Heat Exchangers

 Heat exchangers are essential components in various industrial processes. They are designed to transfer heat between two or more fluids, without allowing them to mix. This process is crucial for maintaining optimal temperatures and increasing energy efficiency. Heat exchangers can be found in a wide range of applications, including power plants, chemical plants, refrigeration systems, and even in everyday appliances like air conditioners and car radiators.

The basic principle behind heat exchangers is the transfer of thermal energy from a hot fluid to a cooler fluid. This is achieved through a combination of conduction, convection, and radiation. The fluids flow through separate channels or passages within the heat exchanger, ensuring that they remain isolated from each other. As the hot fluid passes through one set of channels, it heats up the walls of the heat exchanger. The cooler fluid, flowing through another set of channels, absorbs this heat and gets heated up in the process. The two fluids never come into direct contact, preventing any contamination or mixing.

Heat exchangers come in various designs and configurations, depending on the specific application and requirements. Some common types include shell and tube heat exchangers, plate heat exchangers, and finned tube heat exchangers. Each type has its own advantages and limitations, and the choice of heat exchanger depends on factors such as the temperature and pressure of the fluids, the desired heat transfer rate, and the available space. Regardless of the type, heat exchangers play a crucial role in many industries, helping to optimize processes, reduce energy consumption, and increase overall efficiency.

The Ins and Outs of Heat Exchangers

Heat exchangers play a vital role in the operational efficiency and effectiveness at every processing facility in which heat is essential, whether it is an oil refinery or a biomass power plant. As energy efficiency importance grows, the role of heat exchangers will become even greater, their technologies more advanced.

