Pipe heat exchanger - everything you need to know

A tube heat exchanger, also known as a shell-and-tube exchanger, is an integral component of heat exchange processes in various industries. It consists of tubes that allow the flow of substances, surrounded by external shells forming a jacket. This solution enables thermal energy to be transferred between two different substances. This type of exchanger finds wide applications in industries such as chemical, energy, and food production. The efficiency of both production and process safety often depends on the proper functioning of tube heat exchangers. Therefore, it's worth understanding their principles of operation and the benefits they can bring to industry. Learn more from the article below.

What Is the Purpose of a Tube Heat Exchanger?

A tube heat exchanger serves the purpose of efficiently exchanging heat between fluids at different temperatures. It is a device composed of tubes through which two independent streams of fluids flow. One stream is at a higher temperature, while the other is at a lower temperature. Heat exchange occurs through conduction and flow of heat between these fluids.

A tube heat exchanger can be used in various industries such as chemical, energy, and food processing. It is utilized for cooling, heating, or heat recovery. This device enables the optimization of thermal processes and increased energy efficiency in many industrial applications, as detailed in the following paragraph.

Shell-and-Tube Exchanger - Applications in Industry and Beyond

A shell-and-tube exchanger is a device that finds wide application in various industrial sectors. One of the main areas where it is indispensable is the chemical industry. Exchangers of this type are used for:

• temperature regulation during chemical reactions,
• distillation (separation of substances based on the difference in their boiling points),
• phase conversion (changing the state of matter),
• drying of chemical substances,
• recovery of energy generated in chemical processes.

Another sector where these devices are used is the food industry. Shell-and-tube exchangers assist in the following processes:

• pasteurization,
• cooling and heating of products,
• crystallization (e.g., sugar or chocolate),
• evaporation and concentration (e.g., fruit juices, milk),
• recovery of thermal energy from by-products generated during production processes.

Furthermore, shell-and-tube exchangers are indispensable in the oil and gas industry. They are used for efficient condensation and evaporation of substances such as crude oil or natural gas. This process is essential in the extraction, processing, and transportation of these resources.

Thanks to their various applications, shell-and-tube exchangers play a crucial role in the efficient functioning of many branches of industry. It's also worth mentioning the non-industrial use of tube heat exchangers. These devices are also excellent for heating water in swimming pools.

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Tube Heat Exchanger - Construction

A tube heat exchanger is a device used for transferring heat between two fluids. It consists of a cylindrical shell with thin-walled tubes placed inside it. This design provides a larger heat exchange surface area, contributing to more efficient transmission of thermal energy between fluids. Tube heat exchangers are widely used in various fields such as chemical industry, food industry, and energy sector. They can be used for heating, cooling, or heat recovery. Due to their construction and properties, tube heat exchangers are extremely effective and popular solutions for controlling the temperature of liquid media in various technological processes. Below is a description of the individual structural elements of a tube heat exchanger.

Tubes in Shell-and-Tube Heat Exchangers

Tubes in a shell-and-tube heat exchanger are a crucial element in the heat exchange process. The construction of the tubes depends on the working conditions, so various materials are used for their production. Steel is commonly used due to its durability and corrosion resistance. Nickel alloys are used for aggressive chemical conditions. Copper alloys are preferred for their high thermal conductivity. Meanwhile, titanium alloys are used for demanding operating conditions where mechanical strength and resistance to high temperatures are important. The use of different materials in the tubes allows for optimal heat exchanger performance under various conditions.

Shell of a Tube Heat Exchanger

The shell of a tube heat exchanger is a cylindrical element that surrounds the tubes, creating a chamber. Heat exchange is initiated by the flow of fluids. The structure of the shell itself, sometimes combined with baffles, allows for better mixing of fluids and accelerates the heat exchange process. Additionally, tube heat exchangers reduce the risk of sediment accumulation and scaling, resulting in longer device lifespan - gaining a significant advantage over plate heat exchangers. The shell of a tube heat exchanger is an extremely important element in the process of efficient heat exchange.

Headers in Tube Heat Exchangers

Headers in a tube heat exchanger are short conduits that connect the shell or tube sheets to the tubes. Inlet headers supply the medium to the exchanger, while outlet headers allow the medium to exit the shell-and-tube heat exchanger.

Tube Heat Exchanger - Principle of Operation, Example

A tube heat exchanger is a device used for efficiently transferring heat between two different mediums without their direct contact and mixing. In our example, we'll use a very typical scenario often encountered in industry.

In a production process, mineral oil exceeds the allowable temperature. To cool it down, one can utilize a heat exchanger - for example, a tube heat exchanger. In this case, the cooling fluid can be cold water, which flows through the tubes of the heat exchanger. Meanwhile, the heated oil circulates in the second circuit (jacketed) - on the outer side of the tubes. As the hot oil circulates through the heat exchanger, it releases heat through the surface of the tubes to the cooler water. Baffles within the tube heat exchanger increase the turbulence of the fluid flow, thereby increasing the efficiency of heat exchange.

Pool Heat Exchanger as an Example of a Tube Heat Exchanger

A pool heat exchanger is a good example of a tube heat exchanger. It is used to heat water in a pool. Pool heat exchangers can be made from various materials, such as titanium or stainless steel (316L). Both of these materials are corrosion-resistant (titanium also in a marine/saline environment), which is crucial for pool applications. Thanks to the tubular structure, the pool heat exchanger ensures efficient heat exchange between the heating medium and the heated water. This makes it an effective and efficient solution for heating water in a pool.