Collaboration blog between Venwiz and Nuberg Engineering Ltd.: Understanding how to select heat exchangers for your plant.
Choosing the right heat exchanger for your plant is essential for maintaining efficiency, reducing energy costs, and boosting overall productivity. These equipment help in transferring heat between two or more fluids without mixing them and are widely used in various industries from power generation and chemical processing to food manufacturing, and HVAC systems. This comprehensive blog guides you through the various parameters you should consider when you select a heat exchanger for your plant.
Table of content
- Understanding heat exchangers
- Types of heat exchangers
- Key Factors to Consider When You Select a Heat Exchanger
- Nuberg’s Capabilities
- Venwiz and Nuberg Engineering Ltd : A Partnership for supply of Process Equipments
- NUBERG ENGINEERING LTD
Understanding heat exchangers
Heat exchangers are special devices that transfer thermal energy between two or more fluid streams (liquid, vapour, or gas) at different temperatures. This transfer occurs either through direct contact or through a physical barrier that prevents the fluids from mixing. The Second Law of Thermodynamics governs this transfer. The law states that heat naturally flows from hotter to cooler substances.
Learn how heat exchangers can lower energy Costs.
Types of heat exchangers
We can categorise heat exchangers based on:
Configuration
- Cocurrent Flow: Cocurrent flow heat exchangers, or parallel flow heat exchangers, are heat exchangers where fluids move parallel to and in the same direction, resulting in lower efficiencies but ensuring the greatest thermal uniformity across the heat exchanger’s walls.
- Countercurrent Flow: Countercurrent flow heat exchangers, also known as counter flow heat exchangers, are designed to move fluids in opposite directions within the heat exchanger. These flow configurations are commonly used due to their high efficiencies, which allow for maximum heat transfer and temperature change.
- Crossflow: Crossflow heat exchangers use perpendicular fluid flow, resulting in efficiencies ranging between countercurrent and concurrent heat exchangers.
- Hybrid: Hybrid flow heat exchangers combine various flow configurations, such as counterflow and crossflow arrangements, within a single heat exchanger. These types are designed to meet application limitations like space, budget, or temperature and pressure requirements.
Construction
Finned tube heat exchanger
Finned tube heat exchangers or air-cooled heat exchangers (ACHEs), coolers, or dryers are efficient units that circulate a liquid into tubes while pumping gas or air to cool it down. They can be enclosed in ductwork or fully exposed with air flowing over them. The efficiency of these units is due to the extended fins that protrude into the air/gas flow, improving the structure’s heat transfer ability.
Shell and tube heat exchanger
Shell and tube heat exchangers transfer hot or cold fluid or gas through a tube bundle or series of tubes enclosed in a large metal shell, while the counter-flowing fluid or gas is pumped into the shell, facilitating heat transfer.
Double tube heat exchanger
In double-pipe heat exchangers, the entire heat transfer process takes place inside the bigger pipe, which has a small pipe concentrically inserted inside of it. The inner pipe functions as a conductive barrier because one fluid passes through it and another fluid is between the two pipes. Fluid flow passing on the inner, or tube side, is included in the exterior, or shell side.
Key Factors to Consider When You Select a Heat Exchanger
While selecting a heat exchanger for your plant, some of the factors you need to consider include:
Temperature and pressure requirements:
The temperature and pressure parameters influence the heat exchanger’s material of construction and design. High-temperature applications may require alloys, while low-pressure systems may use carbon steel. Higher-pressure applications may require thicker walls or reinforcement. The input and output temperatures and pressure of fluids must be defined to accommodate thermal expansion and contraction, and have robust design features to prevent failures or leaks.
Fluid properties
To ensure optimal performance and durability of a heat exchanger in a plant exchanger, it is crucial to evaluate fluid properties such as viscosity, fouling, and corrosion. Corrosive fluids may require specific materials or coatings to prevent damage and maintain performance. Fouling potential affects heat transfer efficiency and maintenance requirements. Fluid properties also determine material selection, configuration, and operating parameters.
Ease of maintenance
You need to evaluate the heat exchanger cleaning and maintenance requirements. Select a design that makes it easy to inspect, clean, and access. The ease of maintenance helps to minimize downtime and the long-term performance of the heat exchanger. Maintenance will depend on factors such as the amount of fouling and scaling on the heat exchanger surface. By implementing a regular maintenance schedule, you can help prolong the life of the heat exchanger.
Cost considerations
Cost is a significant factor in heat exchanger selection. To determine the most cost-effective solution, compare the prices of different heat exchangers, including supply and installation costs and maintenance costs. To assess the return on investment, factors like energy efficiency, operational costs, durability, and the projected life span of the heat exchanger need to be factored in.
