Heat Exchanger

Understanding how heat is transferred efficiently is essential in many commercial and residential
applications. At the heart of this process lies the heat exchanger, that facilitates the exchange of thermal
energy between fluids. Whether heating our homes during winter, cooling them during the hot seasons,
heating our pool or recover heat from grey water, heat exchangers play an important role in the process.
In this article, we will explore the following facets in detail, shedding light on how heat exchangers
enable efficient thermal management together looking at the different types of heat exchangers, their
materials, sizing considerations, and diverse applications.

Principle of Heat Transfer

The theory of heat transfer delves into the core principles and mechanisms underlying the exchange of
thermal energy between diverse objects or areas. According to the laws of physics, energy within a
system naturally gravitates towards equilibrium, prompting the flow of driving energy until a state of
balance is attained. Concerning heat transfer, this entails the movement of heat from a warmer source or
fluid to a cooler one, until temperature uniformity is achieved.
The transfer of heat from one medium to another, or from one fluid to another, is governed by several
fundamental rules.
➢ Heat will always be transferred from a hot medium to a cold medium.
➢ There must always be a temperature difference between the media.
➢ The heat lost by the hot medium is equal to the amount of heat gained by the cold medium, except
for losses to the surroundings.
There are three methods by which heat can be transferred.
➢ Conduction
➢ Convection
➢ Radiation

Conduction

Conduction is the transfer of heat by direct contact between bodies or through the same body. conduction,
there is no transfer of matter, only energy.
At higher temperatures, molecules exhibit increased vibration or movement. When these molecules come
into contact with adjacent molecules at a lower temperature, they transfer some of their energy. This
energy transfer occurs within the same object or between two objects in contact.

Convection

Convection – Energy is transferred by mixing part of a medium with another part. Heat is transfer via the
interchange of hot and cold molecules. It occurs when a surface at a certain temperature is in contact with
a fluid moving at a different temperature.
There is 2 ways that convection can happen.
1. Natural convection, in which the fluid motion is entirely because of differences in the density of
the fluid temperature due to the variation between two points.
2. Forced convection where the fluid movement is due to some external factor. The transfer of heat
is better with forced convection, since the movement – the speed – is much higher, as there is
support for that external factor (e.g., pump, fan, wind or stirrer) in addition to the density
difference.

Radiation

Radiation is heat transfer via electromagnetic waves. It could be termed as molecular transport, as energy
is produced by changes in the electronic configurations of constituent molecules or atoms and transported
by electromagnetic waves or photons. There is no direct contact between the two media and the
intermediary or interface does not participate in the exchange functions; in most cases this is air, although
there is also heat transfer in a vacuum.
 Conduction Convection Radiation
Energy transferred by direct Occurs in gasses and liquid Energy Transferred by
contact electromagnetic waves such as
light, microwaves and infra red
radiation
Energy flow directly from warmer Movement of large number of All objects radiate energy
object to cooler object particles in same direction
Can occur within one object Occurs due to difference in Can transfer energy through empty
density space
Continues until object Cycle occurs while temperature
temperatures are equal differences exist

Heat Exchanger

Understanding the principles of heat transfer lays, the foundation to comprehend the function of a heat
exchanger.
Heat exchangers are devices designed to efficiently transfer heat between two or more fluids, or between
a fluid and a solid surface, while keeping them physically separated. Notably, the term "fluid"
encompasses substances in liquid, gas, or vapor form. They operate based on principles of
thermodynamics and fluid dynamics, utilizing conduction, convection, and sometimes radiation to
facilitate the exchange of thermal energy.
Heat exchangers come in various designs and configurations, but their basic principle remains that is
transferring heat from a hot fluid or surface to a cooler one.

Types of Heat Exchanger

There are several common types of heat exchangers, each designed to suit specific applications based on
factors like the fluids involved, space constraints, efficiency requirements, and operating conditions. Here
are some of the most prevalent types:
Shell and Tube Heat Exchanger

Shell and tube Heat Exchanger Consists of a series of tubes housed within a cylindrical shell. One fluid
flow through the tubes (tube side), while the other flows over the tubes within the shell (shell side),
allowing for efficient heat transfer. This Type of Heat exchanger is widely used in industrial processes,
power generation, and HVAC systems.

