Comments Off on Enerquip Donates $500 to Athens High School Track & Field
Enerquip Thermal Solutions in Medford, Wisconsin, is proud to announce a $500 donation to the Athens High School Track & Field program. This contribution will help support the program’s ongoing expenses including competition expenses, student transportation, and more.
Enerquip is dedicated to supporting its community, with a unique program that matches employee donations and volunteer hours up to $500 per employee annually. Lance Bloch, an Enerquip Assembler and Athens Track & Field Coach, chose the Athens Track & Field program as the beneficiary of his employee match.
In 2024, two athletes coached by Bloch medaled at the Wisconsin State Track & Field Championships. “Coaching these young athletes and seeing their hard work culminate in success, from the very first practice to the state podium, is incredibly rewarding,” says Coach Bloch. “On behalf of the entire program, I’m truly grateful for Enerquip’s financial support.”
For more information about Enerquip’s community giving programs and culture, visit www.enerquip.com.
Lance Bloch (left) and Athens High School Sophomore Sy’Rih Hartwig (right): Sy’Rih Hartwig, coached by Lance Bloch, took 5th place in shot put (37 feet, 11.5 inches) at the 2024 WIAA Division 3 State Track & Field Championships.
Athens High School Freshman Delaney Beasley (3rd from right): Coached by Lance Bloch, Delaney Beasley placed 3rd in shot put (32 feet, 11 inches) and 9th in discus (93 feet, 7 inches) at the 2024 Freshman State Track & Field Championships.
Comments Off on How Shell and Tube Heat Exchangers Benefit the Agriculture Industry
Current State of the U.S. Agriculture Industry
Agriculture is a cornerstone of the U.S. economy and lifestyle. As of 2024, this vital sector and its related industries, contributed over $1.5 trillion to the national economy.
With a population exceeding 342 million, according to recent Census Bureau estimates, American households spend approximately 9% of their monthly budget on food. But agriculture extends beyond just providing produce, meat, and dairy. It also supports sectors like textiles, forestry, food services, and more. Currently, the agriculture and food industries provide over 21 million jobs, accounting for about 10% of total employment.
Navigating Modern Challenges and Advancements
Despite its importance, the agricultural sector faces numerous challenges, including:
Climate Change: Persistent droughts and extreme weather events, affecting states like California, continue to challenge agricultural productivity.
Health and Nutrition: Evolving concerns about nutrition and diet require adaptation and innovation.
Pests and Diseases: Emerging diseases and pests threaten livestock, poultry, and crops.
Workforce Shortages: A decline in students pursuing agricultural sciences impacts the future workforce.
The Role of Shell and Tube Heat Exchangers
Shell and tube heat exchangers are essential in maintaining safety and efficiency in agricultural production. These systems are integral to the dairy industry, as well as the food, beverage, and biodiesel sectors.
Dairy and Food Safety
Pasteurization is a critical process for ensuring the safety of dairy products like milk, cheese, and yogurt. Raw milk poses a higher risk of disease transmission compared to pasteurized milk. According to the Centers for Disease Control and Prevention (CDC), unpasteurized milk is significantly more likely to cause disease outbreaks.
Juices and ciders also require pasteurization to eliminate harmful bacteria. The Food and Drug Administration (FDA) mandates Juice Hazard Analysis and Critical Control Point (HACCP) systems to ensure safe pasteurization practices. Pasteurization temperatures for juices range from 160 to 165 degrees Fahrenheit, depending on the duration of the process.
The agriculture sector is instrumental in biofuel production, providing sustainable alternatives to fossil fuels. Biofuels, including biodiesel and ethanol, are derived from agricultural feedstocks. Ethanol production primarily involves fermenting starches and sugars, with ongoing research exploring the use of cellulose and hemicellulose. Biodiesel is produced from fats, such as vegetable oil or cooking grease, and helps reduce vehicle emissions.
Shell and tube heat exchangers play a vital role in biofuel distillation, which involves removing sulfur content and adjusting product characteristics.
Looking Ahead
Research and development continue to drive progress in agriculture, paving the way for innovations that address current challenges and enhance productivity. For more information on how shell and tube heat exchangers can benefit your agricultural operations, contact us or request a quote today.
