scholarly journals Estimation of Shutdown Schedule to Remove Fouling Layers of Heat Exchangers Using Risk-Based Inspection (RBI)

Processes ◽  
2021 ◽  
Vol 9 (12) ◽  
pp. 2177
Author(s):  
Abdelnaser Elwerfalli ◽  
Salih Alsadaie ◽  
Iqbal M. Mujtaba
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Oil And Gas ◽  
Waste Heat ◽  
Complex Phenomenon ◽  
Cleaning Process ◽  
Chemical Substances ◽  
Operation Period ◽  
The Heat Transfer Coefficient ◽  
Gas Plants

Oil and Gas plants consist of a set of heat exchangers, which are used in recovering the waste heat from product streams to preheat the oil. The heat transfer coefficient of exchangers declines considerably during the operation period due to fouling. Fouling in heat exchangers is a complex phenomenon due to the acceleration of many layers of chemical substances across tubes of heat exchangers resulting from chemical reactions and surface roughness. In this paper, the fouling process was determined as a critical failure in the heat exchanger. Failure is an accelerated fouling layer across the heat exchanger tubes, which can be the reason for the clogging of tubes. Hence, a risk assessment was conducted using the Risk-Based Inspection (RBI) approach to estimate the probability of fouling in heat exchangers. The results showed that the RBI approach can be used successfully to predict the suitable time to shut down the plant and conduct the fouling cleaning process.

Development of Heat Exchanger Fouling Model and Preventive Maintenance Diagnostic Tool

2007 ◽  
Vol 2 (2) ◽  
Author(s):  
H. Zabiri ◽  
V. R. Radhakrishnan ◽  
M. Ramasamy ◽  
N. M. Ramli ◽  
V. Do Thanh ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Predictive Model ◽  
Diagnostic Tool ◽  
Preventive Maintenance ◽  
Heat Exchangers ◽  
Waste Heat ◽  
A Priori ◽  
Transfer Efficiency ◽  
Heat Transfer Efficiency

The Crude Preheat Train (CPT) is a set of large heat exchangers which recover the waste heat from product streams back to preheat the crude oil. The overall heat transfer coefficient in these heat exchangers may be significantly reduced due to fouling. One of the major impacts of fouling in CPT operation is the reduced heat transfer efficiency. The objective of this paper is to develop a predictive model using statistical methods which can a priori predict the rate of the fouling and the decrease in heat transfer efficiency in a heat exchanger in a crude preheat train. This predictive model will then be integrated into a preventive maintenance diagnostic tool to plan the cleaning of the heat exchanger to remove the fouling and bring back the heat exchanger efficiency to their peak values. The fouling model was developed using historical plant operating data and is based on Neural Network. Results show that the predictive model is able to predict the shell and tube outlet temperatures with excellent accuracy, where the Root Mean Square Error (RMSE) obtained is less than 1%, correlation coefficient R2 of approximately 0.98 and Correct Directional Change (CDC) values of more than 90%. A preliminary case study shows promising indication that the predictive model may be integrated into a preventive maintenance scheduling for the heat exchanger cleaning.

The Potential Danger of Fire in Gas Turbine Heat Exchangers

1969 ◽  
Author(s):  
C. F. McDonald
Keyword(s):  
Heat Exchanger ◽  
Gas Turbine ◽  
Heat Exchangers ◽  
Heat Recovery ◽  
Waste Heat Recovery ◽  
Waste Heat ◽  
Engine Operation ◽  
Exhaust Heat ◽  
The Subject ◽  
Gas Turbine Cycle

Increased emphasis is being placed on the regenerative gas turbine cycle, and the utilization of waste heat recovery systems, for improved thermal efficiency. For such systems there are modes of engine operation, where it is possible for a metal fire to occur in the exhaust heat exchanger. This paper is intended as an introduction to the subject, more from an engineering, than metallurgical standpoint, and includes a description of a series of simple tests to acquire an understanding of the problem for a particular application. Some engine operational procedures, and design features, aimed at minimizing the costly and dangerous occurrence of gas turbine heat exchanger fires, are briefly mentioned.

scholarly journals Features of creation and use of effective heat exchangers

2020 ◽  
Vol 216 ◽  
pp. 01124
Author(s):  
Shavkat Agzamov ◽  
Sevinar Nematova
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Heat Exchanger ◽  
Heat Exchange ◽  
Prandtl Number ◽  
Flow Rate ◽  
Heat Exchangers ◽  
Heat Transfer Equation ◽  
The Heat Transfer Coefficient ◽  
Outside Diameter

