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Heat Exchanger

Company Profile

 

PIONEER GROUP was founded in 2006, covered an area of 50,000㎡and has more than 200 employees. The headquarters of PIONEER GROUP which located in Zibo city, Shandong province - a famous manufacture base of chemical equipment in RR.China, also build two new manufacturing bases in Weifang city, Shandong province and Zhangye city, Gansu province.
Glass lined and stainless steel reactor, storage tank/receiver, distillation tank , film evaporator, vacuum dryer, filter, separator, heat exchanger, condenser, column systems and various accessories. Also can specializes in GMP standard products and customized operating unit of chemical process.

 

Why Choose Us

 

 

Our Factory
PIONEER GROUP is a professional design & manufacture in chemical equipment especially in glass lined equipment with advanced technology, completed production equipment, perfect quality control system and intimate sale and after-sale service.


Our Certificate
Certification of ISO 9001:2015, Design & manufacture License of pressure vessel, 10 Certificate of Patent


Production Equipment
CNC plasma cutting machine, CNC rolling machine, Automatic submerged arc welding machine, Swagging machine, Grinding machine, PLC control underground electric furnace, Coating room, Painting room, Spark tester, Thickness indicator, RT/MT tester, Hydraulic test machine and etc.


Our Service
The R&D department welcome customization with many years experience,we can design and order all kinds of glass lined and stainless steel products and non-standard products according to the requirements of customers.

 

PPS Alloy Shell & Tube Type Heat Exchanger

 

What is Heat Exchanger?

Heat exchangers are devices that are used to transfer thermal energy from one fluid to another without mixing the two fluids. The fluids are usually separated by a solid wall (with high thermal conductivity) to prevent mixing or they may be in direct contact.
The classic example of a heat exchanger is found in an internal combustion engine in which an engine coolant flows through radiator coils and air flows past the coils, which cools the coolant and heats the incoming air. In power engineering, common applications of heat exchangers include steam generators, fan coolers, cooling water heat exchangers, and condensers. For example, steam generator is used to convert feedwater into steam from heat produced in a nuclear reactor core.

 

Type of Heat Exchanger

 

 

Double pipe heat exchangers. Double pipe heat exchangers are cheap for both design and maintenance, making them a good choice for small industries. In these exchangers one fluid flows inside the tube and the other fluid flows on the outside. Although they are simple and cheap, their low efficiency coupled with the high space occupied in large scales, has led modern industries to use more efficient heat exchangers like shell and tube.

 

Shell and tube heat exchangers. Shell and tube heat exchangers in their various construction modifications are probably the most widespread and commonly used basic heat exchanger configuration in industry. Shell-and-tube heat exchangers are further classified according to the number of shell and tube passes involved. Shell and tube heat exchangers are typically used for high-pressure applications (with pressures greater than 30 bar and temperatures greater than 260 °C). This is because the shell and tube heat exchangers can withstand high pressures due to their shape. In this type of heat exchanger, a number of small bore pipes are fitted between two tube plates and primary fluid flows through these tubes.

 

Plate heat exchangers. A plate heat exchanger is a type of heat exchanger that uses metal plates to transfer heat between two fluids. This arrangement is popular with heat exchangers using air or gas as well as lower velocity fluid flow. The classic example of a heat exchanger is found in an internal combustion engine in which an engine coolant flows through radiator coils and air flows past the coils, which cools the coolant and heats the incoming air. When compared to shell and tube exchangers, the stacked-plate arrangement typically has lower volume and cost. Another difference between the two is that plate exchangers typically serve low to medium pressure fluids, compared to medium and high pressures of shell and tube.

 

Heat Exchanger Material Selection Based on Common Criteria

Selecting the best material for heat exchanger tubes is a critical decision that depends on several factors, including the operating conditions, fluid properties, and the specific requirements of the application. The choice of material significantly influences the heat exchanger's performance, durability, and overall efficiency. Several materials are commonly used for heat exchanger tubes, each with its unique set of advantages and considerations.

Glass Lined Shell and Tube Heat Exchanger
PPS Alloy Shell & Tube Type Heat Exchanger
Stainless Steel Shell and Tube Heat Exchanger
Silicon Carbide Shell and Tube Heat Exchanger

Stainless Steel:
Stainless steel is a popular choice for heat exchanger tubes due to its excellent corrosion resistance and durability. It is particularly effective in environments where exposure to corrosive substances is a concern. The most common stainless steel alloys used for heat exchangers include 304 and 316 grades. These alloys offer good mechanical properties, high corrosion resistance, and the ability to withstand a wide range of temperatures. Stainless steel tubes are widely used in applications such as chemical processing, petrochemical, and food processing industries.