Comments Off on The Impact of Shell & Tube Heat Exchangers in Chemical Processes
Chemical engineers around the world know that the success of chemical processes often hinges on the efficient and reliable performance of the equipment used. Among the most critical components in many chemical plants is the heat exchanger, which plays a vital role in regulating temperature, facilitating reactions, and optimizing energy usage. The shell and tube heat exchanger stands out as a workhorse in the chemical and petrochemical industries, offering a unique combination of efficiency, safety, and versatility.
Understanding the Shell and Tube Heat Exchanger
A shell and tube heat exchanger consists of a shell, or outer casing, and a bundle of tubes housed within it. The two fluids or gases, typically one hot and one cold, flow through the heat exchanger in a counter-current or parallel-flow arrangement, allowing for the efficient transfer of heat between them.
One key advantage of the shell and tube design is its flexibility. The size and configuration of the heat exchanger can be scaled to meet the specific requirements of a chemical process, whether it’s handling large volumes of fluids or dealing with high-pressure or high-temperature conditions. This adaptability makes shell and tube heat exchangers a popular choice for a wide range of chemical applications, from petrochemical refineries to pharmaceutical production facilities.
Shell and Tube Versatility
Shell and tube heat exchangers offer nearly limitless customizations and can optimize almost any process. Common applications include:
Condensing vapors into liquids: Commonly used in power plants, refrigeration systems, and chemical processing industries.
Reboiling: Adding heat to the bottom of a distillation column to boil the liquid, creating vapors that rise up the column.
Preheating fluids: Before they enter process units like reactors or distillation columns, improving efficiency by reducing the energy needed for heating.
Cooling down hot fluids: Using a cooler fluid, often in chemical plants to remove excess heat from reactions or other processes.
Heating a fluid: By transferring heat from a hot fluid to a colder one, used in various chemical processes that require specific temperatures for reactions.
Evaporating liquids: To leave behind concentrated solutions, common in the production of chemicals, pharmaceuticals, and food products.
Recovering waste heat: From industrial processes to improve energy efficiency, with the recovered heat used elsewhere in the plant or for generating power.
Efficiency and Performance
The efficiency of a shell and tube heat exchanger is crucial for its performance and the overall success of a chemical process. The design of the heat exchanger, including the arrangement of the tubes, the flow patterns, and the materials of construction, all contribute to its thermal efficiency.
One factor that enhances the efficiency of shell and tube heat exchangers is the large surface area-to-volume ratio. The multiple tubes within the shell provide a significant surface area for heat transfer, allowing for more effective heat exchange between the two fluid streams. Additionally, the counter-current arrangement ensures that the temperature difference between the hot and cold streams is maximized throughout the length of the exchanger, further improving heat transfer efficiency.
Another aspect that contributes to the efficiency is the ability to optimize fluid flow patterns. The design of the shell and the arrangement of the tubes can be tailored to create optimal flow conditions, minimizing pressure drops and ensuring effective heat transfer.
Safety and Reliability
The design of equipment plays a crucial role in ensuring the safe operation of chemical processes. Shell and tube heat exchangers are renowned for their robust and reliable construction, making them a preferred choice for many chemical applications.
The thick shell and sturdy tube construction of these heat exchangers provide excellent pressure containment, allowing them to withstand high-pressure and high-temperature conditions. This level of structural integrity is particularly important in processes where the fluids involved are hazardous or corrosive.
Additionally, the modular design of shell and tube heat exchangers allows for easy maintenance and inspection, enabling regular checks and preventive measures to ensure continued safe operation. This proactive approach to maintenance helps minimize the risk of unexpected failures and ensures long-term reliability.
High Alloy Materials of Construction
The chemical industry often deals with highly corrosive, abrasive, or aggressive fluids, which can pose a significant challenge to the materials used in heat exchanger construction. Shell and tube heat exchangers are known for their ability to be fabricated from a wide range of high-alloy materials, ensuring compatibility with the specific process requirements.
Stainless steel, Hastelloy, Inconel, and other specialized alloys are commonly used in the construction of shell and tube heat exchangers for chemical applications. These materials are selected for their exceptional resistance to corrosion, erosion, and high-temperature degradation, ensuring the long-term integrity and performance of the heat exchanger.
