Heat Exchanger (Alat Penukar Kalor) MCF 41264 (4 SKS)

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Gambar 3.2.2 Diagram Alir Mata Kuliah Program Studi Teknik Mesin

Tujuan Pembelajaran

Mengenal jenis-jenis alat penukar kalor Mengetahui jenis APK yang paling baik untuk aplikasi industri yang ada Mengerti parameter kunci dalam desain APK Mampu mengestimasi ukuran dan harga APK Memiliki latarbelakang untuk menggunakan software komersial untuk mendesain APK

Pendahuluan Heat Exchangers Untuk apakah Alat Penukar Kalor? Jenis-Jenis Alat Penukar Kalor Bagaimana Alat penukar kalor diklasifikasikan? Dasar-dasar perencanaan Alat Penukar Kalor?

Contents

Mengapa kita membutuhkan APK Konstruksi APK Macam-macam APK Proses Desain APK

Apakah fungsi APK itu ?

Untuk memperoleh aliran fluida pada temperatur yang tepat untuk proses berikutnya Untuk mengkondensasikan uap Untuk menguapkan fluida Untuk memanfaatkan panas buang Untuk pembangkitan daya

Feed-effluent exchanger

Feed-effluent exchanger

Exothermic reaction

Heat recovery

Distillation
Reflux condenser

Top product

Feed

Column
Reboiler

Bottom product

Typical crude oil distillation

Top pump around Desalter Top pump around Heavy gas oil

Naphtha and gases

Kerosene

Distillation tower

E2
Bottom pump around

Light gas oil

E2
Kerosene

E3
Light gas oil

E5

Heavy gas oil

E4 E1 E5
Storage Bottom pump around

Furnace

E6
Reduced crude

Reduced crude

Geothermal Power cycle

Feedwater heater

Nuclear Power Plant

Ocean Thermal Energy Conversion

Contoh sebuah APK

Bundle for shell-and-tube exchanger

Heat utilities

Hot utilities
Boiler generating service steam (maybe a combined heat and power plant) Direct fired heaters (furnace) Electric heaters

Cold utilities
Cooling tower (wet or dry) providing service cooling water Direct air-cooled heat exchanger

Jenis-Jenis Alat Penukar Kalor

KATEGORI UTAMA ALAT PENUKAR KALOR

Heat exchangers

Recuperators
Wall separating streams

Regenerators
Direct contact

Kebanyakan Alat Penukar Kalor memeliki 2 aliran fluida, hot dan cold, tetapi beberapa memiliki lebih dari dua aliran fluida

Recuperators dan regenerators

Recuperative Has separate flow paths for each fluid which flow simultaneously through the exchanger transferring heat between the streams Regenerative Has a single flow path which the hot and cold fluids alternately pass through.

Rotating wheel

Compactness

Can be measured by the heat-transfer area per unit volume or by channel size Conventional exchangers (shell and tube) have channel size of 10 to 30 mm giving about 100m2/m3 Plate-type exchangers have typically 5mm channel size with more than 200m2/m3 More compact types available

Compactness

Double Pipe

Simplest type has one tube inside another - inner tube may have longitudinal fins on the outside

However, most have a number of tubes in the outer tube - can have very many tubes thus becoming a shell-and-tube

Shell and Tube Alat Penukar Kalor tipe shell and tube yang biasa digunakan pada industri proses

Shell-side flow

Baffle

Fin Tube

Complete shell-and-tube

Plate and frame

Plates hung vertically and clamped in a press or frame. Gaskets direct the streams between alternate plates and prevent external leakage Plates made of stainless steel or higher quality material Plates corrugated to give points of support and increase heat transfer

Plate types

Corrugations on plate improve heart transfer give rigidity

Many points of contact and a tortuous flow path
Chevron Washboard

General view of plate exchanger Plate exchanger normally refers to a gasketted plateand-frame exchanger

Flow Arrangement within a PHE

Gaskets arranged for each stream to flow between alternate plates

Alternate plates (often same plate types inverted)

Air-cooled exchanger

Air blown across finned tubes (forced draught type) Can suck air across (induced draught)

Finned tubes

ACHE bundle

Plate-fin exchanger

Made up of flat plates (parting sheets) and corrugated sheets which form fins Brazed by heating in vacuum furnace

Can have many streams

7 or more streams are typical

Typical plate-fin

Spiral (plate)

Good for streams with large solids

Cooling Towers
Large shell with packing at the bottom over which water is sprayed Cooling by air flow and evaporation Air flow driven by forced or natural convection Need to continuously make up the cooling water lost by evaporation

