Maxwor Shell & Tube Heat Exchangers consist of a cylindrical body with parallel heat transfer tubes. While one of the fluids passes through the tubes, the other passes through the body and provides the heat transfer between the fluids. It is the most widely used heat exchanger in oil refineries and large chemical plants and is suitable for higher pressure applications.
Necessary information to design a shell and tube heat exchanger; flow rate, temperature and physical properties of fluids. Besides, other data that may be important depending on the application are the inlet pressure, maximum acceptable pressure drop and flow rate.
DESIGN and MANUFACTURING
Thermodynamic calculations for heat exchangers are made with professional programs and design and mechanical calculations are made according to TEMA standard and 2014/68/EU PED (Pressure Equipment Directive) Pressure Vessel directive EN 13445 standard. Body and heating tubes are made of materials manufactured in conformity with EN 10216 and EN 10217 manufacturing standards, tubesheet, cover and baffles are made of materials manufactured in conformity with EN 10025 and EN 10028 manufacturing standards, counter flanges are made of materials manufactured in conformity with EN 1092 manufacturing standard under fluid and pressure class. They are delivered to customers as painted according to customer request following hydrostatic pressure tests.
Upon the request of the customer they are manufactured with CE certification by generating a quality information file.
All criteria in the directive (material certificates, WPS, WPQR, welding consumables certificates, technical drawings, thermodynamic calculations, mechanical calculations, RT-UT-MT-PT personnel information and test results, pressure test reports, measurement devices, calibration documents, risk analysis, conformity statement, basic safety requirements, operating manual, name plate with CE sign and stamp of the approved institution) are subject to inspection during various phases of production by approved institutions, and CE certificate and quality information file are delivered with the product showing the conformity of the design and the product being manufactured within the limits of the standard.
MATERIAL and TECHNICAL PARAMETERS
Shell Diameter : 3700mm (max)
Length : 25m (max)
Weight : 70 tons (max)
Operating Pressure: 1000bar (max)
Our main engineering materials that we use in heat exchanger manufacturing according to customer request and process information,
- Carbon steel,
- Low Alloy Steel,
- Stainless steel,
- Duplex Stainless Steel,
- Copper and Copper Alloys,
- Copper-Nickel Alloys,
- Nickel,
- Nickel Alloys,
- Titanium.
ADVANTAGES OF SHELL AND TUBE HEAT EXCHANGER
- They can be designed and manufactured to operate under very high pressures.
- They have an extremely flexible and fixed design.
- They can be designed and manufactured to withstand very high and very low temperatures.
- They are resistant to thermal shocks.
- No size limit.
- They can be used in all applications.
- Pressure loss is at a minimum and can be kept to a minimum for process purpose.
- They can be disassembled and reassembled for maintenance, repair and cleaning.
- Tube diameter, tube number, tube length, tube pitch and tube placement can be changed. Therefore, the designs of tube heat exchangers are quite flexible.
DISADVANTAGES OF SHELL & TUBE EXCHANGERS
- The heat transfer coefficient is lower, so the heat transfer areas are usually large,
- Cleaning and maintenance is inconvenient as movement space is required to remove the inner tubes,
- In case of need, the heat exchanger capacity cannot be increased.
STEAM SHELL & TUBE HEAT EXCHANGERS
Steam Heat Exchangers are used for heating gas, water, oil and similar fluids by utilizing steam energy. These are one of the most efficient heat exchangers by enabling constant steam temperature during condensate generation..
Relief valves and gaskets are very important in steam heat exchangers. Gaskets suitable to the temperature at operating pressure values and suitable relief valves for slightly over operating temperature has to be used.
The most important matter to pay attention in steam heat exchangers is the quality and the cleanliness of the steam. Having the feed water calcareous and highly polluted and lower conductivity values can affect heat exchanger output capacity directly. Use of improper water may block heating tubes in the heat exchangers and accordingly heat exchanger output can fall and the heat exchanger may even become unusable.