Nuberg’s Capabilities
| S. No | Parameters | Description |
|---|---|---|
| 1 | Operating temperature | 500-600 DegC |
| 2 | Operating pressure | 250 Kg/cm2 |
| 3 | Sizing (thickness, dia) | 100mm / Up to 6000 mm |
| 4 | Design parameter | ASME (American Society of Mechanical Engineers) Section VIII, Div 1 & 2 U, U2 & S stamp TEMA (Tubular Exchanger Manufacturers Association) U, U2 & S stamp IBR (Indian boiler regulation) PESO ( Petroleum and Explosives Safety Organization) |
| 5. | MOC | • Carbon Steel • Alloy Steel • Stainless Steel • Duplex & Super Duplex Stainless Steel • Clad Steel • Titanium GR 2, GR 5, GR 7, GR 12 • Brass • Monel • Cupro Nickel |
Industries Catered by Nuberg
| S. No | Industry | Heat exchanger | Factor to consider |
|---|---|---|---|
| 1 | Chemical Industry | Shell & Tube type | Process parameter |
| 2 | Oil & Gas | Shell and Tube heat exchanger | Process conditions |
| 3 | Steel | Shell & Tube type | Process parameter |
| 4 | Fertilizers | Shell and Tube heat exchanger | Process conditions |
Venwiz and Nuberg Engineering Ltd : A Partnership for supply of Process Equipments
Venwiz is the perfect platform for streamlining industrial procurement. With over 25,000 vendors spread over 50 categories in our database from across the country, it is easy to find vendors to meet your requirements. Get quotes from multiple suppliers, manage your projects, and streamline your procurement process effortlessly. We’re excited to collaborate with Nuberg Engineering Ltd, a leading Indian manufacturer of heat exchangers and other process equipment, to bring you this valuable information.
NUBERG ENGINEERING LTD
Nuberg Engineering Ltd is a major player in the global project engineering and turnkey contracting industry. Their team of experienced professionals offers top-notch services across various sectors. This includes engineering design, chemical process technology, procurement, project implementation, commissioning, and heavy fabrication.
Nuberg caters to diverse industries, including chemicals & fertilizers, nuclear & defence, steel and oil & gas. Nuberg is a multi-national company with the following divisions:
- EPC
- Heavy Fabrication
- Gas Plant Division
The company specialises in delivering a range of process equipment for various sectors.
Case study
This case study showcases Nuberg Engineering Pvt. Ltd.’s expertise in designing and manufacturing large-scale heat exchangers for challenging environments. We focus on a successful project involving the construction of two PGC Gas Coolers.
Project Overview:
- Equipment: Two (2) PGC Gas Coolers
- Dimensions: Each cooler measured 3.35 meters in length, 3.3 meters in width, and a staggering 22.5 meters in height.
Challenges
- Massive Scale: The sheer size and weight of each cooler presented a significant logistical hurdle. Each unit weighed approximately 150 tons, requiring specialized transportation and installation techniques.
- Angled Tube Design: The project demanded tubes to be positioned at an angle, necessitating intricate inclined drilling of the headers and tube sheets. This added complexity to the manufacturing process and required precise execution.
- Highly Flammable Gas: The coolers were designed to handle highly flammable coke oven gas. This necessitated meticulous sealing of all expanded tube joints to prevent leaks and ensure the safety of personnel and the surrounding environment.
- Protective Coating: The tubes themselves required a Bakelite coating to withstand the harsh operating conditions and potential corrosive nature of the coke oven gas.
Solutions
Nuberg’s team of experienced engineers successfully addressed all the challenges and successfully executed the project:
- Heavy Fabrication Expertise: Nuberg’s experience in handling large and complex equipment allowed them to efficiently manage the massive size and weight of the gas coolers.
- Precision Engineering: Utilizing advanced techniques, Nuberg’s engineers flawlessly executed the angled tube design with precise inclined drilling of the headers and tube sheets.
- Safety First: Stringent quality control measures were implemented to ensure flawless sealing of all expanded tube joints, guaranteeing safe operation with the highly flammable gas.
- Custom Coating: Nuberg applied the required Bakelite coating to the tubes, ensuring their durability and optimal performance within the specific operating environment.
Result
By overcoming these challenges, Nuberg delivered two high-performance PGC Gas Coolers that met all the client’s requirements. These coolers efficiently remove heat from the coke oven gas stream, contributing to a smooth and safe operation of the client’s industrial process.
Product Success
| S. No | Client name | Industry/sector | Project description |
|---|---|---|---|
| 1 | ONGC | Oil & Gas | LSTK contracts for 5 columns with a maximum weight of 154 MT |
| 2 | Warri refinery | Oil & Gas | U Stamp FCCU Columns (4 nos.) |
| 3 | Air Liquide | Edible Oil | IBR Heat Exchanger |
| 4 | Gail | Oil & Gas | Hairpin-type heat exchanger |
Certifications
Nuberg Engineering Pvt. Ltd. is committed to quality, which is reflected in its numerous certifications. The company has the following certifications:
- ISO 9001-2015
- ISO 14001-2015
- ISO 45001-2018
- R Stamp
- PESO
- ASME (U, U2 & S)
Guest Author
Mr. Amit Walia is the AGM – Business Development, with 20+ years of experience in the industry. Throughout his career, he has demonstrated a passion for creating new business opportunities and has proven to be an asset to the organisation.
As an AGM, Mr. Walia has been negotiating high-value contracts and partnerships with industry leaders & developing and implementing innovative sales strategies that have consistently exceeded revenue targets. His commitment to excellence and innovation has earned him the respect and admiration of colleagues and clients alike.
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