The idea is simple, but the system designs and inner workings of heat exchange are magnificently brilliant. Heat is generated for and in various industrial processes, and were it not for heat exchangers, massive amounts of thermal energy would be wasted. For instance, boilers combust fuels such as biomass to generate heat to produce steam for powering a turbine in producing electricity. Once that steam does its job, it still has a lot of thermal energy, some of which can be transferred via a vapor-to-liquid shell-and-tube heat exchanger to raise the boiler feedwater temperature. This serves multiple purposes, including cooling down the steam to avoid thermal shock on the boiler’s steam drum, and reducing the heat load needed to raise the temperature of the boiler feedwater. This is one of many heat exchanger applications at Koda Energy, a biomass combined-heat-and-power (CHP) plant in Shakopee, Minnesota, says Stacy Cook, general manager. Koda Energy, a partnership between Rahr Malting Co. and Shakopee Mdewakanton Sioux Community, began commercial operations in 2009 and produces 500 megawatt-hours of electricity and 2,500 Btu of thermal energy daily from agriculture waste and wood chips. The plant has only the world’s second power boiler to use wall-mounted burners to combust biomass in suspension, meaning airborne burning of biomass. About 25 percent of Koda Energy’s total electrical output is provided to Rahr Malting, slightly more than 50 percent is sold to Xcel Energy (i.e., the grid), and the remainder sustains operations at the CHP plant. And 100 percent of its thermal output is provided to Rahr Malting. The electricity and energy is used to malt barley for beer at the largest site producer of malted barley in the world. Common sources of waste heat in industry, according to Kevin McGinnis, sales director for heavy industries and mining at Kelvion—the successor to Germany-based GEA Heat Exchangers Group—include turbines, dryers, kilns, incinerators, boilers and flue gas from heaters or burners, to name a few. “In general, waste heat can be captured with various types of heat exchangers and used for various applications,” McGinnis says, “including combustion air preheating; heating a facility, plant, building or home; boiler feedwater preheating; heating a process fluid for another application; or even for the ORC process.” ORC stands for organic Rankine cycle, the thermodynamic cycle using water as a working fluid that provides 85 percent of the world’s electricity production, according to Turboden. Numerous heat exchanger companies exist, many specializing in particular types. Kelvion offers its customers one of the world’s largest product portfolios in the field of heat exchangers, McGinnis says. “It includes individual solutions for practically all conceivable applications and complex environmental conditions, including plate, shell-and-tube, finned-tube and refrigeration heat exchangers, and modular cooling tower systems.” Another big name in heat exchange is Alfa Laval. Wes Crozier, product manager, has been with the Sweden-based company for nearly 30 years in various roles. “In the area of heat transfer, we have gasketed plate heat exchangers for liquid-to-liquid and vapor-to-liquid, air coolers for air-to-liquid, fully welded heat exchangers for high pressures and temperatures, a specialty spiral heat exchanger for extreme fouling services, as well as more niche products,” Crozier says. Netherlands-based HeatMatrix developed what Paul van Dillen, director of global sales and marketing, calls a new generation air-preheater that enables heat recovery from corrosive or fouling gas streams from biomass boilers, refinery furnaces, heaters, ovens or dryers. “This innovative heat exchanger consists of lightweight, corrosion resistant polymer modules, which can be applied at high temperatures and is ideally suited for waste heat recovery from flue gases that are corrosive or have fouling in it,” van Dillen says. HeatMatrix only designs and supplies air-to-air heat exchangers, often used to preheat air from waste heat flue gas streams. At Koda Energy, another shell-and-tube heat exchanger, called a surface condenser, condenses steam flow on the turbine exhaust, Cook says. “The exhaust enters the condenser and puts a vacuum on the exhaust to allow the turbine to run more efficiently,” he says. In addition, a boiler economizer uses combustion gases leaving the boiler to further elevate the feedwater temperature before entering the steam drum on the boiler. “In general, the economizer adds 10 percent efficiency,” Cook says. “We’re taking every opportunity to capture heat.” Kelvion manufactures a welded plate heat exchanger that can be used as a small vacuum condenser or traditional fin/fan technology to serve as an air-cooled condenser. “With our global footprint, we manufacture steam surface condensers and feedwater heaters, both of which are used in the steam cycle,” McGinnis says. “With waste heat generating steam for a steam turbine, Kelvion has all the exchangers in the steam process.” Alfa Laval’s Niagara Wet Surface Air Cooler can also be used to condense the vacuum exhaust steam from the turbine. “The ability to efficiently condense the turbine exhaust steam at low absolute pressures allows for more power generation,” Crozier says. “This is accomplished by a single approach to the ambient wet bulb temperature for cooling.” The prime heat mover at Koda is a very large plate-and-frame heat exchanger. This uses propylene glycol as thermal fluid