The use of high-alloy materials also enables shell and tube heat exchangers to be designed for specific process conditions, such as handling highly acidic or alkaline fluids, or operating in extreme temperature ranges. This flexibility in material selection is a key advantage that allows chemical engineers to tailor the heat exchanger to the unique requirements of their processes, further enhancing the overall efficiency and reliability of the system.
The widespread use of shell and tube heat exchangers in the chemical and petrochemical industries has had a significant impact on the efficiency, safety, and overall performance of chemical processes. By providing reliable and efficient heat transfer, these heat exchangers have enabled chemical engineers to optimize process parameters, reduce energy consumption, and ensure the safe operation of their facilities.
One primary impact is the improvement in energy efficiency. By effectively transferring heat between fluid streams, these heat exchangers can reduce the amount of energy required for heating, cooling, or maintaining specific temperature conditions. This translates into lower energy costs and a reduced environmental footprint for chemical plants, making them more sustainable and cost-effective.
Additionally, the safety and reliability of shell and tube heat exchangers have been instrumental in mitigating the risks associated with chemical processes. The robust construction and use of high-alloy materials ensure that these heat exchangers can withstand harsh operating conditions, reducing the likelihood of equipment failures and potential accidents or environmental incidents.
The shell and tube heat exchanger is an indispensable component in the chemical industry, due to its exceptional efficiency, safety, and versatility. By providing reliable and efficient heat transfer, these heat exchangers have enabled chemical engineers to optimize their processes, reduce energy consumption, and ensure the safe operation of their facilities.
Are you looking for a custom process solution? Contact us today.
Comments Off on Enerquip Supports Westboro Volunteer Fire Department
The Westboro Volunteer Fire Department, committed to enhancing public safety and rescue services for Westboro and neighboring communities, has been actively fundraising to purchase a new fire engine. Enerquip Thermal Solutions has donated $500 to support this critical initiative.
In January 2024, the Westboro Volunteer Fire Department ordered a state-of-the-art fire engine to better serve the 700 residents and 125 square miles of Westboro. This new engine will also bolster the department’s ability to provide mutual aid to the surrounding areas in Taylor and Price counties.
The fundraising efforts, fueled by the community’s dedication, have already enabled a substantial down payment; however, the department still needs to raise an additional $180,000 to fully fund the new fire engine. Enerquip’s contribution marks a step toward reaching this goal.
“We are incredibly grateful for the community’s generous support,” said Captain Bryan Strobach of the Westboro Volunteer Fire Department. “Enerquip’s donation, and others, not only brings us closer to acquiring the new fire engine but also strengthens the safety and well-being of our community and neighboring areas.”
Enerquip Sales Engineer Will McCarron and Enerquip Design Engineering Manager Cam Diedrich, who also volunteer as firefighters for the Stetsonville and Athens Volunteer Fire Departments, respectively, presented the donation to Captain Strobach. Their dual roles highlight the deep commitment and close-knit nature of the community.
This donation exemplifies the power of local businesses in supporting essential community services. The Westboro Volunteer Fire Department encourages other businesses and individuals to contribute to this vital cause, ensuring the safety and protection of all residents and visitors in the area. For more information on how to donate, please contact the Westboro Volunteer Fire Department at (715) 905-0702.
Comments Off on Two Methods for Cleaning Heat Exchanger Tubes: Chemical Cleaning vs. Hydroblasting
Shell and tube heat exchangers are crucial in many industries, from oil and gas to food and beverage. Despite the differences in these fields, they share the need for well-maintained shell and tube heat exchangers to prepare products for consumers.
When using a shell and tube heat exchanger, the fluid that is more likely to corrode or foul is typically placed on the tube side. This is because the tubes are easier to clean or replace than the shell. This makes it vital for operators to know how to properly clean and maintain the tubes.
Shell and tube heat exchangers come in various sizes and configurations. Some are easier to clean than others, mainly because some have tube bundles and bonnets that can be easily removed from the shell, while others are connected to the body of the exchanger. Knowing the type of bonnet your exchanger has and the appropriate cleaning method is crucial when purchasing the exchanger.
