New Build Tubular Heat Exchanger


New Heat Exchanger Design

hiTRAN Thermal Systems benefit any duty where the main heat transfer resistance is on the tubeside, reducing the required surface area.  Many common problems found in the design of heat exchangers can be overcome, such as:

  • Low tubeside heat transfer coefficients due to laminar flow
  • Inefficiency caused by a requirement for a single pass arrangement
  • Uncertainty of prediction in laminar and transitional flows
  • Low wall temperatures in systems with high pour points
  • High wall temperatures in systems with temperature sensitive fluids
  • Mist flow conditions in boiling systems at high vapour fraction
  • Poor shellside characteristics caused by large shell diameters (shell and tube heat exchangers)
  • High fan costs and large power requirements caused by large bundle sizes (air-cooled heat exchangers)

Benefits – New Exchanger:

  • Reduced heat transfer area
  • Effective use of pressure drop
  • Reduced number of parallel or series units
  • Reduced size and weight
  • Reduced capital cost
  • Reduced installed costs
  • Reduced operating and maintenance costs
  • Design performance maintained in many fouling services

  

 

Shell and tube exchanger comparison with and without hiTRAN® System

 

Improved design for shell and tube heat exchanger cooling heavy cycle gas oil fluid catalytic cracking unit of an oil refinery

 

DESIGN COMPARISON

PLAIN TUBE

HITRAN® ENHANCED

TEMA designation

BEM

BEM

Shell diameter (mm)

1524

689

Number of tubes

1828

371

Number of tube passes

8

1

Tube length (mm)

6096

6096

Length of flow path (m)

48.8

6.1

Tube diameter (mm)

25.4

25.4

Effective surface area (m2)

874

178.5

 

PERFORMANCE DETAILS

PLAIN TUBE

HITRAN® ENHANCED

PrandIt number (in/out)

170/3800

170/3800

Reynolds number (in/out)

306/14

306/14 190/8

Overall service co-efficient (W/M2)

40

182

Tubeside co-efficient (W/m2)

51

295

Tubeside pressure drop (kPa)

70

70

                        

BENEFITS OF HITRAN® ENHANCED SHELL AND TUBE EXCHANGER

  • Requires less than 1/4 of the effective heat transfer area
  • Achieves the same heat duty at the same pressure drop
  • Fluid residence time at the wall is reduced
  • Risk of thermal degradation fouling is lowered

 

 AIR COOLED LUBE OIL COOLER COMPARISON WITH AND WITHOUT HITRAN® SYSTEM

   

Improved design for an air-cooled lube oil cooler, installed on a gas turbine driven compressor. Heat load: 373kW

 

DESIGN COMPARISON

PLAIN TUBE

HITRAN® ENHANCED

Number of tubes

46

30

Number of rows of tubes

6

3

Tube length (mm)

7925

3350

Number of tube passes

6

1

Flow length (m)

47.55

3.35

Reynolds number

1344

687

Heat transfer rate (W/m2K) finned surface

3.29

20.95

Air rate (m/s)

2.29

3.2

Air temperature rise (°C)

6.67

15.33

Number and size of fans (mm)

2 x 2250

2 x 1250

Approximate total fan power (KW)

11.8

5.0

Plot dimensions (m)

2.74 x 8.54

2.05 x 3.95

Plot area (m2)

23.40

8.12

Finned surface (m2)

3058.3

563.2

Oil pressure drop (kPa)

71

71

Weight (kg)

8500

2200

 

BENEFITS OF HITRAN® ENHANCED AIR COOLED LUBE OIL COOLER

  • Requires only 1/3 of the plot area
  • Achieves the same heat duty at the same pressure drop
  • Uses less than 1/2 of the fan power
  • Allows flexibility to design within noise level limits
  • Lowest cost option 

 

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