to transfer heat via piping to Rahr Malting. Then, a similar but smaller unit takes even more leftover Btu from condensate from the steamed glycol heater to gain another 3 percent efficiency. “This was sized to capture the available Btu that were being wasted,” Cook says. “We’re capturing those and putting them back into glycol and useful sales.” Crozier says plate heat exchangers can have a heat transfer coefficient up to four times greater than shell and tube. This, along with its construction, means the footprint can be just 20 percent needed for a shell and tube. “The size advantage is achieved through embossing plates with carefully designed patterns, many of which are patented,” Crozier says. “This embossing creates channels for the fluids to ensure maximum turbulence. This results in maximum efficiency in transferring heat from one medium to the other. In addition, many of our designs are fully counter current, which allow temperature crosses where the outlet temperature of the hot side can be cooler than the outlet temperature of the cold side—very difficult to do with other types of heat exchangers.” Higher temperatures and pressures are being achieved in compact plate heat exchangers, McGinnis says, through new welding technology Kelvion uses, offering alternate designs to traditional shell-and-tube solutions. “Efficiency gains are realized through more effective channel geometries with built-in enhancements,” McGinnis says. Additional plate-and-frame heat exchangers are utilized at Koda for cooling applications, mostly for equipment health. Pumps handle high-temperature liquids, and a portion of these liquids is used in a mechanical shaft seal, so heat is shed to the cooling tower before reaching the pumps so as to not burn up the seals. Another application is to cool the turbine lube oil using circulating water from the cooling tower. “This keeps the turbine lube oil at an acceptable temperature,” Cook says. “We’re running 900-pound steam through the turbine and we need to keep the shaft lubed. If the oil heats up to 900 degrees, it will decompose.” McGinnis says Kelvion has a specialty for cooling the rotating equipment associated with waste heat to energy, manufacturing a range of extended surface shell and tubes and compact plate heat exchangers. Koda also employs a liquid-to-air, radiant air heater using glycol heat to preheat combustion air to avoid acid dew-point corrosion. “If the air temperature drops too low prior to the tubular air heater, it will condense out acid gases on the flue gas side,” Cook says. The plant also uses an air-to-air heat exchanger, called a tubular air heater, which captures waste heat in flue gas. Van Dillen says the heat transfer properties of HeatMatrix’s air-to-air polymer technology, used to capture flue gas heat, is very good in comparison to other, more conventional technologies because of its compactness, thin tube wall, strong honeycomb structure, and 100 percent counter flow. Kelvion’s finned-tube heat exchanger options for air-to-air or air-to-liquid applications include two major types—compact/plate fin coils and spiral-finned tubes—but also finned elliptical tubes. “A specific difference we offer on our spiral fins is our patented ‘groovy’ fin for our spiral-finned tubes,” McGinnis says. “The ‘groovy’ fin enhances heat transfer by turbulating the air more than a regular spiral fin can, which results in better heat transfer and a smaller coil size, making it ideal for replacement coils or in situations where a smaller footprint is needed.” Just like the medium flowing through heat exchangers, technology advancements in the field continue to move the needle. Van Dillen says he believes HeatMatrix’s polymer bundle technology will be a game changer in the industry. While the company currently only manufactures air-to-air exchangers, he says air-to-liquid polymer designs are now under development. “This will be the next focus for HeatMatrix in this field,” van Dillen says. Alfa Laval’s latest patented design, the CurveFlow, is for asymmetrical ports and features a new fluid distribution pattern that Crozier says lowers pressure drop, or increases efficiency with the same pressure drop. “We have also introduced a new method to secure gaskets to plates without glue being required,” he says. The company continues to develop new patterns used on various plates to increase efficiency vs. pressure drop, reduction of material thickness while maintaining pressure capabilities, applying new construction materials for plates and gaskets, as well as special unit types for specific applications. “Unlike the traditional shell-and-tube ‘one design type fits all,’ the Alfa Laval frames have been drastically improved,” Crozier says, “with better ways to open and close the units, studded ports that are in-place rather than nozzles, and bearing boxes that reduce resistance during tightening of bolts.” McGinnis says in finned-tube technology, Kelvion continues to produce advancements in dry-air cooling in both fin- and tube-side augmentation, fan efficiency increases, and reduced noise footprint. “The future of dry-air-cooled heat exchange is small, incremental improvements that benefit everyone involved,” McGinnis says. “The future of heat exchange is using greater thermal efficiencies through more efficient use of pressure drop, flow distribution, and effective use of proper channel hydraulic diameters based upon application suitability.” http://biomassmagazine.com/articles/13799/the-ins-and-outs-of-heat-exchangers