There are several ways to clean the tubes of a heat exchanger, each with pros and cons. It’s important to choose the right method for your specific machine and operation.
Chemical Cleaning
Chemical cleaning is effective for fixed-channel box designs, which can be particularly challenging to clean because the tubes are not detachable from the shell. The chemicals can be circulated through the tubes or cascaded. This approach is advantageous for exchangers with substantial build-up, as the chemicals can remove more deposits than many alternative cleaning techniques.
However, chemical cleaning is one of the more expensive options. It often necessitates mechanical cleaning afterward to eliminate any residual substances that could contaminate future batches. Additionally, this method can be time-consuming and pose potential environmental risks, depending on the type of chemicals used and waste management practices.
Hydroblasting
Hydroblasting uses high-pressure water to blast away debris or deposits in the tubes. Hydroblasting does not involve the use of hazardous chemicals, making it a more environmentally-friendly cleaning option.
This method can be done manually or with an automated system. The manual approach involves an operator using a high-pressure hose to clean each tube individually, which is effective and relatively inexpensive but can result in uneven cleaning and safety concerns due to the high water pressure.
Automated systems, such as flexible lance and rigid lance systems, allow multiple tubes to be cleaned at once, saving time. Flexible lance systems are suitable for U-tube heat exchangers and those with curved tubes, while rigid lance systems are better for exchangers with straight tubes due to the higher water pressure they can provide.
While hydroblasting is effective, if the water pressure is not carefully controlled, could weaken the tubes and create leaks. The water and debris generated during the hydroblasting process must be properly collected and disposed of, which can add to the overall cost of the cleaning operation.
Choosing the Right Cleaning Method
When it comes to selecting the best cleaning method for your heat exchanger tubes, there are several factors to consider, including the type and severity of the deposits, the materials of the heat exchanger, the available budget, and the overall impact on your operations.
In general, chemical cleaning may be the preferred option for larger heat exchanger systems or for removing stubborn deposits that are difficult to access. However, if environmental concerns or the potential for residual chemical deposits are a priority, hydroblasting may be the better choice.
It’s important to carefully evaluate the pros and cons of each method and consult with experienced professionals to determine the most suitable approach for your specific heat exchanger cleaning needs. Regular maintenance and cleaning are essential for ensuring the optimal performance and longevity of your heat exchanger equipment.
Facilities increasingly opt for industrial thermal oil heaters to replace or upgrade their existing equipment. Learn more about thermal oil heaters, including how they work, their potential applications, and their advantages.
What Are Thermal Oil Heaters?
Thermal oil heating systems use a closed-loop design and high temperatures to transfer heat between an original heat source and a heat sink with thermal oil as the transfer medium.
Thermal oil heaters consist of the following key components:
Heat Source. The heat source in these systems can be an electric heating component, burner, or a waste heat recovery source.
Thermal Fluid. Thermal oil travels through the heater to transfer heat energy from the source to the intended application.
Heat Exchanger. A heat exchanger enables the system to transfer heat from the thermal oil to another process medium, such as air or another liquid.
Pump. The pump manages the flow of thermal fluid, ensuring proper circulation.
Control System. Contemporary thermal oil heaters include advanced control systems and safety features, including precise temperature regulation.
Applications of Thermal Oil Heaters
Many types of industrial processes rely on thermal oil heating solutions. Chemical and pharmaceutical facilities use these systems for reactor heating and drying. Energy plants can utilize them to generate electricity or to power combined heat and power (CHP) systems. Both plastic and rubber plants rely on heat energy for mold heating, curing, and extrusion processes.
Thermal oil heaters facilitate the production of many materials. Manufacturers can bond plywood layers and dry paper rolls. Textile and printing facilities can use thermal oil heaters for dyeing and printing. Specifically, these heaters may help to control temperature or ink viscosity. Food processing facilities may also thermal heating with industrial baking, sterilization, and frying.
Platform heating systems also use thermal oil with offshore gas and oil platforms. Cargo heating applications include using thermal oil heating systems to regulate cargo temperature when transporting shipments.