 

Copper and Copper Alloys:
Copper and its alloys, such as admiralty brass and aluminum brass, are known for their exceptional thermal conductivity. Copper tubes are efficient in transferring heat and are often used in applications where high thermal performance is crucial, such as HVAC systems and refrigeration. However, copper is susceptible to corrosion in certain environments, and the cost can be a factor in some applications.

 

Carbon Steel:
Carbon steel is a robust and cost-effective material for heat exchanger tubes. It is known for its strength and ability to withstand high temperatures and pressures. Carbon steel tubes are commonly used in industrial applications, such as power plants and chemical processing, where the emphasis is on strength and durability. However, carbon steel is more susceptible to corrosion compared to stainless steel, and corrosion-resistant coatings may be applied to enhance longevity.

 

Titanium:
Titanium offers a unique combination of high strength, low density, and excellent corrosion resistance, making it suitable for heat exchanger tubes in demanding environments. It is particularly favored in applications where exposure to seawater is a concern, such as in marine and offshore industries. While titanium is more expensive than some other materials, its performance in corrosive environments justifies its use in critical applications.

 

Nickel Alloys:
Nickel alloys, including Inconel and Monel, are known for their exceptional corrosion resistance, high-temperature strength, and resistance to thermal expansion. These alloys are commonly used in heat exchanger tubes for applications involving aggressive chemical processes and high-temperature environments. Nickel alloys are particularly suitable for industries such as petrochemical, aerospace, and pharmaceuticals.


Aluminum:
Aluminum is valued for its lightweight nature and good thermal conductivity. Aluminum tubes are often used in applications where weight is a critical factor, such as in automotive heat exchangers and air conditioning systems. While aluminum is less robust than some other materials, its advantageous combination of properties makes it a suitable choice for specific applications.

 

Duplex Stainless Steel:
Duplex stainless steel, characterized by a dual-phase microstructure of austenitic and ferritic phases, offers a balance of strength and corrosion resistance. This makes it suitable for heat exchanger tubes in applications involving corrosive fluids and high temperatures. Duplex stainless steel is often chosen for offshore and marine applications, as well as in the chemical and petrochemical industries.

 

Ceramic Tubes:
In extremely high-temperature applications, ceramic tubes may be considered. Ceramics offer excellent resistance to heat and can withstand harsh operating conditions. However, their brittleness and potential challenges in fabrication make them less common in conventional heat exchanger designs.

 

Applications and Use of Heat Exchangers

While heat-exchanger are instrumental in a variety of industries. Like in power plants, HVAC systems, chemical,

Power plants

In power plants, for example, heat exchanger are used to transfer heat from the hot exhaust gas to a fluid medium (usually water), which then becomes steam and is used to drive turbines.

HVAC systems

The heat exchangers transfer heat from the indoor air to the outdoor air or vice versa, ensuring a comfortable indoor temperature.

Silicon Carbide Shell and Tube Heat Exchanger
Cylindrical Block Type Graphite Heat Exchanger

Chemical plants

Indeed, chemical plants employ heat exchanger to regulate the temperature of chemical reactions, requiring precise temperature control.

Other industries

The use of heat-exchanger extends to many other sectors. The food and beverage industry employs them for pasteurizing milk and juice, the oil and gas industry uses them to cool and condense hydrocarbon fluids, and the automotive industry relies on them to cool engine coolant and oil.

 

Thermodynamics of Heat Exchangers
 

All types of heat exchangers operate using the same thermodynamic principles and mechanism of heat transfer. These principles basically describe how thermal energy is transferred at the macroscopic level. Three bodies are interacting in a heat exchanger system: the hot fluid, the cold fluid, and the wall separating the two fluids. Energy flows from the hot fluid, through the wall or barrier, and then into the cold fluid. The following are some thermodynamic principles that are useful to understand how heat exchangers work:

First Law of Thermodynamics

The first law is referred to as the Law of Conservation of Energy, which states that energy (in the form of heat and work) can neither be created nor destroyed. It can only be transferred to another system or converted to one form or another. In heat exchangers, this statement is translated by the heat balance equation written as:

Assuming it operates in a steady-state flow, that means that the thermal properties remain constant at all points as time changes, and the system is adiabatic (perfectly insulated), the heat balance equation simplifies to Heat In = Heat Out. This is one of the most basic equations which is used in the design and operation of heat exchangers.