Heatric wins Bergading heat exchanger contract

Heatric Ltd has been awarded a contract to supply its unique printed circuit heat exchangers (PCHEs) for the Bergading Central Processing Platform (CPP) in the North Malay Basin, Malaysia.
The platform is currently being constructed under an EPCIC contract awarded to Hyundai Heavy Industries of South Korea. The Heatric PCHEs will be part of a 20 000 t (topsides) installation which, once commissioned, will be fed by up to thirteen well-head platforms.
Heatric is to supply seven exchangers in all, including three designs of compression aftercooler and a gas/gas exchanger. Together they will weigh 150 t.
The core matrices of the after-coolers will be manufactured from Duplex stainless steel to increase resistance to corrosion from acid process gases. The design of the 30 t gas/gas exchanger will feature a pair of six-metre-long diffusion-bonded cores with direct glycol injection into each of the unit’s numerous flow channels.
The Heatric PCHEs will be delivered by 5 September 2015.

http://www.energyglobal.com/upstream/exploration/13032015/Heatric-Bergading-heat-exchanger-contract-616/

The Global Heat Exchangers Market to Reach US$18.04 billion by 2020: Transparency Market Research

Transparency Market Research has recently published a research report titled “Heat Exchangers Market - Global Industry Analysis, Market Size, Share, Growth, Trends and Forecast 2014 - 2020”. The market was worth US$11.86 billion in 2013 and it is estimated to reach US$18.04 billion in 2020, increasing at a CAGR of 6.02% from 2013 to 2020.

Browse Report: http://www.transparencymarketresearch.com/heat-exchanger-market.html
The global heat exchangers market is evaluated on three fronts: product type, end-users, and region. The report provides an in-depth analysis of every aspect of the heat exchangers market.
Request Sample Report: http://www.transparencymarketresearch.com/sample/sample.php?flag=S&rep_id=1302
Segmentation of Global Heat Exchangers Market
Based on product type, air cooled heat exchangers, plate and frame heat exchangers, shell and tube heat exchangers, and others are the segments of heat exchangers market. The shell and tube heat exchangers is expected to dominate the heat exchangers market by 2020, owing to the increasing number of infrastructure and oil field development projects planned globally.
Press Release: http://www.transparencymarketresearch.com/pressrelease/heat-exchanger-market.htm
By end-users, the heat exchangers market is classified into heating, ventilation, and air conditioning market, chemicals market, power generation market, and others. The speedy growth in HVAC market with vigorous capacity additions in both the hydrocarbons and power sectors are expected to trigger demand for heat exchangers.
Regionally, North America, Europe, Asia Pacific, and Rest of the World are the main markets for heat exchangers. Asia Pacific held around 33.6% of the overall heat exchangers market share in 2013, which was valued at US$3.94 billion. This region is likely to reach US$6.12 billion, increasing at a CAGR of 6.34% from 2014 to 2020.
Other Report:

• Lubricant Additives Market: http://www.transparencymarketresearch.com/lubricant-additives-market.html
• Compressed Natural Gas Market: http://www.transparencymarketresearch.com/compressed-natural-gas.html

Major Players in Global Heat Exchangers Market
The key players of heat exchangers market are Alfa Laval Corporate AB, Doosan Heavy Industries and Construction Co., Ltd., Spx Corporation, and Hisaka Works, Ltd.
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http://www.businesswire.com/news/home/20150122005537/en/Global-Heat-Exchangers-Market-Reach-US18.04-billion#.VM3EwCxzvLU

Heat Exchanger Market Trends and 2019 Forecasts in New Research Reports

MarketReportsOnline.com adds "Global Heat Exchanger Market: Trends and Opportunities (2014-2019)" industry research report to the energy and power as well as manufacturing and construction business intelligence sections of its online library.

The report titled Global Heat Exchanger Market: Trends and Opportunities (2014-2019) assesses the sizing and growth of the heat Exchanger market, the growth of various types of heat exchangers, and market segmentation based on various parameters and factors. The report provides a comprehensive overview of major market drivers, restraints, opportunities, key issues in the market and challenges faced by leading players in the industry. Further, key players like Alfa Laval, GEA Heat Exchangers, Danfoss and Xylem Inc. are analyzed in the report.

Heat Exchanger Market Segment Coverage of this report includes: Plate and Frame Type, Shell and Tube, Cooling Towers, Air Cooled Heat Exchangers and Other Heat Exchangers.

Industry Coverage of Heat Exchangers discussed in this research include: Chemical Industry, HVAC & Refrigeration, Food & Beverage Industry, Oil and Gas, Power Generation and Automotive.

