Tubular heat exchangers have an important advantage besides their heat and pressure resistance, which is the variety of subtypes that can be used in various processes. Tube type heat exchangers, consisting of body, inner tube, and necessary curtains, can be produced horizontally and vertically according to the application. This is another advantage of tube exchangers that allows them to be compatible with different environments.
Custom Production Heat Exchangers
Tubular heat exchangers are a class of heat exchangers that can be customized according to the need to be used in all processes.
In heat transfer applications, different solutions are often required for different processes. After learning the details of the process and determining the needs based on these details, tube exchangers specially designed for that process are designed by expert mechanical engineers and schematic drawings are prepared. After confirming that there are no dimensional issues in the controls made on the schematic drawings, manufacturing drawings are prepared.
Each approved exchanger manufactured is specially designed for the process it is intended for and usually has no equivalent. After manufacturing, exchangers can be insulated according to demand to minimize heat losses to the outside. There is no capacity limit in the manufacture of tube exchangers. Exchangers can be grouped in series or parallel and their capacities can be increased in multiple ways.
Ekin Endüstriyel, one of the leading companies in the sector with its experience in supplying facilities requiring high capacities such as Petrochemical Plants and Power Plants.
According to process needs, the following materials are used in the manufacture of tube exchangers:
- ST37
- ST35.8
- AISI304
- AISI316
- Copper
- Titanium
- Bafon
Hygienic Tubular Heat 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 seals of plate heat exchangers cannot withstand the mentioned temperatures and pressures, tubular exchangers are preferred in these applications.
Removable and fully hygienic tubular heat exchangers developed by MIT engineers for such applications have a temperature limit of up to 350°C. The welds in these exchangers are also made very precisely to provide a smooth flow surface.
In MIT's production facility, these types of welds are applied by certified welders and examined by expert engineers within a 3-stage quality control process. MIT engineers specializing in food processing processes take into account various factors such as capacity, location, and type of food to be processed to offer the most suitable solutions for the process during the design phase.
In high-pressure applications, factors such as material thickness, welding technologies are also crucial. Therefore, each exchanger produced by Ekin Endüstriyel is subjected to a pressure test at 1.5 times the normal operating pressure for 72 hours, and only exchangers that pass this test without any issues are dispatched for use.
Stainless Steel and Titanium Pool Heat Exchangers
MIT tubular pool heat exchangers can be used in a variety of systems such as solar pool heating systems or boiler-equipped pool heating systems.
MIT pool heat exchangers ensure long life for all system components. By preventing direct contact of chlorine, salt, and other chemicals with the solar system or boiler system, they protect heating systems and play an important role in the continuity of the systems.
MIT pool heat exchangers are designed innovatively by Ekin Endüstriyel engineers. These innovative products provide much more efficient heat transfer than their counterparts thanks to their spiral and helical designs. MIT pool heat exchangers are designed to offer solutions suitable for various needs with a wide capacity range. These exchangers are indispensable for applications such as pools, spas, and similar applications.
Features:
- High heat transfer efficiency
- Fast flow due to soft and smooth tubes
- Compact and advanced design
- Wide range of usage
- Different and wide range of capacities
MIT pool heat exchangers are built entirely with a pressurized outer shell and grooved tube inner tubes. Thus, while achieving high flow rates inside the exchanger, the exchanger becomes more durable, more efficient, and more cost-effective.
Due to the wide capacity range of Ekin Endüstriyel's pool heat exchangers, they can be used in all kinds of projects from small spa pools to Olympic pools. MIT pool heat exchangers, which are produced in a range from 15 kW to 1750 kW, offer competitive-priced solutions that can adapt to different needs.
Advantages of Pool Heat Exchangers
- High efficiency coefficient of 10000 W/m² °C (5 to 6 times more efficient than traditional exchangers)
- Compact design (occupies 1/10 of the space compared to traditional exchangers)
- Corrosion and pressure resistance with stainless steel and/or titanium materials
- Non-burdening connection design
- Compliance with ASME Standards VIII-1
- Easy assembly and durability
MIT pool heat exchanger bodies and tubes are designed to operate under 205 °C and 1.3 MPa pressure. The body is made of AISI 316L or titanium, while the tubes and connections are selected from AISI 316L, AISI 304, or titanium materials according to operating conditions and chlorine content.
Working Principle of Tubular Pool Heat Exchangers
- MIT pool heat exchangers transfer the heating/cooling process from the boiler/chiller to the water in the pool
- By keeping the system and pool separate, MIT pool heat exchangers prevent the passage of chlorine and other chemicals from the pool to the system
- MIT pool heat exchangers provide heat transfer between hot water from the heat source and cold water in the pool and transfer the cooled water back to the heat source for reheating
- MIT pool heat exchangers keep harmful substances away from the system, ensuring the health and longevity of the pool
- MIT pool heat exchangers can be designed according to the size of the boiler, the length of the pool, and the system to be used
BOY Oil Cooler Heat Exchanger
The grooved copper tubes used in BOY oil coolers have a wall thickness of 1.2mm and a diameter of Ø16mm. These products, suitable for a maximum operating temperature of 140 degrees and a working pressure of 9 Bar by default, can be improved to work with special operating values. There are 24 different sub-models available between 18,100 kcal/h and 371,000 kcal/h based on capacity.