Second important matter that has to be paid attention in steam heat exchangers is that the amount of condensate during the regime and at peak times can be balanced by steam trap. The compensator (expansion joint) used in the heat exchanger body is designed according to the elongation amounts determined by considering the expansion calculations of the heat exchangers. Thanks to the compensator (expansion joint), the expansions that may arise from the material and temperature difference during heat transfer can be absorbed and a longer life of the heat exchanger is ensured.
SUPERHEATED and HOT WATER HEAT EXCHANGERS
KHot water heat exchangers are used for heating gas, water, oil and similar fluids by utilizing superheated and hot water energy. Hot water heat exchangers offer a simple and effective solution. Armature of hot water heat exchangers are less costly compared to other processes.
The most important matter to pay attention in superheated water and hot water heat exchangers is the pollutive effect of the substances in the water. When the amount of pollutive substances and lime amount is high, radiator output can drop and maintainance period becomes shorter. Also special attention is paid on pressure values in designs and calculations in order to avoid steam formation in hot water. High pressures may occur in superheated water heat exchangers when there is steam formation. Not to cause steam formation, plate values on the heat exchangers has to be observed.
SWIMMING POOL HEAT EXCHANGERS
Shell and Tube type heat exchangers produced for use in swimming pool heating are generally produced from 316L or 316Ti material. There is a usage area from small pools to large olympic pools in the range of 15KW-1750KW.
EXHAUST GAS HEAT EXCHANGERS
Exhaust Gas Shell and Tube Heat exchangers are used to increase the efficiency of stationary engines in combined cycle power plants, cogeneration and trigeneration systems. The energy obtained from cooling the exhaust gas is generally used to heat water or hot oil.
Multi-stage exhaust gas heat exchanger concepts are also realized, in which the exhaust gas is cooled below the dew point. In this way, the energy of the exhaust gas, including the heating value part, can be used efficiently.
It is generally used in the exhausts of natural gas and biogas engines.
In line with the demands of our customers, materials and components are selected in accordance with the requirements of the facility/site.
OIL COOLER HEAT EXCHANGERS
Oil cooler Shell and Tube heat exchangers are used for cooling of heat transfer oils, lubricating oils and cooling oils. These high quality products are produced with the combination of the best materials and the latest production techniques.
It can be designed as fresh water cooled and sea water cooled in standard production. It is possible to classify products as high efficiency, easy cleaning, durability and economical.
It is used in processes where gasketed and brazed plate exchangers are difficult.
DOUBLE PIPE HEAT EXCHANGERS
It is frequently used in the food and pharmaceutical industries thanks to its high heat transfer. They are specially designed corrugated double pipe heat exchangers. While the product passes through the inner tube, the heater or refrigerant flows between the inner and outer tubes. Corrugated inner tube increases heat transfer. Thanks to the double pipes, even in case of a puncture, the fluids do not mix with each other.
The tubes used in this heat exchanger can be SS316L quality and polished according to the process. It can also be manufactured in accordance with ASME BPE standards. The smoothness of the surfaces on which the product passes and the absence of any dead space inside prevents microorganisms from living. The connections on the pipe side (hygienic side) are designed as flanged according to DIN 32676-A (Tri-Clamp), while the connections on the body side are designed with flanges according to EN 1092-1.
EVAPORATOR AND CONDENSER
Evaporators are heat exchangers used to enable another fluid from waste gases or similar fluids to pass from liquid state to gas state at high temperatures.
KCondensers are heat exchangers produced for the purpose of condensing secondary refrigerant or gas fluids by utilizing the energy of the process air.
While making thermodynamic calculations, the amount of moisture to be condensed, the type of gas, the temperature and the specific heat values are in the foreground. Humidity, which directly affects the capacity, is manifested by latent heat.
In such cooling systems, pressure values can be at high levels due to evaporation. One of the most important issues in evaporators is the safety valves in the heat exchanger. Excessive pressure can disrupt the system and cause loss of life and property. Another important issue is the thermophysical properties of the refrigerant. In gaseous processes, fluid velocities must remain within certain limits according to TEMA. It is important that the gasket selections are made correctly.
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