Agitated Vessel
Used for batch heating or cooling of fluids An agitator and baffles promote mixing A range of agitators are used Often used for batch chemical reaction

Printed circuit heat exchanger

Plates are etched to give flow channels Stacked to form exchanger block Block diffusion welded under high pressure and temperature Bond formed is as strong as the metal itself

Printed circuit exchanger

Note that compact does not mean small but means large surface area per unit volume

Distribution of types
in terms of market value in Europe

Cooling Towers 9% Air Coolers 10% Other Proprietary 2% Other Plate 4% Plate & Frame 13% Other Tubular 5%

Waste Heat Boilers 5%

Other Heat Recovery 10%

Shell & Tube 42%

Preliminary points on selection

Tubes and cylinders can withstand higher pressures than plates If exchangers can be built with a variety of materials, then it is more likely that you can find a metal which will cope with extreme temperatures or corrosive fluids More specialist exchangers have fewer suppliers, longer delivery times and must be repaired by experts S&Ts cannot normally give high thermal effectiveness, e

Design sequence

Design the process flow flow-sheet Specify the heat exchanger requirements Select the best exchanger type for the job Thermal design of exchanger Mechanical design of exchanger Looping back may be necessary at any stage but can be difficult because of the project timetable

Who does what?

Processor/ end user

Design the process flow flowsheet Specify the heat exchanger requirements Select the best exchanger type for the job Thermal design of exchanger Mechanical design of exchanger

Contractor

Manufacturer

The design of a process heat exchanger usually proceeds through the following steps:
1.
2. 3. 4.

Process conditions (stream compositions, flow rates, temperatures, pressures) must be specified.
Required physical properties over the temperature and pressure ranges of interest must be obtained. The type of heat exchanger to be employed is chosen. A preliminary estimate of the size of the exchanger is made, using a heattransfer coefficient appropriate to the fluids, the process,and the equipment. A first design is chosen, complete in all details necessary to carry out the design calculations. The design chosen in step 5 is evaluated, or rated, as to its ability to meet the process specifications with respect to both heat transfer and pressure drop.

5. 6.

7.On the basis of the result of step 6, a new configuration is chosen if necessary and step 6 is repeated. If the first design was inadequate to meet the required heat load, it is usually necessary to increase the size of the exchanger while still remaining within specified or feasible limits of pressure drop, tube length, shell diameter, etc. This will sometimes mean going to multiple-exchanger configurations. If the first design more than meets heat-load requirements or does not use all the allowable pressure drop, a less expensive exchanger can usually be designed to fulfill process requirements. 8. The final design should meet process requirements (within reasonable expectations of error) at lowest cost. The lowest cost should include operation and maintenance costs and credit for ability to meet long-term process changes, as well as installed (capital) cost. Exchangers should not be selected entirely on a lowest-first-cost basis, which frequently results in future penalties.

Exchanger specification Heat load (duty) along with the terminal temperatures of the streams Maximum pressure drop each streams
liquids - 0.5 bar gases/vapours below 2bar - 10% of inlet pressure

Design pressures and temperatures Size/weight constraints Standards to apply

General standards like ISO, TEMA, ASME, API etc Companies own standards

Other requirements

The designer must supply an exchanger which

Meets the stated specification Has reasonable initial costs and operating costs (most exchangers are bought on the basis of the cheapest tender) Has a reasonable lifetime
no damaging vibration no thermal fatigue no unexpected fouling or corrosion

Fouling may be classified by mechanism into six basic categories:

1. Corrosion fouling. The heat transfer surface reacts chemically with elements of the fluid stream producing a less conductive,corrosion layer on all or part of the surface. 2. Biofouling. Organisms present in the fluid stream are attracted to the warm heattransfer surface where they attach, grow, and reproduce. The two subgroups are microbiofoulants such as slime and algae and macrobiofoulants such as snails and barnacles. 3. Particulate fouling. Particles held in suspension in the flow stream will deposit out on the heat-transfer surface in areas of sufficiently lower velocity. 4. Chemical reaction fouling (ex.Coking). Chemical reaction of the fluid takes place on the heat-transfer surface producing an adhering solid product of reaction. 5. Precipitation fouling (ex.Scaling). A fluid containing some dissolved material becomes supersaturated with respect to this material at the temperatures seen at the heat-transfer surface. This results in a crystallization of the material which plates out on the warmer surface. 6. Freezing fouling. Overcooling of a fluid below the fluids freezing point at the heattransfer surface causes solidification and coating of the heat-transfer surface.