End User Outlook temperatures( DTs) tailored to specific components— based on their actual thermal exposure— engineers can optimize material use, reduce costs, and improve heat exchanger performance. This case study explores the practical benefits of differential DTs in the context of the shell-and-tube heat exchanger handling gas on the shell side and superheated steam on the tube side. When using uniform design temperatures across all components, the overall dimensions of the heat exchanger tend to increase, which consequently raises the total weight of the equipment. This added weight leads to higher wind and seismic loads, necessitating more robust supporting structures and increasing the overall cost of installation. Additionally, as the tubesheet thickness grows, there is a slight reduction in the effective tubeside heat transfer surface area, which may impact thermal performance. Furthermore, due to the elevated operating temperatures, a material upgrade to 2¼ Cr( chromium steel) may be required, as temperatures around 454 ° C bring certain components into the creep range, where long-term deformation under stress becomes a concern.
With Same Temperatures |
Tubesheet thickness( 1¼ Cr) |
420 mm |
Shell flange thickness |
345 mm |
Shell thickness |
107 mm |
Channel thickness |
85 mm |
Total Weight |
85500 |
With Different Temperatures |
Tubesheet thickness( 1¼ Cr) |
345 mm |
Shell flange thickness |
290 mm |
Shell thickness |
107 mm |
Channel thickness |
85 mm |
Total Weight |
82200 |
Conclusion High-temperature and high-pressure heat exchangers are critical for improving energy efficiency in various industrial processes, from oil refineries to power generation. Addressing the challenges posed by extreme conditions requires the careful selection of materials, robust design solutions, and advanced safety mechanisms. Implementing the solutions discussed and outlined in this article provides insight to ensure that heat exchangers remain reliable, durable, and efficient in operation, ultimately reducing maintenance costs and extending the life of the equipment.
References:
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2. Al-Attab, Khaled A., and Z. A. Zainal.“ Performance of high-temperature heat exchangers in biomass powered externally fired gas turbine systems.” Renewable Energy 35.5( 2010): 913-920.
3. Kwon, J. S., Son, S., Heo, J. Y., & Lee, J. I.( 2020). Compact heat exchangers for supercritical CO2 power cycle application. Energy Conversion and Management, 209, 112666.
4. Reay D. Learning from experiences with compact heat exchangers, Center for the Analysis and Dissemination of Demonstrated Energy Technologies( CADDET), Series No. 25, Netherlands; 1999.
5. Samantray, J. S., Goswami, S., Sharma, V. K., Biswal, J., & Pant, H. J.( 2014). Leak detection in a high-pressure heat exchanger system in a refinery using radiotracer technique. Journal of Radioanalytical and Nuclear Chemistry, 302, 979-982.
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