Benefits of Thermal Oil Heaters
Thermal oil heaters also offer a few critical advantages over other heat transfer systems, such as:
Efficiency. Thermal oil heaters offer greater overall efficiency compared to alternative heating methods.
Installation flexibility. This equipment also allows users to optimize available space when updating or replacing heating systems.
Reduced maintenance. Thermal oil heaters require less maintenance than steam boilers and other heating solutions.
Precise temperature control. Thermal fluid systems allow for improved temperature regulation for process heating.
Wider temperature ranges. Oil has a higher boiling point than water and can thus safely maintain higher temperatures.
Thermal Oil Heaters from Enerquip
If you require a high-quality industrial thermal oil heater for your application, you’ll find some of the best solutions at Enerquip. As one of the leading thermal oil heater manufacturers, we aim to consistently provide our customers with reliable products and custom designs.
Comments Off on Enerquip Donates $500 to Beggs Lady Warriors
Enerquip Thermal Solutions is proud to announce a $500 donation to the Beggs Lady Warriors Youth Softball team to help purchase new uniforms. This contribution supports Beggs Little League, which provides a nurturing environment for dozens of young athletes each summer, promoting values such as hard work, sportsmanship, and teamwork.
Enerquip is committed to giving back to the community by matching employee donations and volunteer hours up to $500 per employee each year. This year, Enerquip Quality Control Manager Kenny Devilbiss (back right), who also coaches the team, chose the Beggs Lady Warriors as the recipient of his employee match.
Comments Off on 5 Ways Shell & Tube Heat Exchangers Help Recover Waste Heat
One of the most significant sources of energy loss in industrial processes is waste heat – the thermal energy that escapes without being put to productive use. However, there’s a powerful tool at our disposal that can help us recapture this valuable resource: the shell and tube heat exchanger.
Below, we’ll explore five ways that shell and tube heat exchangers can assist in recovering waste heat, ultimately improving your overall process efficiency and bottom line.
1. Reclaiming Heat from Exhaust Streams
One of the primary applications of shell and tube heat exchangers is the recovery of heat from exhaust streams. Whether it’s the flue gas from a boiler, the hot air from a drying process, or the discharge from a compressor, these heat exchangers can be strategically placed to capture the thermal energy that would otherwise be lost to the environment.
By using a shell and tube design, the heat exchanger can effectively transfer this waste heat to a secondary fluid, such as water or a process stream, which can then be used to preheat incoming process materials or generate steam for other applications. This not only reduces the overall energy consumption of the facility but also helps to minimize the environmental impact of the operation.
2. Improving Process Heating Efficiency
In many industrial processes, heat is required to maintain specific temperature setpoints or to raise the temperature of raw materials or intermediates. Conventional heating methods, such as electric heaters or steam boilers, can be energy-intensive and often result in significant heat losses.
Shell and tube heat exchangers can be used to improve the efficiency of these process heating applications. By using the waste heat from one stream to preheat another, the overall energy required for the heating process can be significantly reduced. This can be particularly beneficial in applications where the process stream needs to be heated to a high temperature, as the shell and tube design allows for efficient heat transfer over a wide temperature range.
3. Enabling Cogeneration and Combined Heat and Power (CHP) Systems
Cogeneration and combined heat and power (CHP) systems are powerful tools for improving overall energy efficiency. These systems generate both electricity and useful thermal energy, often by capturing the waste heat from power generation equipment, such as turbines or engines.
Shell and tube heat exchangers play a crucial role in CHP systems by allowing the efficient transfer of this waste heat to a secondary fluid, such as water or steam. This thermal energy can then be used for a variety of applications, such as space heating, process heating, or the generation of additional electricity through a steam turbine.
By implementing a CHP system with shell and tube heat exchangers, facilities can achieve remarkable improvements in energy efficiency, often reaching overall system efficiencies of 80% or higher.
4. Facilitating Heat Integration in Complex Processes
In many industrial processes, there are multiple streams of hot and cold fluids that could potentially be integrated to improve overall efficiency. However, the complexities of these systems can make it challenging to identify and implement effective heat recovery strategies.
Shell and tube heat exchangers are well-suited for these types of complex heat integration projects. Their modular design and flexible configurations allow them to be easily integrated into existing processes, enabling the recovery of waste heat from a wide range of sources and the efficient transfer of this energy to other process streams.