Second Law of Thermodynamics:

The second law introduces the concept of entropy, the degree of disorderliness and randomness of a system. The entropy of the universe is constantly increasing and can never decrease. It tells us the direction of the flow of energy between two interacting systems in which the highest entropy is generated. Heat is always transferred from a body with higher temperatures to lower temperatures which is the natural tendency of all systems. For heat exchangers, the cold fluid gains heat and increases its temperature, and the hot fluid loses heat and decreases its temperature.

 

 

Heat Exchanger Components and Their Functions

 

 

A heat exchanger is a device used for the transfer of thermal energy, and its components are crucial in influencing the performance, safety, and lifespan of the heat exchanger. The main components and their functions are as follows:

Baffle Plate:
Located inside the shell, the baffle plate guides the flow of the medium, increasing its velocity and turbulence, thereby enhancing heat transfer efficiency.

Corrugated Tube:
A core component of the heat exchanger, the corrugated tube is primarily used to increase the heat transfer area, thus improving heat transfer efficiency. Its special corrugated shape also enhances flexibility and pressure resistance, allowing the heat exchanger to operate effectively under high pressure.

Tube Sheet:
Positioned inside the heat exchangers shell, the tube sheet fixes the pipes, preventing displacement, vibration, and wear. It also ensures the flow direction and velocity of the medium, enhancing heat transfer efficiency.

Thermal Insulation Material:
This material is employed to reduce energy loss during the heat transfer process, preventing thermal energy leakage and enhancing the heat efficiency of the heat exchanger. Common thermal insulation materials include glass wool, rock wool, and aluminum silicate fiber.

Pipe Clamp:
Used to secure pipelines, the pipe clamp prevents pipe loosening or detachment, ensuring the normal flow of the medium. Additionally, it reduces the thermal expansion and contraction of the pipes, ensuring the safety and stability of the pipelines.

Leak Detector:
The leak detector is primarily used to monitor whether leakage occurs in the heat exchanger. It promptly alarms in the event of a leak, ensuring the safety and reliability of the equipment.

 

 

How to Maintain Heat Exchangers

Importance of Cleaning Heat Exchangers
Heat exchangers play a crucial role in various industries, including HVAC systems, power plants, and manufacturing processes. They are responsible for transferring heat from one fluid to another, ensuring efficient operation and maintaining optimal performance. However, over time, heat exchangers can accumulate dirt, debris, and other contaminants, leading to reduced efficiency, increased energy consumption, and potential system failures.
Regular cleaning of heat exchangers is essential to maintain their functionality and prolong their lifespan. By removing the buildup of dirt and contaminants, the heat exchanger can operate at its maximum efficiency, resulting in cost savings and improved performance. Neglecting to clean heat exchangers can lead to decreased heat transfer efficiency, increased pressure drop, and even complete system shutdowns.

 

Overview of the Step-by-Step Guide
To help you understand the process of cleaning heat exchangers, this step-by-step guide will provide you with the necessary information and instructions. From preparing for the cleaning process to the actual cleaning techniques, this guide will ensure that you have a comprehensive understanding of how to properly clean your heat exchanger.
By following this guide, you will be able to effectively clean your heat exchanger, remove any accumulated debris, and restore its efficiency. This will not only save you money on energy costs but also prevent potential system failures and ensure the longevity of your heat exchanger.

 

Understanding Heat Exchangers
Heat exchangers are crucial components in various industrial processes and systems. They play a vital role in transferring heat from one medium to another, ensuring efficient operation and preventing overheating. Understanding the basics of heat exchangers is essential for maintaining their optimal performance and prolonging their lifespan.

Glass Lined Porous Plate Type Condenser

 

 
Our Certificate
 

Certification of ISO 9001:2015, Design & manufacture License of pressure vessel, 10 Certificate of Patent

 

20220427083423efc981ab9d014b0bad1369b38d15b7cb.jpg (900×524)

 

 
FAQ
 
 

Q: What is the purpose of a heat exchanger?

A: Heat exchangers are used to transfer heat from one medium to another. These media may be a gas, liquid, or a combination of both. The media may be separated by a solid wall to prevent mixing or may be in direct contact. Heat exchangers are required to provide heating and/or cooling to meet a process requirement.

Q: Is a heat exchanger the same as a furnace?