Plate Heat Exchanger

A Plate Heat Exchanger is Composed of multiple thin, slightly separated plates that have fluid passages
between them. The Fluids flow alternatively through the channels formed between the plates, facilitating
heat exchange through the plate surfaces. This type of heat exchanger is now used in many types of
hydronic heating and cooling systems, as well as for the evaporator and condenser in some refrigeration
systems.

Air Cooled Heat Exchanger

The Air-Cooled Heat Exchanger uses ambient air as the cooling medium to remove heat from a process
fluid. the Process fluid passes through finned tubes while air flows over the external surface of the tubes,
carrying away heat. It is often used in refineries, petrochemical plants, and other industries where water
availability or contamination concerns limit the use of water-cooled systems.
Double Pipe Heat Exchanger

In its Simplest form the Double Pipe Heat Exchanger consist of one pipe inside another larger pipe
(annular space between them). One fluid flow inside the inner pipe while the other flows in the annular
space between the pipes, enabling heat transfer. It is Suitable for small-scale applications or where space
is limited, such as laboratories or small process systems.

Plate-Fin Heat Exchanger

Plate-Fin Heat Exchanger Utilizes a series of fins to increase the surface area for heat transfer. The Fluids
flow in alternate channels formed by finned plates, enhancing heat exchange efficiency. Commonly used
in aerospace, cryogenics, and HVAC systems due to their lightweight design and efficient heat transfer
capabilities.
Each type of heat exchanger has its advantages and limitations, depending on factors such as heat transfer
efficiency, pressure drop, maintenance requirements, and cost considerations. The selection of a heat
exchanger type is crucial in optimizing the overall performance and energy efficiency of industrial
processes and systems.

Sizing
Properly sizing and configuring a heat exchanger is crucial to ensure its effectiveness and cost-efficiency.
If the exchanger is undersized, it won't transfer enough heat, leading to poor performance. This can also
cause high pressure drops and fluid speeds that might damage the equipment through erosion or vibration.
On the other hand, if the exchanger is oversized, it becomes inefficient and may lead to low fluid
velocities that increase the risk of fouling.
Factors to Consider when sizing a heat exchanger

When determining the appropriate size for heat exchangers, several factors must be carefully considered.
This includes the following:
❖ calculating the heat load - the amount of heat that needs to be transferred between the fluids or
surfaces
❖ terminal (inlet and outlet) temperatures
❖ the surface area
❖ pressure drops - difference (loss) in pressure between the inlet and outlet of a single process
stream as it goes through the heat exchanger
❖ flow rates
❖ viscosities

Heat exchanger materials by purpose

Selecting the right material for a heat exchanger depends on factors such as the operating environment,
fluid characteristics, temperature, pressure, and corrosion resistance requirements.
❖ Corrosion-resistant heat exchanger: Hastelloy, Inconel, Tantalum, Titanium, Zirconium
❖ high-temperature heat exchangers: Nickel-based alloys, Advanced carbon and silicon carbide
composites
❖ Heat exchangers used in seawater environments: Nickel-based alloys, Tantalum, Titanium
Stainless steel is also a material that is often used to manufacture heat exchanger due to its exceptional
combination of mechanical, thermal, and corrosion-resistant properties.
Stainless steel alloys, particularly grades like 304 (AISI 304) and 316 (AISI 316), offer excellent
resistance to corrosion from various chemical environments, including acids, alkalis, and chloride-
containing solutions
Certain grades of stainless steel, such as 304H and 316H, are designed to withstand elevated temperatures
without significant deformation or oxidation.
Stainless steel heat exchangers find use across various industries, including HVAC chemical processing,
oil and gas.

