Tubular exchangers, in addition to their heat and pressure resistance, have another significant advantage: a variety of subtypes that can be used in various processes. Tubular type heat exchangers, consisting of a body, inner tubes, and baffles where necessary, can be produced horizontally or vertically depending on the application. This is another advantage that makes tubular exchangers adaptable to different environments.
Custom Manufactured Exchangers
Tubular heat exchangers are a class of heat exchanger that can be customized for use in all processes as needed.
Most of the time, different solutions need to be offered for different processes in heat transfer applications. After learning the details of the process and determining the needs according to these details, tubular exchangers specific to that process are designed by expert mechanical engineers, and a schematic drawing is produced. After checks are made on the schematic drawing to confirm that there are no dimensional problems, manufacturing drawings are produced.
Each exchanger, whose manufacturing drawings are approved, is unique to the process it was designed for and usually does not have an equivalent. After the exchangers are manufactured, they can be insulated on request to minimize heat losses to the exterior. There is no capacity limit in the manufacture of tubular exchangers. Exchangers can be connected in series or parallel, grouped in multiple ways, and their capacities can be increased.
Ekin Industrial, which supplies facilities requiring high capacities such as Petrochemical Plants and Power Plants, is among the leading companies in the sector with its experience in this field.
The following materials are used in the manufacture of tubular exchangers, according to process needs:
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ST37
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ST35.8
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AISI304
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AISI316
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Copper
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Titanium
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Bronze
Hygienic Tubular Exchangers
One of the areas where tubular heat exchangers are used is in food and chemical applications where hygiene is important.
In some food and chemical applications, heat transfer processes are carried out at very high temperatures or pressures. Since the gaskets of plate exchangers cannot withstand these temperatures and pressures, tubular exchangers are preferred in these applications.
The removable and fully hygienic tubular exchangers developed by MIT engineers for these types of applications can withstand temperature limits up to 350°C. The welds in these types of exchangers are also done with great precision to ensure a smooth flow surface.
At the MIT production facility, these types of welds are applied by certified welders and examined by expert engineers within a three-stage quality control process. MIT engineers, experts in food processing processes, consider many variables such as capacity, space, and the type of food to be processed to offer the most suitable solutions during the design process.
In high-pressure applications, factors such as material wall thickness and welding technologies are also of vital importance, in addition to capacity calculations. Therefore, every exchanger produced by Ekin Industrial is tested under pressure 1.5 times the normal operating pressure for 72 hours, and only those that pass this test without issues are dispatched for use.
Stainless and Titanium Pool Exchangers
MIT tubular pool exchangers can be used in a variety of systems, including solar pool heating systems or boiler-based pool heating systems.
MIT pool exchangers ensure a long lifespan for all system components. They protect heating systems by preventing direct contact of chlorine, salt, and other chemicals with the solar system or boiler system, playing a significant role in the continuity of the systems.
MIT pool exchangers are innovatively designed by Ekin Industrial engineers. These innovative products provide much more efficient heat transfer than their counterparts due to their spiral and twisted designs. MIT pool exchangers are designed to offer solutions suitable for the required capacity, making them indispensable for pools, spas, and similar applications.
Features:
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High heat transfer efficiency
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Fast flow due to smooth and polished tubes
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Compact and advanced design
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Wide range of use
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Diverse and extensive capacity sizes
MIT pool exchangers are constructed from a fully pressurized outer shell
and ribbed tubular inner tubes. Thus, while achieving high flow rates inside the exchanger, it also ensures that the exchanger is more durable, more efficient, and more cost-effective.
Ekin Industrial's pool exchangers can be used in projects ranging from small spa pools to Olympic pools due to their wide capacity range. Produced in a range from 15 kW to 1750 kW, MIT pool exchangers offer solutions that can adapt to different needs, with competitive pricing.
Advantages of Pool Exchangers
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High efficiency coefficient of 10000 W/m² °C (5 or 6 times more efficient than traditional exchangers)
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Compact design (Takes up 1/10 the space of traditional exchangers)
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Corrosion and pressure resistance with stainless steel and/or titanium materials
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Non-pressurizing connection design
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Compliance with ASME Standards VIII-1
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Easy installation and durability
MIT pool exchanger bodies and tubes are designed to operate under 205 °C and 1.3 MPa pressure. The body can be chosen from AISI 316L or titanium, and tubes & connections from AISI 316L, AISI 304, or titanium, depending on operating conditions and chlorine content.
Operating Principle of Tubular Pool Exchangers
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MIT pool exchangers perform the heating/cooling process by transferring the heat from the boiler/chiller to the pool water.
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MIT pool exchangers keep the system and pool separate, preventing the passage of chlorine and other chemicals from the pool to the system.
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MIT pool exchangers facilitate heat transfer between the hot water from the heat source and the cold water in the pool, and circulate the cooled water back to the heat source for reheating.
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MIT pool exchangers keep harmful substances away from the system, ensuring the pool is healthy and long-lasting.
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MIT pool exchangers can be designed according to the dimensions of the boilers or the size and system to be used in the pool.
BYS Oil Cooler Exchanger
The grooved copper tubes used in BYS oil coolers have a thickness of 1.2mm and a diameter of Ø16mm. Standard models are suitable for a maximum operating temperature of 140 degrees and a working pressure of 9 Bar, but these products can be enhanced for special operating values. There are 24 different submodels ranging from 18,100 kcal/h to 371,000 kcal/h in terms of capacity.