- Outer Tube Material: ST 35.8
- Inner Tube Material: Copper
- Caps: Casting
MOR Oil Cooler Heat Exchanger
The copper tubes used in MOR oil coolers have a wall thickness of 0.6mm and a diameter of Ø9.52mm. These products, suitable for a maximum operating temperature of 120 degrees and a working pressure of 6 Bar, have 9 different sub-models available between 60lt/min and 1200 lt/min based on capacity.
- Inner Tube Material: Copper
- Outer Tube Material: ST 35.8
- Caps: Casting
Tubular Heat Exchangers: In Industrial Heat Transfer Systems
Tubular heat exchangers play a critical role as fundamental elements of heat transfer in industrial processes. Providing energy efficiency and sustainable process optimization, these exchangers are indispensable in various sectors such as chemistry, energy, food processing, and HVAC. This article provides a broad perspective ranging from the design of tubular heat exchangers, material selection, contributions to energy efficiency, innovative design and improvements, installation and maintenance guides, cost analysis, and compliance with legal standards.
Detailed Design Features and Material Selection for Tubular Heat Exchangers:
Main Components of Tubular Heat Exchangers:
1-Tube Bundle: Tubes placed in various arrangements constitute the main heat transfer surface.
2-Header and Body: Structural elements that direct the entry and exit of fluids into the exchanger. While the body protects the tubes from external influences, the header ensures the distribution of fluids.
3-Flanges and Gaskets: Parts that ensure the integrity of the system and provide sealing properties.
Material Selection and Characteristics:
Stainless steel, copper, aluminum, and titanium provide high heat conduction capacity and corrosion resistance. Factors such as high-temperature and pressure resistance are decisive in material selection.
Working Principle and Heat Transfer Models:
Heat Transfer Dynamics:
Counterflow: Provides heat transfer with the highest efficiency. Fluids move in opposite directions.
Parallel Flow and Crossflow: These arrangements, suitable for certain processes, meet different heat transfer needs.
Energy Efficiency and Environmental Sustainability
Exchangers increase energy efficiency through low energy consumption and waste heat recovery. In terms of environmental sustainability, these systems play an important role in reducing businesses' carbon footprint.
Innovative Design and Technology Integration
Smart tubular exchanger systems equipped with sensors and IoT devices continuously monitor and optimize performance. These innovations provide lower maintenance costs and higher system efficiency.
Cost Analysis and Economic Impacts
In addition to initial investment and operating costs, tubular exchangers offer cost-effective solutions in terms of return on investment periods.
Legal and Standard Compliance
Compliance with ASME, PED, ISO, and other national and international standards ensures the safe and efficient use of tubular exchangers. Compliance with environmental regulations, design, and operation standards enhances industrial safety and performance.
Tubular heat exchangers, as essential elements of industrial facilities, are of great importance for energy efficiency and operational safety. Evolving technologies and materials science enable more effective use of these exchangers, ensuring that they continue to be the cornerstone of industries in the future.
Installation of Tubular Heat Exchangers: Step by Step
Tubular heat exchangers are critical thermal devices that play a significant 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 tubular heat exchangers and address challenges that may be encountered, along with proposed solutions.
Pre-Installation Preparation
Site Selection:
The area where the exchanger will be installed should be sufficiently spacious to provide easy access for maintenance and repair operations.
A location where environmental factors are sheltered and heat and humidity are controlled should be preferred.
Tools and Equipment:
The necessary tools for installation, such as a key set, screwdriver, pliers, and measuring instruments, should be prepared in advance.
Lifting and transportation equipment (winch, forklift, etc.) should be planned for handling heavy exchangers.
Installation Process
Step 1: Foundation Layout and Assembly
The foundation on which the exchanger will be mounted should be prepared sturdily and smoothly. The foundation should be designed to prevent vibrations and support structural integrity.
Proper positioning of pipe connections, flanges, and supports should be ensured.
Step 2: Making Pipe Connections
Gaskets should be carefully placed for tightness, and connection points should be securely tightened for a safe connection.
Fluid lines should be connected to the exchanger correctly, and checks should be made for any errors in the system.
Step 3: System Tests
After all connections are completed, the system should undergo important tests such as pressure testing and leak testing.
Detailed checks should be made for air leakage, water leakage, or other potential problems in the system.
Post-Installation Procedures
System Commissioning:
Before commissioning the exchanger, all checklists should be reviewed, and operations should be carried out in accordance with operating instructions.
The system should be started at low speed to reach full operational capacity gradually.
Maintenance and Monitoring:
Regular maintenance and monitoring after installation ensure the long life and efficient operation of the exchanger.
After the initial operational period, any abnormal conditions in the exchanger should be immediately detected, and necessary interventions should be made.
As a result, the correct installation of tubular heat exchangers is of critical importance to ensure the efficient and reliable operation of the system. This guide will be a valuable resource for engineers and technical personnel planning the installation of tubular exchangers in industrial facilities. Careful implementation of steps is required to overcome challenges encountered during the installation process and to ensure optimal performance.