Advantages/disadvantages of heat exchangers

Reference
James,W. 2000. Advantages/Disadvantages of plate heat exchangers. [Online]. [Accessed on the 9th of August 2013].Available from: http://www.onlineheatexchanger.com/news/news_detail-63.html

Compactness- The units in a plate heat exchanger occupy less floor space and floor loading by having a large surface area that is formed from a small volume. This in turn produces a high overall heat transfer coefficient due to the heat transfer associated with the narrow passages and corrugated surfaces. Flexibility- Changes can be made to heat exchanger performance by utilizing a wide range of fluids and conditions that can be modified to adapt to the various design specifications. These specifications can be matched with different plate corrugations. Low Fabrication Costs- Welded plates are relatively more expensive than pressed plates. Plate heat exchangers are made from pressed plates, which allow greater resistance to corrosion and chemical reactions. Ease of Cleaning- The heat exchanger can be easily dismantled for inspection and cleaning (especially in food processing) and the plates are also easily replaceable as they can be removed and replaced individually. Temperature Control- The plate heat exchanger can operate with relatively small temperature differences. This is an advantage when high temperatures must be avoided. Local overheating and possibility of stagnant zones can also be reduced by the form of the flow passage. Disadvantages The main weakness of the plate and frame heat exchanger is the necessity for the long gaskets which holds the plates together. Although these gaskets are seen as drawback, plate-and-frame heat exchangers have been

successfully run at high temperatures and pressures. There is a potential for leakage. The leaks that occur are sent to the atmosphere and not between process streams. The pressure drop that occurs through a plate heat exchanger is relatively high and the running costs and capital of the pumping system should be considered. When loss of containment or loss of pressure occurs, it can take a long time to clean and reinitialise this type of exchanger as hundreds of plates are common in larger builds. The narrow spacing between plates can become blocked by particulate contaminants in the fluid, for example oxide and sludge particles found in central heating systems. For the reason above most manufacturers will only guarantee their units for 12 months, furthermore replacement plate and gasket sets can be as much as the plate to buy initially.

Disadvantages/Advantages of compact plate heat exchangers

Due to their compact size, Plate Heat Exchangers (PHEs) are widely used in industrial processes. They have higher heat-transfer performance, lower temperature gradient, higher turbulence, and easier maintenance in comparison with shell and tube heat exchangers. For minimizing material consumption and space requirements compact models have been developed over the last years. By using thin plates forming a small gap, these compact models impress with larger heat transfer coefficients and, thus, smaller required heat transfer area. The advantages of compact heat exchangers over shell and tube ones at a glance: larger heat transfer coefficients smaller heat transfer surfaces required lower fouling due to high fluid turbulences (self-cleaning effect) significantly smaller required installation and maintenance space lighter weight simplified cleanability especially for GPHE lower investment costs closer temperature approach pure counter-flow operation for GPHE

Fouling and its affects

Deposits create an insulating layer over the surface of the heat exchanger that decreases the heat transfer between fluids and increases the pressure drop. The pressure drop increases as a result of the narrowing of the flow area, which increases the gap velocity (Wang et al., 2009). Therefore, the thermal performance of the heat exchanger decreases with time, resulting in an undersized heat exchanger and causing the process efficiency to be reduced. Heat exchangers are often oversized by 70 to 80%, of which 30 to 50% is assigned to fouling. While the addition of excess surface to the heat exchanger may extend the operation time of the unit, it can cause fouling as a result of the over-performance caused by excess heat transfer area; because the process stream temperature change greater than desired, requiring that the flow rate of the utility stream be reduced (Mller-Steinhagen, 1999). The deposits must be removed by regular and intensive cleaning procedures in order to maintain production efficiency. As a result of the effects of fouling on the thermal and hydraulic performance of the heat exchanger, an additional cost is added to the industrial processes. Energy losses, lost productivity, manpower and cleaning expenses cause immense costs. The annual cost of dealing with fouling in the USA has been estimated at over $4 billion (Wang et al., 2009).

Fouling in plate heat exchanger compared to shell and tube

The manner in which fouling and fouling factors apply to plate exchangers is different from tubular heat exchangers. There is a high degree of turbulence in plate heat exchanger, which increases the rate of deposit removal and, in effect, makes the plate heat exchanger less prone to fouling. In addition, there is a more uniform velocity profile in a plate heat exchanger than in most shell and tube heat exchanger designs, eliminating zones of low velocity which are particularly prone to fouling.

Fouling inside heat exchanger can be reduced by:

Appropriate heat-exchanger design Proper selection of heat-exchanger type Mitigation methods (mechanical and/or chemical) Heat exchanger surface modification/coating

http://www.geaphe.com/fileadmin/user_upload/documents/2_GEA_PHE_System/InT ech-Fouling_in_plate_heat_exchangers_some_practical_experience.pdf

Nano-composite coatings were used to reducing of fouling an inside the corrugated plate heat exchangers.