The article discusses the features of the creation and use of efficient heat exchanger. Designs of pipes with a developed heat exchange is presented. The procedure for determining the degree of development of the heat exchanging surface, the heat transfer coefficient, and the calculation of the heat transfer equation are given. As a result of creating efficient heat exchangers, three main parameters are used: the pipe outside diameter; the estimated flow rate; the Prandtl number.

scholarly journals Experimental Research and Simulation of Fin and Tube Heat Exchanger

2017 ◽  
Vol 9 (4) ◽  
pp. 451-461
Author(s):  
Artur Rubcov ◽  
Sabina Paulauskaitė ◽  
Violeta Misevičiūtė
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Heat Exchanger ◽  
Transfer Coefficient ◽  
Heat Exchangers ◽  
Ventilation System ◽  
Experimental Tests ◽  
Maximum Heat ◽  
Tube Heat Exchanger ◽  
The Heat Transfer Coefficient

The paper provides the results of experimental and theoretical test of a wavy fin and tube heat exchanger used to cool air in a ventilation system when the wavy fin of the heat exchanger is dry and wet. The experimental tests, performed in the range of 1000<Re<4500 of the Reynolds number applying LMTD-LMED methodology, determined the dependency of the heat transfer coefficient on the supplied air flow rate with the varying geometry of the heat exchanger (the number of tube rows, the distance between fins, the thickness of the fin and the diameter of the tube). The experimental tests were performed on 9 heat exchangers in heating and 6 heat exchangers in cooling mode. After processing the results of the experimental tests, empirical equation defining the characteristics of the heat transfer coefficient of all heat exchangers were derived. The maximum heat transfer coefficient deviation is 11.6 percent. The correction factor of the wet fin (Lewis number) depending on the number of Reynolds, which ranges from 0.75 to 1.1 also is determined. Maximum capacity deviation equals 3.7 percent. The obtained equations can only be applied to a certain group of heat exchangers (with the same shape of fins or the distance between the tubes). The results of the experimental test and simulation with ANSYS program are compared and the heat transfer coefficients vary from 6.5 to 11.4 percent.

scholarly journals Heat Transfer Characteristics of Heat Exchangers for Waste Heat Recovery from a Billet Casting Process

Energies ◽  
2019 ◽  
Vol 12 (14) ◽  
pp. 2695
Author(s):  
Ju O Kang ◽  
Sung Chul Kim
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Waste Heat ◽  
Casting Process ◽  
Effective Area ◽  
Total Heat ◽  
Process Conditions ◽  
Heat Absorption ◽  
Industrial Facilities ◽  
The Difference

The application of the thermoelectric generator (TEG) system to various industrial facilities has been explored to reduce greenhouse gas emissions and improve the efficiency of such industrial facilities. In this study, numerical analysis was conducted according to the types and geometry of heat exchangers and manufacture process conditions to recover waste heat from a billet casting process using the TEG system. The total heat absorption increased by up to 10.0% depending on the geometry of the heat exchanger. Under natural convection conditions, the total heat absorption increased by up to 45.5%. As the minimum temperature increased, the effective area increased by five times. When a copper heat exchanger of direct conduction type was used, the difference between the maximum and minimum temperatures was significantly reduced compared to when a stainless steel heat exchanger was used. This confirmed that the copper heat exchanger is more favorable for securing a uniform heat exchanger temperature. A prototype TEG system, including a thermosyphon heat exchanger, was installed and a maximum power of 8.0 W and power density of 740 W/m2 was achieved at a hot side temperature of 130 °C. The results suggest the possibility of recovering waste heat from billet casting processes.

Performance Evaluation of Multi-Stage Shell and Tube Transport Membrane Condenser Heat Exchangers for Low Grade Waste Heat and Water Recovery

2017 ◽  
Author(s):  
Soheil Soleimanikutanaei ◽  
Cheng-Xian Lin ◽  
Dexin Wang
Keyword(s):  
Water Vapor ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Power Plants ◽  
Ceramic Membrane ◽  
Waste Heat ◽  
Low Grade ◽  
Water Recovery ◽  
Multi Stage ◽  
Shell And Tube