A: Furnaces are designed to ensure the gases emitted from them are safe to breathe. A heat exchanger is a metal shield between the combustion chamber and the blower that works to dispense heated air from the furnace into your home.

Q: What are heat exchangers HVAC?

A: Heat exchangers are used to transfer heat between the indoor and outdoor air streams while keeping them physically separated as a means of cooling the indoor air. In addition, heat exchangers can also be used to heat indoor air. These systems are called heat pumps.

Q: Do heat exchangers use electricity?

A: Electric heat exchangers have electrically resistive wires inside of the tubes (Called electric heating elements) that create heat. Temperatures can range from -260F to as high as 2500F. Electric heating elements are very efficient at transferring heat to the product flowing through the vessel.

Q: How many heat exchangers does a furnace have?

A: Furnaces that are 70-80% efficient have one heat exchanger. The more efficient a heat exchanger is, the less energy needs to be spent heating your home. Some furnaces only have a single heat exchanger, but more efficient ones often also have a secondary heat exchanger.

Q: What is the cheapest type of heat exchanger?

A: Plate and frame heat exchangers are the most economical heat exchangers of all the types available. However, the most economical choice comes with the most restrictions on the fluid to be introduced into the heat exchanger.

Q: Why do you need a heat exchanger?

A: A heat exchanger is a system used to transfer heat between a source and a working fluid. Heat exchangers are used in both cooling and heating processes. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact.

Q: How long does HVAC heat exchanger last?

A: In most cases, the heat exchanger determines how long your furnace will last. The heat exchanger is responsible for heating the air that circulates through your home in the winter. Heat exchangers usually last about 15 years.

Q: Is it worth repairing a heat exchanger?

A: So, if your furnace is still under its labor warranty, we definitely recommend replacing just the heat exchanger since most of the repair cost will be covered under warranty. But if your furnace is no longer under the labor warranty and it's over 10 years old, you might as well just replace the furnace completely.

Q: Can a HVAC heat exchanger be repaired?

A: The best way to repair a cracked heat exchanger is to remove it and put in a new one. This doesn't require replacing other parts of the furnace. However, it's an expensive repair. Often a repair that's too expensive compared to having a new furnace put in.

Q: Can a furnace still run with a cracked heat exchanger?

A: So, can you run a furnace with a cracked heat exchanger? The straightforward answer is no. Operating a furnace under these conditions is unsafe and can lead to severe consequences, including the risk of carbon monoxide poisoning.

Q: What causes a heat exchanger to go bad?

A: Clogged filters reduce the air flow that result in development of cracks inside the system. Other reasons for reduced air flow are the dirty fan blades, dirty duct work, and obstructed air vents. All of these factors can cause major damage to the heat exchanger.

Q: What happens if heat exchanger is faulty?

A: Essentially, if you've found yourself with a faulty heat exchanger, you'll soon find yourself without hot water or heating. For that reason, it's important to take good care of a heat exchanger to ensure your boiler is running at peak efficiency, saving you money on costly repairs.

Q: Can you replace just the heat exchanger?

A: An HVAC technician can replace the damaged heat exchanger and install a new one. However, replacing a heat exchanger is one of the most expensive furnace repairs you can do. The component is expensive; it has to match your model furnace, and the labor to remove the old one and install the new one is considerable.

Q: How often do heat exchangers fail?

A: While heat exchangers are typically manufactured to last between 10 – 20 years, many factors can accelerate the process of heat exchanger failure. These factors usually fall under the categories of poor maintenance, poor initial system design and installation, or poor equipment design by the manufacturer.

Q: What type of heat exchanger is used for HVAC?

A: There are several types of heat exchangers used in HVAC systems, including plate and frame, shell and tube, and spiral heat exchangers. Plate and frame heat exchangers consist of a series of thin metal plates that are clamped together. This forms a series of channels for the fluid to flow through.

Q: What is the best heat exchanger?

A: With a plate heat exchanger, there is a greater surface area in contact with the fluids, so it has better rates of heat transfer compared to all other types. Although plate heat exchangers can be more expensive, the efficiency gained by the design is a big plus.

Q: Who uses heat exchangers?

A: Food, dairy, beverage, and pharmaceutical industries all use heat exchangers as part of an efficient, hygienic production process. To meet regulatory requirements, processes must be carefully controlled to maintain proper temperatures for pasteurization, filling operations, and food safety.

We're well-known as one of the leading heat exchanger manufacturers and suppliers in China. Please feel free to buy or wholesale high quality heat exchanger at competitive price from our factory. For more information, contact us now.

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