Regional Coverage of this heat exchanger market research report include North America, Asia Pacific and Europe.

Supported with 1 table and 53 figures on the global heat exchanger market, this 2014-2019 research report can be purchased online at http://www.marketreportsonline.com/contacts/purchase.php?name=390048 .

Heat Exchangers are used to transfer heat between two or more fluids, between a solid surface and a fluid, or between solid particulates and a fluid, at different temperatures and in thermal contact. Heat Exchangers are an integral part of many businesses which includes industries, buildings, power generation and transport. The market for heat exchangers has been segmented on the basis of types and applications with major types including shell and tube heat exchangers and plate heat exchangers and major application areas being chemical industry, oil and gas industry, HVAC, food and beverage and power generation amongst the others.

The global Heat Exchanger market has been witnessing phenomenal growth over the past few years and the market is expected to continue its growth momentum in the near future due to worldwide energy infrastructure expansion, increased demand from nuclear power sector, as well as a growing emphasis on reducing heat energy costs by increasing energy efficiency. New emerging technologies and regulations in certain regions have also helped in the growth of the industry.

Regional Analysis of the heat exchanger market reveals that Asia Pacific is the fastest growing region in terms of demand of heat exchangers whereas China is experiencing the highest demand globally, mainly due to new manufacturers entering the industry. European Union is also showing abundant signs of improvement and this can be seen from the statistics of rising demand of heat exchanger.

However, with immense growth opportunities, the heat exchanger market faces the challenges in terms of rising competition from new entrants, cost of replacing old models and rising energy cost. Due to rising environmental concerns many industries are adopting high-end energy-saving heat exchangers to mitigate the loss of their revenue, which is largely due to the rise in the cost of energy.

Comprehensive table of contents and more on the Global Heat Exchanger Market: Trends and Opportunities (2014-2019) research report is available at http://www.marketreportsonline.com/390048-toc.html .

On similar lines, the Global Database of the Top 1000 Power Boiler and Heat Exchanger Producers - Company Names, Financial Performance, Key Executives, and Contact Details market research report is an invaluable database resource for industry executives, marketing, sales and product managers, analysts, and other people looking for key company information in readily accessible and clearly presented format. The database is essential for companies who want to find out more about the leading players on the market or to find and contact potential customers and partners. This vital database contains the following information about the companies (when available):

Company name

Financial data

Number of employees

Contact details (address, phone, fax, email, web site)

Names of the key executives

Complete report is available at http://www.marketreportsonline.com/348981.html .

The Power Boiler and Heat Exchanger Manufacturing Industry in the U.S. and its International Trade [2014 Q3 Edition] contains analysis on the industry's key financial data, competitive landscape, shipment and inventory data, upstream and downstream industries, and trade data. The report's 165 pages and over 150 charts and tables cover the domestic market, global market and overseas growth opportunities. Find the latest data on shipments, inventory, international trade, and essential industry price indices available through July 2014. Relying on over a decade of historic data and sophisticated forecasting, the report projects industry trends through 2018. The report's broad scope includes topics from foreign trade to industry structure, while also diving into the details such as market sizes of products and players. Industry experts consistently subscribe to this quarterly-updated market research report. The industry's revenue for the year 2013 was reported at $6.4 billion USD, with an estimated gross profit of 26.53%. Import was valued at $1.7 billion USD from 68 countries. The industry also exported $1.7 billion USD worth of merchandise to 158 countries. Adding import value to and subtracting export value from the industry's shipment value, the total domestic demand for the industry in 2013 was $6.3 billion USD. Read more at http://www.marketreportsonline.com/350509.html .

Explore more energy and power market research as well as other newly published reports by Daedal Research at http://www.marketreportsonline.com/publisher/daedal-research-market-research.html .