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Outer Tube Material: ST 35.8
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Inner Tube Material: Copper
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Covers: Cast
MOR Oil Cooler Exchanger
The copper tubes used in MOR oil coolers have a thickness of 0.6mm and a diameter of Ø9.52mm. Suitable for a maximum operating temperature of 120 degrees and a working pressure of 6 Bar, these products have 9 different submodels ranging from 60lt/min to 1200 lt/min in terms of capacity.
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Inner Tube Material: Copper
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Outer Tube Material: ST 35.8
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Covers: Cast
Shell and Tube Heat Exchangers: An In-Depth Examination of Industrial Heat Transfer Systems
Shell and tube heat exchangers are fundamental components in industrial processes that require heat transfer. These exchangers, which play a critical role in energy efficiency and sustainable process optimization, are indispensable in various sectors such as chemical, energy, food processing, and HVAC. This article provides a broad perspective on shell and tube heat exchangers, covering their design, material selection, contributions to energy efficiency, innovative designs and developments, installation and maintenance guides, cost analyses, and legal compliance standards.
Detailed Design Features and Material Selection
Main Components of Shell and Tube Heat Exchangers:
Tube Bundle: Consists of variously arranged tubes that form the primary heat transfer surface.
Shell and Headers: Structural elements that direct the flow of fluids into and out of the exchanger. The shell protects the tubes from external influences, while headers facilitate fluid distribution.
Flanges and Gaskets: Parts that maintain system integrity and provide sealing properties.
Material Selection and Properties:
Materials such as stainless steel, copper, aluminum, and titanium are chosen for their high heat transfer capacity and corrosion resistance. Factors such as resistance to high temperatures and pressures are decisive in material selection.
Operating Principles and Heat Transfer Models
Heat Transfer Dynamics:
Counterflow: Provides the highest efficiency in heat transfer as fluids move in opposite directions.
Parallel Flow and Cross Flow: These arrangements meet specific process needs by offering different heat transfer requirements.
Energy Efficiency and Environmental Sustainability
Exchangers enhance operational efficiency by minimizing energy consumption and recovering waste heat. From an environmental sustainability perspective, these systems play a significant role in reducing the carbon footprint of operations.
Innovative Design and Technology Integration
Smart shell and tube heat exchanger systems equipped with sensors and IoT devices continuously monitor and optimize performance. These innovations lead to lower maintenance costs and higher system efficiency.
Installation, Maintenance, and Operational Guide
The installation and maintenance of shell and tube heat exchangers have critical impacts on system performance. Regular maintenance prevents failures and extends the life of the exchanger.
Cost Analysis and Economic Impacts
In addition to initial investment and operational costs, the payback periods of shell and tube heat exchangers offer cost-effective solutions
Legal and Standard Compliance
Compliance with ASME, ISO, and other national and international standards ensures the safe and efficient use of shell and tube heat exchangers. Environmental regulations shape design and operational standards while compliance enhances industrial safety and performance.
Conclusion As indispensable elements of industrial facilities, shell and tube heat exchangers hold significant importance for energy efficiency and operational safety. Advances in technology and materials science will continue to enhance the effectiveness of these exchangers, ensuring they remain fundamental to industries in the future.
This comprehensive review should give a detailed overview of shell and tube heat exchangers, providing readers with insights into technical details, applications, and economic evaluations.
Installation of Shell and Tube Heat Exchangers:
A Step-by-Step Guide
Shell and tube heat exchangers play a critical role in industrial processes. Proper installation directly affects the efficiency, functionality, and lifespan of these systems. This article will provide a step-by-step guide to the installation process of shell and tube heat exchangers, addressing potential challenges and offering solutions.
Pre-Installation Preparation
Site Selection:
The area where the exchanger will be installed should be spacious enough to allow easy access for maintenance and repair.
Choose a location that is protected from environmental elements and where heat and humidity can be controlled.
Tools and Equipment:
Prepare necessary tools such as wrench sets, screwdrivers, pliers, and measuring instruments in advance.
Plan to use lifting and transporting equipment (like cranes, forklifts, etc.) for heavy exchangers. Installation Process
Step 1: Base Placement and Assembly
The foundation for mounting the exchanger should be solid and properly prepared. The base should be designed to absorb vibrations and support structural integrity.
Ensure correct positioning of pipe connections, flanges, and supports.
Step 2: Making Pipe Connections
Gaskets should be carefully placed for sealing, and connection points securely tightened.
Fluid lines must be appropriately connected to the exchanger and checked for any errors in the system.
Step 3: System Testing
After all connections are made, the system should undergo critical tests such as pressure testing and leak testing.
Detailed checks for air leaks, water leaks, or other potential issues should be conducted.
Post-Installation Procedures
System Commissioning:
Before commissioning the exchanger, review all checklists and follow operating instructions accurately.
Start the system at low speed and gradually adjust it to reach full operational capacity.
Maintenance and Monitoring:
Regular maintenance and monitoring after installation ensure the long-term and efficient operation of the exchanger.
Any abnormal conditions in the exchanger should be immediately identified and addressed after the initial operation period.
Proper installation of shell and tube heat exchangers is critical for ensuring efficient and reliable system operation. This guide serves as a valuable resource for engineers and technical staff planning to install shell and tube heat exchangers in industrial facilities. Careful execution of these steps is necessary to overcome installation challenges and achieve optimal performance.