In this type, the steams are separated by a wall, usually metal. Examples of these are tubular exchangers, see Figure 6, and plate exchangers, see Figure 7.
Tubular heat exchangers are very popular due to the flexibility the designer has to allow for a wide range of pressures and temperatures. Tubular heat exchangers can be subdivided into a number of categories, of which the shell and tube exchanger is the most common.
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A Shell and Tube Exchanger consists of a number of tubes mounted inside a cylindrical shell. Figure 8 illustrates a typical unit that may be found in a petrochemical plant. Two fluids can exchange heat, one fluid flows over the outside of the tubes while the second fluid flows through the tubes. The fluids can be single or two phase and can flow in a parallel or a cross/counter flow arrangement. The shell and tube exchanger consists of four major parts:
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The popularity of shell and tube exchangers has resulted in a standard being developed for their designation and use. This is the Tubular Exchanger Manufactures Association (TEMA) Standard. In general shell and tube exchangers are made of metal but for specialist applications (e.g., involving strong acids of pharmaceuticals) other materials such as graphite, plastic and glass may be used. It is also normal for the tubes to be straight but in some cryogenic applications helical or Hampson coils are used. A simple form of the shell and tube exchanger is the Double Pipe Exchanger. This exchanger consists of a one or more tubes contained within a larger pipe. In its most complex form there is little difference between a multi tube double pipe and a shell and tube exchanger. However, double pipe exchangers tend to be modular in construction and so several units can be bolted together to achieve the required duty. The book by E.A.D. Saunders [Saunders (1988)] provides a good overview of tubular exchangers.
Other types of tubular exchanger include:
Plate heat exchangers separate the fluids exchanging heat by the means of plates. These normally have enhanced surfaces such as fins or embossing and are either bolted together, brazed or welded. Plate heat exchangers are mainly found in the cryogenic and food processing industries. However, because of their high surface area to volume ratio, low inventory of fluids and their ability to handle more than two steams, they are also starting to be used in the chemical industry.
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Plate and Frame Heat Exchangers consist of two rectangular end members which hold together a number of embossed rectangular plates with holes on the corner for the fluids to pass through. Each of the plates is separated by a gasket which seals the plates and arranges the flow of fluids between the plates, see Figure 9. This type of exchanger is widely used in the food industry because it can easily be taken apart to clean. If leakage to the environment is a concern it is possible to weld two plate together to ensure that the fluid flowing between the welded plates can not leak. However, as there are still some gaskets present it is still possible for leakage to occur. Brazed plate heat exchangers avoid the possibility of leakage by brazing all the plates together and then welding on the inlet and outlet ports.
Plate Fin Exchangers consist of fins or spacers sandwiched between parallel plates. The fins can be arranged so as to allow any combination of crossflow or parallel flow between adjacent plates. It is also possible to pass up to 12 fluid streams through a single exchanger by careful arrangement of headers. They are normally made of aluminum or stainless steel and brazed together. Their main use is in gas liquefaction due to their ability to operate with close temperature approaches.
Lamella heat exchangers are similar in some respects to a shell and tube. Rectangular tubes with rounded corners are stacked close together to form a bundle, which is placed inside a shell. One fluid passes through the tubes while the fluid flows in parallel through the gaps between the tubes. They tend to be used in the pulp and paper industry where larger flow passages are required.
Spiral plate exchangers are formed by winding two flat parallel plates together to form a coil. The ends are then sealed with gaskets or are welded. They are mainly used with viscous, heavily fouling fluids or fluids containing particles or fibres.
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