In this work for the first time the performance of multi-stage shell and tube Transport Membrane Condenser (TMC) based heat exchangers are evaluated numerically. The present heat exchanger is design to work under high pressure and temperature condition for both heat and water recovery in Oxy-Combustion processes. TMC heat exchangers use the nano-porous and ceramic membrane technology to extract the water vapor and latent heat of condensation from the flue-gas. The most important application of TMC heat exchangers is in the power plants which the water vapor in the presence of other non-condensable gases (i.e. CO2, O2 and N2) exist. Effect of the different arrangement of the multi-stage shell and tube TMC heat exchangers, number of branches and number of heat exchangers in each branch on the heat transfer and water recovery have been studied numerically. A single phase multi-component model is used to assess the capability of single stage TMC heat exchangers in terms of waste heat and water recovery at various inlet conditions. Numerical simulation has been performed using ANSYS-FLUENT software and the condensation rate model has been implemented applying User Define Function. Finally, an optimum configuration for the TMC heat exchanger unit has been proposed and the results of numerical simulations are depicted in terms of temperature and water vapor mass fraction contours.

scholarly journals Investigation of effect of heat exchanger size on power output in low-temperature difference Stirling engines

2021 ◽  
Vol 313 ◽  
pp. 03002
Author(s):  
Linda Hasanovich ◽  
David Nobes
Keyword(s):  
Heat Exchanger ◽  
Low Temperature ◽  
Power Output ◽  
Heat Exchangers ◽  
Waste Heat ◽  
Significant Loss ◽  
Stirling Engine ◽  
Dead Volume ◽  
Optimal Geometry ◽  
Stirling Engines

The Stirling engine is capable of converting any source of thermal energy into kinetic energy, which makes it an attractive option for utilizing low-temperature sources such as geothermal or waste heat below 100 °C. However, at these low temperatures, the effects of losses are proportionally higher due to the lower thermal potential available. One such significant loss is excess dead volume, wherein a significant contributor is the heat exchangers. The heat exchangers must be selected to optimize power output by minimizing the dead volume loss while maximizing the heat transfer to and from the engine. To better understand what the optimal geometry of the heat exchanger components is, a Stirling engine is modelled using a third-order commercial modelling software (Sage) and trends of engine properties of power, temperature, and pressure for different heat exchanger geometries are observed. The results indicate that there is an optimum heat exchanger volume and geometry for low temperature Stirling engines. This optimum is also affected by other engine properties, such as regenerator size and engine speed. These results provide insight into the optimal geometry of these components for low-temperature Stirling engines, as well as providing design guidance for future engines to be built.

scholarly journals DEVELOPMENT OF HIGH EFFICIENT SHELL-AND-TUBE HEAT EXCHANGERS BASED ON PROFILED TUBES

2020 ◽  
Author(s):  
Djamalutdin Chalaev ◽  
◽  
Nina Silnyagina ◽  
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Heat Exchanger ◽  
Heat Exchange ◽  
Transfer Coefficient ◽  
Hydraulic Resistance ◽  
Heat Exchangers ◽  
Experimental Studies ◽  
Corrugated Tube ◽  
The Heat Transfer Coefficient

The use of advanced heat transfer surfaces (corrugated tubes of various modifications) is an effective way to intensify the heat transfer and improve the hydraulic characteristics of tubular heat exchangers. The methods for evaluating the use of such surfaces as working elements in tubular heat exchangers have not been developed so far. The thermal and hydrodynamic processes occurring in the tubes with the developed surfaces were studied to evaluate the efficiency of heat exchange therein. Thin-walled corrugated flexible stainless steel tubes of various modifications were used in experimental studies. The researches were carried out on a laboratory stand, which was designed as a heat exchanger type "tube in tube" with a corrugated inner tube. The stand was equipped with sensors to measure the thermal hydraulic flow conditions. The comparative analysis of operation modes of the heat exchanger with a corrugated inner tube of various modifications and the heat exchanger with a smooth inner tube was performed according to the obtained data. Materials and methods. A convective component of the heat transfer coefficient of corrugated tube increased significantly at identical flow conditions comparing with a smooth tube. Increasing the heat transfer coefficient was in the range of 2.0 to 2.6, and increased with increasing Reynolds number. The increase in heat transfer of specified range outstripped the gain of hydraulic resistance caused by increase of the flow. Results and discussion. CFD model in the software ANSYS CFX 14.5 was adapted to estimate the effect of the tube geometry on the intensity of the heat transfer process. A two-dimensional axially symmetric computer model was used for the calculation. The model is based on Reynolds equation (Navier-Stokes equations for turbulent flow), the continuity equation and the energy equation supplemented by the conditions of uniqueness. SST-turbulence model was used for the solution of the equations. The problem was solved in the conjugate formulation, which allowed assessing the efficiency of heat exchange, depending on various parameters (coolant temperature, coolant velocity, pressure). The criteria dependences were obtained Nu = f (Re, Pr). Conclusions. The use a corrugated tube as a working element in tubular heat exchangers can improve the heat transfer coefficient of 2.0 - 2.6 times, with an increase in hydraulic resistance in the heat exchanger of 2 times (compared with the use of smooth tubes). The criteria dependences obtained on the basis of experimental studies and mathematical modeling allow developing a methodology for engineering calculations for the design of new efficient heat exchangers with corrugated tubes.