By carefully analyzing the heat and mass balances of the entire process and strategically placing shell and tube heat exchangers, engineers can unlock significant energy savings and improve the overall sustainability of the operation.
5. Enhancing the Reliability and Longevity of Heat Recovery Systems
Effective heat recovery systems are not only about maximizing energy efficiency – they also need to be reliable, durable, and easy to maintain. Shell and tube heat exchangers excel in this regard, thanks to their robust construction and proven track record of long-term performance.
The shell and tube design, with its separate fluid paths and sturdy tube bundle, is inherently less susceptible to fouling and corrosion than other heat exchanger types. This translates into fewer maintenance requirements, longer service life, and a lower risk of unexpected downtime or system failures.
Additionally, shell and tube heat exchangers can be easily inspected, cleaned, and repaired, allowing facility operators to proactively maintain the performance and reliability of their heat recovery systems. This, in turn, helps to ensure a consistent and reliable supply of recovered thermal energy to support the overall process efficiency.
Shell & Tube Heat Exchangers from Enerquip
Most operations are looking to optimize energy efficiency and minimize waste. The shell and tube heat exchanger is a powerful tool that can help achieve these goals, enabling the recovery of waste heat and the implementation of more sustainable and cost-effective operations. By leveraging the benefits of shell and tube, you can unlock significant energy savings and reduce environmental impact.
As we continue to navigate the challenges of today’s energy landscape, the shell and tube heat exchanger will undoubtedly play an increasingly important role in our quest for greater efficiency and sustainability. By embracing this technology and incorporating it into our operations, we can build a brighter, more sustainable future for our industries and our planet.
Comments Off on How to Prepare to Clean a Shell and Tube Heat Exchanger
As most manufacturers working with shell and tube heat exchangers know, fouling can be detrimental to an operation. It is crucial that all equipment used to process a product is working at its optimal capacity. To ensure this, manufacturers and operators need to take the time to inspect and clean shell and tube heat exchangers.
The complexity and time required for these tasks vary depending on the heat exchangers’ design and configuration. Manual inspection and cleaning might take a day or two, resulting in downtime. Therefore, it’s important to choose the best day to minimize losses and to plan ahead. Scheduling maintenance in advance helps manage downtime and ensures a smooth turnaround process.
Knowing When to Clean
In sanitary industries, like food, dairy and pharmaceutical, there are often well-established protocols established for the timing of heat exchanger cleaning. These cleanings are most commonly accomplished through the use of an automated CIP (clean-in-place) system that will clean and sanitize the tubing without having to disconnect the piping or exchanger parts. These cleanings are often done daily or weekly between batches of product.
Chemical Processing explained that over the past half-century, companies have changed the way they view scheduled maintenance days. In the past, cleanings took place one or more times a year. The years have brought equipment that is more reliable and requires fewer cleaning days. Today, the norm is closer to cleaning once every four to 10 years. Of course, this depends on the exchanger type and what it is being used for. Some materials that pass through an exchanger are less prone to fouling than others. For this reason, it is important that operators and manufacturers know the signs of fouling and the nature of the chemicals and products they work with.
There are many advantages to going several years without a cleaning. The fact that cleanings are less necessary indicates the resiliency and efficiency of the exchanger. It also means there are fewer days during which the company loses profit due to ceased production. However, there are some downsides to this as well. Chemical Processing points out that since the last turnaround day may have happened as long as a decade ago, fewer operators and maintenance experts will be familiar with the process of cleaning and inspecting the machines. Because of this, it is important that all people involved in the cleaning day be properly educated and prepared for it.
Getting Prepared
Chemical Processing advised people getting ready for a turnaround day to make a checklist of everything that needs to be completed on that day. This will help someone who is inexperienced or out of practice keep track of all necessary tasks. This list should include recording how the machine is operating just before you shut it down, whether all the measuring tools available make sense or if others would be best, layout dimensions for the machine and all its parts, and whether there is any damage or other factors that could cause harm to the product or machine later on. It is also important to have any replaceable spare parts on hand, like gaskets, O-rings and hardware, so that any damaged or compressed parts can be replaced before the unit is re-connected and brought back online. Because exchanger parts can be very heavy, it is also important to have a safe lifting plan with adequate clearance to remove bonnets, piping and other parts in order to gain access to the tube bundle.