Application

Snow & ice melting (sim) systems

Snow and ice Melting system can either designed solely for snow and ice melting or can also be used to
served multiple load such as space heating and domestic water heating. The ratio of antifreeze in a Snow
and ice Melting system is not the same as the one in space heating. Even some space heating systems are
designed without the use of anti freeze.
In case that Snow & ice melting system are couple with space heating and domestic water heating, then
then a heat exchanger is often used to separate the Snow and ice Melting system “subsystem” from the
remainder of the system. This allows the majority of the system to operate with water only or a different
antifreeze ratio.

Pool Heating

In setups where a boiler or hydronic heat pump provides winter space heating and continuous domestic
hot water throughout the year, there is typically surplus heating capacity during the offseason. If the
property includes a swimming pool, this excess heat can be utilized to maintain comfortable water
temperatures for swimming.
Tube and shell are the heat exchange type the mostly used as it is better suited for the higher flow rates
needed for pool filter systems.
Water from the heat source flows through the outer shell of the heat exchanger, which is made from
materials such as steel, cast iron, or cast brass, forming part of a closed-loop system. Meanwhile, pool
water circulates through the tube bundle within the heat exchanger. These tubes are usually made from
titanium or a titanium alloy combined with stainless steel to withstand the corrosive nature of heavily
chlorinated pool water.

Domestic water heating

In hydronic systems that provide both space heating and domestic hot water, the most common approach
for heating domestic water is through the use of an indirect water heater. Indirect water heaters use
internal coil heat exchangers.

On-demand domestic water heating

Another method for heating domestic water involves utilizing a brazed plate heat exchanger, which draws
heat from either a buffer tank or a boiler system. This setup ensures that hot water is generated almost
instantaneously when needed at any faucet. This method is suitable for residential and small commercial
applications that incorporate a heated buffer tank. the tank can be linked to sustainable energy sources
like solar thermal collectors, biomass boilers, or heat pumps, or alternatively, it can be heated by any
conventional fossil fuel boiler.

Hydronic Cooling

Hydronic systems offer a wide range of benefits and the least common one but which its coming more
and more popular is hydronic cooling. Water not only conducts heat efficiently but also serves as an
excellent medium for cooling. It has the capacity to absorb more than 3000 times the heat energy
compared to an equivalent volume of air.
In cooling mode, the hydronic system circulates cold water through the pipes instead of warm water. This
cold water absorbs heat from the space, acting as the medium for heat exchange.
Numerous products have been designed for these applications, focusing on forced convection heat
transfer on both the water and air sides of the heat exchanger. These products can be classified into the
following categories:

Fan Coils

A fan-coil unit is essentially an assembly consisting of a water-to-air heat exchanger, commonly referred
to as a "coil," paired with a fan or blower that generates forced convection on the air side of the coil.
Typically, fan-coil units are intended to either heat or cool specific areas within a building. By
strategically placing multiple fan-coil units, heating and cooling zones can be established throughout the
building.

Air Handler

Air handlers are units specifically designed to integrate with standard ducting systems. Alternatively,
there are specialized "high velocity" models equipped with blowers capable of generating significant
static pressure. These units typically feature a single trunk duct that distributes air through several flexible
branch ducts, each around two inches in diameter.
These smaller branch ducts can be routed through partitions or along framing cavities and terminate at
small orifices installed on ceilings or walls. Normally, about six to seven branch ducts are required per
ton (12,000 Btu/h) of cooling capacity. Branch ducts typically have a maximum allowable length of 25
feet from their connection point to the trunk duct.
Plumbing

Heat exchanger are also used in plumbing contexts, such as Recovery heat from domestic hot water that
has been used in fixtures such as sinks, or shower. This water, known as greywater still retains much of
its heat as it drains. Typically, this heat is lost into the sewer system in many buildings. However, using a
greywater heat exchanger can recover as much as 40% of this otherwise wasted heat

Conclusion

In conclusion, the heat exchanger plays an important role in contemporary heating systems, providing
efficiency and dependability for both home and business applications. Whether you're upgrading an
existing system or embarking on a new project, the right heat exchanger can make all the difference in
performance and energy savings.
We invite you to visit our physical store or give us a call for advice. Alternatively, browse our online
store for detailed product descriptions, customer reviews, and convenient ordering. Enhance your heating
system today with our quality heat exchangers.