scholarly journals Heat Exchanger Process Optimization in A Typical Brewery Plant

2020 ◽  
Vol 5 (1) ◽  
pp. 76-81
Author(s):  
Shadrack Uzoma Mathew ◽  
Lebari Aban Tamzor
Keyword(s):  
Heat Exchanger ◽  
Heat Exchangers ◽  
Waste Heat ◽  
Production Capacity ◽  
Network System ◽  
Heat Exchanger Network ◽  
Heat System ◽  
Pinch Technology ◽  
Cold Stream ◽  
Gross Energy

The research attempts to improve upon the performance efficiency of the heat exchanger network system of Pabod Brewery, Port Harcourt, Rivers State, Nigeria. It swaps the heat system of the plant by the use of Pinch Technology to recover waste heat and integrating the recovered energy for process application. The application software is Microsoft Excel and Problem Table Method was employed in the numerical analysis of data. The gross energy expenditure by the plant is 10.44MW at production capacity of 400,000 liters of beer per day. On quantitative aggregate 6.157MW goes for heating and 4.267MW for cooling. A temperature pinch or minimum approach temperature (ΔTmin)of 100C was used in the pinch analysis of the heat exchangers performance. The research findings confirmed minimum heating utility of 5.04MW and cooling utility of 3.09MW. with energy upturn of 1.08MW and 1.23MW for the hot and cold flows respectively. This correlates to energy conservation of 18% for hot utility and 21% for the cold utility. The hot stream pinch temperature is 710C while that of the cold stream is 610C. Heat exchangers network configuration design were performed above and below the pinch The network designs were produced and integrated to produce improved heat exchanger network system for the Brewery plant.

scholarly journals EFFICIENCY OF THE NOZZLES OF CONTACT HEAT EXCHANGERS

2021 ◽  
Vol 1 (38) ◽  
pp. 92-98
Author(s):  
R. Klimov ◽  
V. Kirilyuk
Keyword(s):  
Energy Efficiency ◽  
Heat Exchanger ◽  
Hydraulic Resistance ◽  
Specific Energy ◽  
Heat Exchangers ◽  
Waste Heat ◽  
Exhaust Gases ◽  
Secondary Energy ◽  
Heat Engineering ◽  
Optimal Type

At powerful thermal power plants or boiler houses, the efficiency depends to the greatest extent on the amount of heat lost with the cooling of turbine condensers, exhaust gases that have a high temperature. Each type of such losses is a large unused energy potential, that is, a secondary energy resource that can be used. At the same time, the use of secondary resources and industrial emissions will improve the ecological situation in the regions, and this has always been an urgent task. As a rule, large losses of thermal secondary energy resources in boilers are reduced by installing economizers and air heaters. Contact types of heat exchangers are distinguished by the best efficiency in operation. In contact economizers, to increase the surface of heat and mass transfer, it is advisable to use various types of nozzles. The aim of the study is to develop such an indicator, with which it is possible to determine the optimal type of nozzle of the contact economizer installed after the steam boiler. This indicator should show the highest heat engineering efficiency of the packing with a small hydraulic resistance of the heat exchanger. By using the coefficient of specific energy efficiency of the packing in the heat exchanger of waste gases of heating equipment, it is possible to analyze the work of the packing space from the standpoint of thermal and hydraulic efficiency and select the optimal type of packing for each individual unit or installation. Geometric parameters determine the required volume of the apparatus and the hydraulic resistance of the exhaust gases movement. The hydraulic resistance affects the consumption of electrical energy for the drive of smoke exhausters for sucking off exhaust gases from heat engineering installations through the free section of the heat exchanger. Taking into account the developed indicator of the specific energy efficiency in waste heat utilizers, it is possible to select such a type of packing, at which the optimal level of waste heat utilization will be achieved.

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