How to Clean
It’s a good idea to take pictures of everything mentioned in the notes taken throughout the day. This will help explain any damage encountered and provide reference for the notes the person performing the turnaround takes.
There are many ways to clean a shell and tube heat exchanger, though most require being offline. The most widely chosen method is mechanical cleaning. This involves determining what kind of deposits you will be removing from the tubes. Deposits range from small amounts of silt to substances that are more difficult to remove, depending on the materials that are used in the exchanger. Once this is determined, decide which cleaning method is appropriate. Some common examples include brushes, used for lighter debris; calcite cleaners, used to remove stubborn calcite deposits which couldn’t be removed with acid; and metal tube cleaners, used for harder deposits.
Hydroblasting has also been commonly used, though precautions to reduce risk of injury or tube damage must be taken if managers choose to go with this option. Good Way explained this method involves water pressurized to 10,000 to 25,000 pounds per square inch, which is then blasted through the tubes to remove deposits.
Chemical cleaning is another preferred method, though it is a more expensive option. Chemicals that are mildly acidic will take off debris faster and more efficiently than a mechanical process. However, the tubes will still need to be cleaned of the chemicals used to prevent contamination or environmental hazards.
Comments Off on Designing a Shell and Tube Heat Exchanger
Shell and tube heat exchangers are an integral part of many operations. The product flowing through the exchanger, such as dairy, food, or pharmaceuticals, will eventually be in the hands of customers who rely on consistent quality for their health and well-being. For this reason, it is crucial the exchanger is the best one for the job.
Manufacturers need to choose the right style of shell and tube heat exchanger. Different processes and industries have different requirements for their equipment. Because of this, customizing a shell and tube heat exchanger takes expertise from both the supplier and the buyer of the equipment. A lot that goes into fabricating a heat exchanger and taking all pertinent items into consideration is essential during the design phase.
The Shell
Perhaps the most recognizable part of the shell and tube heat exchanger is the shell itself. There are many different options for the shell design, including one-pass shells, two-pass shells, double split flows, divided flows and cross flows. These are all classified as different standards with the Tubular Exchanger Manufacturers Association. There are also several streams within the shell that need to be taken into consideration when designing it.
There are many different materials that shells can be made from. The materials should be resistant to corrosion and sturdy enough to encase the tubes and the high-pressure processes that will occur within. Carbon steel is a common material used for shells, as is stainless steel. Stainless steel is highly resistant to many forms of corrosion, making it a preferred material for many manufacturers.
It’s important to understand what liquid will be flowing through the shell side. Knowing the liquid that will be used will help to determine the material, as the metal chosen should not react with the fluid used. Viscous fluids can be used either on the tube side or the shell side. However, many exchangers that use viscous liquids on the shell side experience vibrations, which puts the equipment at risk of damage and maldistribution.
Tubes and Tube Sheets
There are three types of tube sheet designs. A fixed tube sheet has tubes that run from one end of the shell to the other and is welded to the shell. A U-tube heat exchanger only requires one tube sheet because the tubes leaving the tube sheet are bent at the end of the exchanger and returned to the same sheet. The third type is the floating head. This requires two tube sheets; one, which is fixed to the shell, and a second, which is located at the other end but is not fixed, allowing for tube expansion.
There are many factors to consider when choosing between these three. One of them is cost. The u-tube tube sheet is likely the least expensive as only one tube sheet and channel is required. The fixed tube sheet is more expensive but gives you more options for more viscous fluids. Finally, the floating head tube sheet is the costliest, as it has the most complex design.
However, while cost plays an important part in the decision-making process, it cannot be the only factor. It is crucial that the tubes and tube sheets be cleaned and maintained to prevent breaks, leaks and fouling. The fixed tube sheet’s tubes can be accessed for cleaning (with cleaning rods or pressurized water), but the tube bundle cannot be removed from the shell, making cleaning difficult. On the other hand, the U-tube and floating head designs allow for the bundle to be removed, so cleaning is easier.
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