Heat Exchanger Types and Selection

In order to achieve optimum process operations, it is essential to use the right type of process
equipment in any given process. Heat exchangers, commonly used to transfer energy from one fluid
to another, are no exception.

The selection of the proper type of heat exchangers is of critical importance. Selecting the wrong
type can lead to sub-optimum plant performance, operability issues and equipment failure.

The following criteria can help in selecting the type of heat exchanger best suited for a given process:
Application (i.e. sensible vapor or liquid, condensing or boiling)
Operating pressures & temperatures (including startup, shutdown, normal & process upset
conditions)
Fouling characteristics of the fluids (i.e. tendency to foul due to temperature, suspended
solids ...)
Available utilities (cooling tower water, once through cooling water, chilled water, steam, hot
oil...)
Temperature driving force (i.e. temperature of approach or cross and available LMTD)
Plot plan & layout constraints
Accessibility for cleaning and maintenance
Considerations for future expansions
Mechanical considerations such as: 1) material of construction; 2) thermal stresses (during
startup, shutdown; process upset and clean out conditions); 3) impingement protection
Shell-and-tube heat exchangers accounts for more than 50% of all heat exchangers
installed. However, in many cases, there are more attractive alternatives in terms of cost and energy
recovery. Any time a heat exchanger is being replaced, the opportunity should be taken to re-assess
if the type used is best for the given process. Operating changes since initial installation as well as
advancements in the field of heat transfer may point towards a different type as being optimal.
Heat Exchangers Types

Shell & tube heat exchangers
Baffle types
Segmental baffles
Double segmental baffles
No-tube-in-window (NTIW) baffles
Rod baffles
EM baffles
Helical baffles
Tube Enhancements
Twisted tubes
Low finned tubes
Tubes inserts (twisted tapes, Cal Gavin)

Compact type heat exchangers
Plate & frame heat exchangers (gasketed, semi-welded, welded)
Spiral
Blazed plate & frame
Plate-fin heat exchanger
Printed circuits

Air-cooled heat exchangers

Heat Exchangers Selection

Past experience, is always the best place to start to guide the selection of heat exchanger
types. Understanding the reasons behind both successes and failures will lead to better equipment
selection.

When comparing different types of heat transfer equipment, one must take into consideration the total
cost of the equipment which includes:

1. purchase cost
2. installation cost
3. operating cost (pumping, fan)
4. maintenance cost
In order to make the best selection, it is important to have some knowledge of the different types of
heat exchangers and how they operate. The tables below offer the advantages and disadvantages
of common types of heat exchangers. They can be used to arrive at a type that is best suited for a
given process.

Shell & tube heat exchangers
Advantages Disadvantages
Widely known and understood since it is the most
common type
Less thermally efficient than other types of heat
transfer equipment
Most versatile in terms of types of service Subject to flow induced vibration which Can
lead to equipment failure
Widest range of allowable design pressures and
temperatures
Not well suited for temperature cross conditions
(multiple units in series must be used)
Rugged mechanical construction - can withstand
more abuse (physical and process)
Contains stagnant zones (dead zones) on the
shell side which can lead to corrosion problems
Subject to flow mal-distribution especially with
two phase inlet streams


Compact Heat Exchangers
Advantages Disadvantages
Low initial purchase cost (plate type) Narrower rage of allowable pressures and
temperatures
Many different configurations are available
(gasketed, semi-welded, welded, spiral)
Subject to plugging/fouling due to very narrow
flow path
High heat transfer coefficients (3 or more times
greater than for shell & tube heat exchangers,
due to much higher wall shear stress)
Gasketed units require specialized opening and
closing procedures
Tend to exhibit lower fouling characteristics due
to the high turbulence within the exchanger
Material of construction selection is critical since
wall thickness very thin (typically less than 10
mm)
True countercurrent designs allow significant
temperature crosses to be achieved

Require small footprint for installation and have
small volume hold-up



Air Cooled Heat Exchangers
Advantages Disadvantages
Attractive option for locations where cooling
water is scarce or expensive to treat
High initial purchase cost
Well suited for cooling high temperature process
streams (above 80
o
C when using cooling water
should be avoided)
Require relatively large footprint
Low maintenance and operating costs (typically
30-50% less than cooling water)
Higher process outlet temperature (10-20
o
F
above the ambient dry bulb temperature
Differences of Shell & Tube and Plate Heat Exchanger.
What is Shell & Tube Heat Exchanger ?
Shell & Tube Heat Exchangers are the earliest and most commonly used type of heat exchangers for heat
transfer application processes. However, with the expanding technology, the trend is changing to Plate Heat
Exchangers. Surely there is a solid reason for such a change. The following explains the differences between
both heat exchanging technologies.

Item Plate Heat Exchangers Shell & Tube Exchangers
Heat Efficiency Effective and High, The U value is 3 5 times
higher
Low
Maintenance Space
requirement
10% 50% of the unit size. Twice the size of the machine to
pull the tube bundle
Ease of
Disassemble
Easy, Loosening bolts and nuts Complex, to pull out the tube
bundle
Costs Less when stainless steel/higher grade material is
being used
Higher, except in all carbon steel
construction
Fouling Low due to corrugations and inherent turbulence High due to circular cross -
sectioning and channeling
Heat Transfer
Surface
Plates can be easily added and removed, affecting
the heat transfer surface
Difficult, because the tube bundle
is fixed and not changeable
Weight and
Installation
Low, No Concrete pads required High, concrete pads are normally
required
Intermix Between
Fluids
Impossible due to gasket design on plates and high
pressure between plates
Mixable, at the welds and at the
tube sheet.
Inspection Easy Disassemble and inspection Difficult, necessary to pull the
bundle out
Chemical Cleaning Excellent due to corrugations/channels Satsifactory but need to be
careful on dead spots
Maximum Viscosity 30,000 cps nominal 10, 000 cps
Pressure Drop Low to Medium Low
Heat Loss Practically none, no insulation needed Great amount, needs insulation
Temperature
Approach
Can be designed to a 1 degree celcius approach
with more than 90% of heat recovery attainable
3-5 degree celcius minimum
approach required.
Design Sizing Computer custom designed as per application Must always oversized to be safe
Hold-Up Volume Low Very High
Operations Multiple duties possible, with each connection plate One unit required for each duty.

Contact us at heatexc@hisaka-asia.com to find out more on the applications of PHE.