Minimizing Fouling
The rate of heat transfer surface fouling is affected by fluid velocity. Tranter recommends that the flow rate be increased if possible at regular intervals. The increased turbulence within the channel retards the rate of fouling. The frequency and duration of this preventive cleaning practice will vary depending on operating fluid velocities and fouling tendencies of the medium.

Maintaining Plate Heat Exchangers

Heat exchanger maintenance is critical for controllability and energy efficiency. Operations managers will be quick to detect a problem and contact you about it. Typical problems include interior comfort complaints, off-grade product, escalating utility bills and related troubles. Methodical diagnostics will save time and prevent wasted effort. These should be outlined in your heat exchanger operations and maintenance manuals. Dirt, deposits, scale and other fouling rob your plate-type heat exchangers of their design efficiency, risking damage to expensive equipment and unscheduled downtime for repairs.

Reference
Paul,D. 2007.Tranter Service Center Crews website. [Online]. [Accessed 14 August 2013]. Available from:http://www.tranter.com/Pages/service/maintenanceprocedures.aspx

Cleaning plate heat exchanger

Citric Acid will work, and will dissolve scale. Using a strong acid ( sulphuric or hydrochloric) is not recommended, especially HCl, as this will cause severe chloride corrosion inside the heat exchanger, especially in joints and where plates meet. I generally use Absorbic acid, as it is, for me, readily available, and makes a good descaler,

especially as I have aluminium plate heat exchangers that tend to corrode internally with plain water. If the water output is in any way going to be used directly by humans ( washing or showering) then rinsing after descaling is a good idea..

A good link for the maintenance of plate heat exchanges

http://www.syska.com/cms/docs/articles/DistrictEnergy_tredinnick_0110.pdf

References (Books)
Sandu C. and Lund D. 1983. Fouling of heat exchangers: optimum design and operation. New York. Engineering Foundation.

Mller-Steinhagen H. and Zhao Q. 1997. Investigation of low fouling surface alloys made by ion implantation technology. Germany. Elsevier Publications

Augustin, W., Geddert, T. and Scholl, S. 2007. Surface treatment for the mitigation of whey protein fouling, Proceedings of 7th International Conference on Heat Exchanger Fouling and Cleaning, Volume RP5. pp. 206-214. Portugal. ECI Symposium Series

Ethanol
Ethanol can be made from any crop or plant that contains a large amount of sugar or components that can be converted into sugar, such as starch or cellulose. As their names imply, sugar beets and sugar cane contain natural sugar. Crops such as corn, wheat and barley contain starch that can be easily converted to sugar. Most trees and grasses are made of cellulose, which can also be converted into sugar, although not as easily as starch. Most ethanol is produced using a four-step process: The ethanol feedstock (crops or plants) are ground up for easier processing; Sugar is dissolved from the ground material, or the starch or cellulose is converted into sugar; Microbes feed on the sugar, producing ethanol and carbon dioxide as byproducts; and The ethanol is purified to achieve the correct concentration. It is also possible to produce ethanol through a wet-milling process, which is used by many large ethanol producers. This process also yields byproducts such as high-fructose corn syrup, which is used as a sweetener in many prepared foods. Larry west

Reference
Larry, W. 2002. About.com website. [Online]. [Accessed on the 17 of August 2013]. Available from:
http://environment.about.com/od/ethanolfaq/f/ethanol_process.htm

Ethanol production from ethene

http://www.chemguide.co.uk/physical/equilibria/ethanol.html

This page describes the manufacture of ethanol by the direct hydration of ethene, and then goes on to explain the reasons for the conditions used in the process. It looks at the effect of proportions, temperature, pressure and catalyst on the composition of the equilibrium mixture and the rate of the reaction. The equation shows that the ethene and steam react 1 : 1. In order to get this ratio, you would have to use equal volumes of the two gases.

Because water is cheap, it would seem sensible to use an excess of steam in order to move the position of equilibrium to the right according to Le Chatelier's Principle. In practice, an excess of ethene is used.

Manufacture
There are two major industrial pathways to ethanol. Ethanol which is intended for industrial use is made by the first method, while ethanol intended for food use tends to be made by the second method. Reaction of Ethene with Steam Most of the ethanol used in industry is made, not by alcoholic fermentation, but by an addition reaction between ethene and steam.
C2H4 Ethene + H2O ==> Steam C2H5OH Ethanol

Alcoholic Fermentation A solution of sucrose, to which yeast is added, is heated. An enzyme, invertase, which is present in yeast is added and

this acts as a catalyst to convert the sucrose into glucose and fructose.,
C12H22O11 Sucrose Glucose The Fructose + H2O ==> C6H12O6 + C6H12O6

glucose, C6H12O6, and fructose, C6H12O6, formed are then converted into ethanol and carbon dioxide by another enzyme, zymase, which is also present in yeast.
zymase ==> 2C2H5OH + 2CO2 Ethanol

C6H12O6

The fermentation process takes three days and is carried out at a temperature between 250C and 300C. The ethanol is then obtained by fractional distillation.