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http://www.prnewswire.com/news-releases/heat-exchanger-market-trends-and-2019-forecasts-in-new-research-reports-286993791.html

Acquisition of GEA Heat Exchangers by Triton is finalised

Triton has finalised its acquisition of GEA Heat Exchangers, taking over all companies in the former group, as well as all staff.

According to the company, the heat exchanger business will be further developed, as part of an autonomous group, under the aegis of the new investor:
Christoph Michel, CEO of GEA Heat Exchangers Group, welcomes the new situation: “In Triton, we have a trustworthy partner that will strengthen and support our future activities.” Except for a new brand name that will be rolled out mid-term, he explains, nothing will change for the customers of GEA Heat Exchangers as a result of the move from GEA Group to Triton: “All projects and orders will be executed as accustomed, and our customers’ familiar and trusted contact partners in Sales and Support will now as before stand at their side.”
Company positions will be further developed in markets such as power generation, exploration, chemistry and petrochemistry, food and beverages and other process industries, as well as water and air treatment. The portfolio will be developed on a more customer-oriented basis.
This process will include internal reorganisation of business units within the GEA Heat Exchangers Group, which will now – in a simplified structure – serve the market in three Segments.
One Segment will focus on the areas of climate and environment, with activities including all products for applications of HVAC technology.
The second Segment will concentrate on solutions in the area of major power-generation projects. These efforts will include wet cooling towers, dry cooling systems, filing media for cooling towers, as well as further applications.
The third Segment consists of systems and components for further heat exchanger application areas such as those in the markets of oil and gas and petrochemistry, food and beverages, marine and transportation systems. These include plate heat exchangers, finned-tube heat exchangers, as well as shell-and-tube heat exchangers, which are used in a great number and variety of processes.
This orientation will be accompanied by establishment of a new brand. An autonomous profile for our heat exchanger activities – a profile that is independent of GEA – will prove effective in future penetration of new markets.
At the same time, this corporate profile will express the values of the brand GEA that our regular customers have learned to respect, as well as the benefits of our product brands. We will continue to use the name “GEA” until introduction of the new brand.

http://www.racplus.com/news/-acquisition-of-gea-heat-exchangers-by-triton-is-finalised/8671912.article

Chillers and Heat Exchangers Enhance Looped Liquid Electronics Cooling

Advanced Thermal Solutions, Inc., ATS, has introduced a series of portable Chiller Systems and liquid-to-air Heat Exchangers for controlling fluid temperatures in looped liquid cooling systems.

The new chillers allow precise temperature control of the recirculating coolants used for managing heat in electronic equipment. Coolant temperatures are regulated by thermoelectric module or PID control, depending on the model. For fluid baths, an immersion chiller, the ATS-CHILL iM controls fluid temperature via an immersible evaporator.

Each ATS chiller is portable and readily integrates with liquid cooling systems wherever precise fluid temperatures are required. The chillers provide cooling capacity up to 600W for ensuring accurately cold fluids in labs, industrial systems, laser thermal management, and in calibration and characterization studies.

The new ATS liquid-to-air heat exchangers have the industry’s highest density of metal fins. This maximizes heat transfer from liquid to air, allowing the liquid to be cooled to lower temperatures than other exchangers can achieve. All tubes and fins are made of copper and stainless steel to accommodate a wide choice of fluids. Provided with integral fans, the ATS heat exchangers are available in a range of sizes, and heat transfer capacities up to 250W. They can be used in a wide variety of automotive, industrial, HVAC, electronics and medical applications.

Also for use with liquid cooling system, ATS now provides automatic shut-off valves. These battery-operated electronic devices detect water leaks in piping systems. If a leak is detected it automatically closes a valve to prevent water flow and sounds an alarm.

The new liquid chillers, heat exchangers and leak detectors are available direct from ATS or from its global distributors. All units can be ordered online at Qats.com or by calling Advanced Thermal Solutions: 781-769-2800.
http://www.emsnow.com/npps/story.cfm?pg=story&id=54910