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How to Design a Heat Exchanger

A Heat Exchanger is a device that exchanges heat and/or coolant. There are different types, including Shell and tube, Frame, Plate, and Air Cooled. The design of the device must meet process requirements and specifications while minimizing cost. There are several factors to consider in the design of a Heat Exchanger.
Shell and tube
There are several types of shell and tube heat exchangers. A fixed tube-sheet type BEM has an inside diameter of 120 inches, while an internal-floating-head type AES has an outside diameter of 24 inches. Both types of shells are commonly made of steel. Shells larger than 24 inches are typically made of rolled steel plate. The relative cost of the two types is not much different.
A plate heat exchanger uses alternating channels to move hot and cold fluids. The plate size can range from a few square centimeters to two to three square meters. The number of plates within the exchanger can range from ten to several hundred. In addition to the size, the surface exchange area can reach thousands of square meters.
The frame of the heat exchanger is made up of a number of parts. These include the follower plate, two divider plates, some legs, and an end plate. Some heat exchangers have no plates.
Air Cooled
An air cooled heat exchanger is an efficient method for transferring heat from a liquid or gas to another fluid. This type of exchanger works by passing air over a surface containing conductive fins. The air then transfers that heat to the fluid flowing through conductive tubing that is mechanically bonded to the fins. These exchangers are widely used in industrial applications. Air cooled heat exchangers are the most effective type of heat exchanger for gas-to-liquid heat transfer.
A recuperator is a special purpose counter-flow energy recovery heat exchanger. It is used in the exhaust gas stream of industrial processes or in air handling systems to recover waste heat.