Uses of Ethanol
Ethanol is used in the manufacture of alcoholic drinks, e.g. Vodka, etc., as a widely used solvent for paint, varnish and drugs, in the manufacture of ethanal, (i.e. acetaldehyde), and ethanoic acid, (i.e. acetic acid), as a fuel (e.g. in Gasahol), as the fluid in thermometers, and in preserving biological specimens.

http://www.ucc.ie/academic/chem/dolchem/html/comp/et hanol.html

Preparation

Ethanol is prepared as 95% alcohol (i.e. a 95% solution of ethanol in water) by distillation of the solution which results from the fermentation of sugars.

Reference
Donald, O. 2000. Ethanol Production. [Online]. [Accsessed 11th of August 2013]. Hypertext. Available from: http://www.ucc.ie/academic/chem/dolchem/html/comp/ethanol.html

Industrial Production of Ethanol from Sugar Cane (Video Link)

The industrial production of ethanol from sugar cane involves: Fermenting the sugar cane under the required conditions. Distilling the ethanol produced in fermentation from the water it is dissolved with. The distillation of ethanol can require the equivalent of half the energy released when it is burnt.

http://www.youtube.com/watch?v=y8UrDvLBsJw

The production of ethanol or ethyl alcohol from starch or sugarbased feedstocks is among man's earliest ventures into valueadded processing. While the basic steps remain the same, the process has been considerably refined in recent years, leading to a very efficient process. There are two production processes: wet milling and dry milling. The main difference between the two is in the initial treatment of the grain.

Ethanol production from the process of dry milling

In dry milling, the entire corn kernel or other starchy grain is first ground into flour, which is referred to in the industry as "meal" and processed without separating out the various component parts of the grain. The meal is slurried with water to form a "mash." Enzymes are added to the mash to convert the starch to dextrose, a simple sugar. Ammonia is added for pH control and as a nutrient to the yeast. The mash is processed in a high-temperature cooker to reduce bacteria levels ahead of fermentation. The mash is cooled and transferred to fermenters where yeast is added and the conversion of sugar to ethanol and carbon dioxide (CO2) begins. The fermentation process generally takes about 40 to 50 hours. During this part of the process, the mash is agitated and kept cool to facilitate the activity of the yeast. After fermentation, the resulting "beer" is transferred to distillation columns where the ethanol is separated from the remaining "stillage." The ethanol is concentrated to 190 proof using conventional distillation and then is dehydrated to approximately 200 proof in a molecular sieve system. The anhydrous ethanol is then blended with about 5% denaturant (such as natural gasoline) to render it undrinkable and thus not subject to beverage alcohol tax. It is then ready for shipment to gasoline terminals or retailers. The stillage is sent through a centrifuge that separates the coarse grain from the solubles. The solubles are then concentrated to about 30% solids by evaporation, resulting in Condensed Distillers Solubles (CDS) or "syrup." The

coarse grain and the syrup are then dried together to produce dried distillers grains with solubles (DDGS), a high quality, nutritious livestock feed. The CO2 released during fermentation is captured and sold for use in carbonating soft drinks and beverages and the manufacture of dry ice.

The Ethanol Production Process - Wet Milling

In wet milling, the grain is soaked or "steeped" in water and dilute sulfurous acid for 24 to 48 hours. This steeping facilitates the separation of the grain into its many component parts. After steeping, the corn slurry is processed through a series of grinders to separate the corn germ. The corn oil from the germ is either extracted on-site or sold to crushers who extract the corn oil. The remaining fiber, gluten and starch components are further segregated using centrifugal, screen and hydroclonic separators. The steeping liquor is concentrated in an evaporator. This concentrated product, heavy steep water, is co-dried with the fiber component and is then sold as corn gluten feed to the livestock industry. Heavy steep water is also sold by itself as a feed ingredient and is used as a component in Ice Ban, an environmentally friendly alternative to salt for removing ice from roads. The gluten component (protein) is filtered and dried to produce the corn gluten meal co-product. This product is highly sought after as a feed ingredient in poultry broiler operations. The starch and any remaining water from the mash can then be processed in one of three ways: fermented into ethanol, dried and sold as dried or modified corn starch, or processed into corn syrup. The fermentation process for ethanol is very similar to the dry mill process described above.

Reference
Renewable Fuels Association. 2005-2013. How ethanol is made. [Online]. [Accessed on the 15th of August 2013]. Available from: http://www.ethanolrfa.org/pages/how-ethanol-is-made#sthash.gUyL959P.dpuf