Heat Exchanger Principles

Heat Exchanger Overview

• Heat exchangers facilitate heat transfer between two materials without direct contact, typically through conduction.
• Hot fluid transfers heat to cooler fluid, resulting in increased temperature for the cooler fluid and decreased temperature for the warmer fluid.
• Separation of fluids is achieved using metal tubes, with one stream flowing inside the tubes and the other outside.
• Heat transfer occurs as fluids move and contact the metal tubes.

Shell and Tube Exchanger

• Comprised of hollow cylindrical vessels called shells containing bundles of tubes.
• One fluid circulates through the shell while another flows through the tubes, allowing effective heat exchange.
• Cooler fluid increases in temperature while warmer fluid decreases, optimizing the heating and cooling process.
• Traditionally used for cooling products before transport, now also utilized for heat integration to preheat incoming streams.

E-100 (Ethylene Preheater)

• Multi-tube, U-type heat exchanger designed specifically for heating pipeline ethylene.
• Operates with 100 psig steam on the shell side to superheat ethylene before the next stage of processing.
• Enhances energy efficiency and process effectiveness by preheating the ethylene.

D-110 (Charge Gas Compressor Suction Drum)

• Dimensions: 5’6” diameter x 9’ length, serving both Charge Gas Compressors (C-120A/B).
• Incorporated with internal demister pads below top vapor outlets to eliminate liquid entrainment in ethylene streams.
• Pipeline and recycle ethylene enter from the side; heavier components (C4+) are expelled from the bottom while vapor ethylene exits from the top.

Heat Exchanger Overview

• Heat exchangers transfer heat between two fluids without direct contact, using conduction.
• The hot fluid transfers heat to the cooler fluid through metal tubes, which separate the two streams.
• Designs vary, but all heat exchangers aim to heat one stream while cooling another, excluding cooling towers which operate differently.

Shell and Tube Exchanger

• Consists of cylindrical vessels (called shells) containing tube bundles for fluid flow.
• One product flows through the shell, while another flows through the tubes, facilitating heat exchange via metal walls.
• Utilized to cool products before shipment, increasingly repurposed for heat integration due to rising energy costs.

E-100 (Ethylene Preheater)

• A multi-tube, U-type heat exchanger specifically designed for heating pipeline ethylene.
• Operates with ethylene on the tube side and 100 psig steam on the shell side.
• Installed to superheat ethylene before the next processing stage.

D-110 (Charge Gas Compressor Suction Drum)

• Dimensions: 5’6” diameter and 9’ length.
• Serves both C-120A/B Charge Gas Compressors, enhancing efficiency and functionality.
• Equipped with internal demister pads to eliminate liquid entrainment in the ethylene streams.
• Receives pipeline and recycled ethylene streams; heavier components (C4+) exit from the bottom, while vapor ethylene exits from the top.

This quiz explores the fundamental concepts of heat exchangers, specifically focusing on the ethylene preheater. It covers the mechanisms of heat transfer, the role of conduction, and the design elements that prevent fluid contact. Test your understanding of these critical processes in thermal engineering.