are several types of heat exchangers including shell and tube, plate, and regenerative. Each type has its own advantages and disadvantages.

Q: What are some common uses of heat exchangers?

A: Heat exchangers are used in many different industries for a variety of purposes including HVAC systems, chemical processing, food and beverage production, and power generation.

Q: What are the benefits of using a heat exchanger?

A: Heat exchangers offer many benefits including increased energy efficiency, reduced operating costs, improved system performance, and enhanced environmental performance.

Q: How can I select the right heat exchanger for my application?

A: When selecting a heat exchanger, it is important to consider the fluid types, flow rates, pressure and temperature requirements, and any specific industry requirements. Consulting with a heat exchanger specialist can help ensure the most suitable equipment is selected for your specific application.

Q: Are there any maintenance requirements for heat exchangers?

A: Routine maintenance of a heat exchanger typically involves cleaning and inspection to ensure optimal performance and prevent potential issues. It is important to follow the maintenance guidelines provided by the manufacturer.

Q: Can heat exchangers be repaired if they fail?

A: In many cases, failed heat exchangers can be repaired rather than replaced. The feasibility of repair will depend on the extent of the damage and the availability of replacement parts.

Q: Can used heat exchangers be recycled?

A: Yes, many heat exchanger components can be dismantled and recycled for scrap metal.

Q: What safety precautions should I follow when working with heat exchangers?

A: When working with heat exchangers, it is important to follow all safety guidelines provided by the manufacturer and to wear appropriate protective equipment to prevent injury.

Q: What is the life expectancy of a heat exchanger?

A: The life expectancy of a heat exchanger will depend on factors such as the type of equipment, the materials used, and how well it is maintained. Proper maintenance and cleaning can help extend the lifespan of a heat exchanger.

Q: What is a shell-and-tube heat exchanger?

A: The shell-and-tube heat exchanger is the type used in almost all industrial applications. SiC-based heat exchangers are commonly used by the chemical industry, for example, in the processing of sulfuric acid. This type of heat exchanger is popular because of its simplicity (as it has no moving parts), its inherent strength (as it is cylindrical), its ability to handle pressures greater than 30 bar and temperatures higher than 260ºC, as well as easy servicing, especially when tube bundles are removable for maintenance.

Q: How does heat transfer work in a shell-and-tube heat exchanger?

A: All heat exchangers perform essentially the same function: transferring heat from one liquid or gas to another without the fluids coming into direct contact. A shell-and-tube heat exchanger, for example, has an outer, cylindrical pressure vessel (the shell), two independent bundles of tubes that typically run longitudinally within

Q: What are the problems associated with corrosion? How are they mitigated?

A: Corrosion is the result of complex chemical reactions between the heat exchanger tubes and the fluids that circulate through them. The types and severity of corrosion vary with fluid types and the materials from which the tubes are made. The best way to mitigate corrosion is by using a material that is inherently resistant to it.
In contrast to the many other materials used as heat exchanger tubes (for example, Graphite, Hastelloy, Tantalum), Hexoloy® SiC is universally resistant to corrosion and erosion, which makes it inherently more reliable with a longer operating life. In addition, it is extremely hard and lightweight, can handle extremely high temperatures and thermal shock and its thermal conductivity is exceeded only by carbon.

Q: Should tubes in shell-and-tube heat exchangers be pressure tested?

A: All heat-exchanger tubes must be pressure-tested at the time of manufacture, even those destined for applications in which pressure is not unusually high.Among the other tests Saint-Gobain performs on its heat-exchanger tubes, each one is subjected to rigorous pressure testing at levels higher than they will experience in service. This is not just a quality-control measure but also an assurance of safety, as all applications, especially high-pressure environments, can be potentially hazardous.

Q: Why are my plates crooked when I hang them in the heat exchanger?

A: Remember, it's the thin plates inside your heat plate exchanger that make it work so well. Typically, these plates range in thickness from 0.40 mm to 0.60 mm (although they can be thicker). Some manufacturers will reinforce the areas of the plates where they contact the upper and lower bars in the heat exchanger. If these areas are NOT reinforced, the plates can bend in these areas and cause serious misalignment issues. Here is a view of the hanger areas of some plates that have been seriously compromised.

Q: How can I tell if my plates have holes in them?

A: This is a common question that we receive. While some folks have constant process measurements that would immediately notify them of a cross contamination, in other applications, the engineer may not be aware that the hot and cold fluids are mixing. If you suspect that your plate heat exchanger may be leaking hot fluid into the cold circuit or vice versa, there is a relatively simply way to find out. Isolate and drain either the hot or cold circuit on the plate heat exchanger. After this circuit is drained, if the drain is nearby the bottom piping leaving the heat exchanger, simply leave the drain open. If the drain is far away from the heat exchanger or if you have a spool installed on the bottom of the drained circuit, you could just remove the spool for visual access. Now pressurize the opposite side and watch the drain or look into the open port at the bottom of the heat exchanger. If you see process fluid, you'll know that at least some of your plates have holes in them and it's likely that all of your plates have reached the end of their useful service life.

Q: What is the difference between fouling and scaling?

A: This is a common point of confusion for plate heat exchanger owners. Fouling is a term typically used to refer to physical build up on the plates that can be easily hydroblasted or brushed off the plate surface. The most common source of fouling is biological growth from a cooling tower. Scaling is the term typically used to refer to a hard mineral build up on the surface of the plates that usually has to be removed via chemical cleaning of the plates. The most common culprits are calcium-based salts at elevated temperature.

Q: What should I do to monitor the overall health of my plate heat exchanger?

A: First, it's important to have a baseline performance from when your unit is either brand new or freshly cleaned. Don't rely on the design data sheet from the factory. Variances in flows and temperature from design to operation are a virtual certainty. If you don't have temperature and pressure gauges on the inlets and outlets of your plate heat exchanger, install them during the next outage. Record these reading when your plate heat exchanger is at a known clean stage and you're operating at a point where you expect to run most of the time.

Q: What reduces the efficiency of heat exchanger?

A: In general, fouling reduces the efficiency of the heat transfer. As the performance degrades over time, more heating duty and associated utilities are required to meet the same heating/cooling demand.Without enough airflow to carry heat away, the heat exchanger overheats in excess of safe operating temperatures. Such overheating can cause premature metal fatigue and lead to stress cracks throughout the heat exchanger.

Q: What causes heat loss in heat exchanger?

A: Fouling is one of the most common issues in heat exchangers. It occurs when solids, such as sand, algae, dirt or scale are deposited on conducting surfaces, thereby inhibiting the exchanger's ability to transfer heat from one medium to another.Typically, a plate heat exchanger is the right choice because they're the most efficient and least expensive option. Plate heat exchangers are up to five times more efficient than shell-and-tube designs. The series of gaskets in a plate-and-frame heat exchanger creates spaces and formed flow paths between plates.

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