How to Select the Right Fixed Tube Sheet Heat Exchanger?

How to Select the Right Fixed Tube Sheet Heat Exchanger?

1. ‌Core Parameter Matching‌

1. ‌Operating Condition Compatibility‌

   • ‌Temperature & Pressure‌:
     Ensure the design temperature (≤550°C) and pressure (≤600 bar) meet actual requirements. For high-temperature/pressure scenarios, prioritize reinforced tube-sheet structures7.
   • ‌Fluid Properties‌:
     • Corrosive media (e.g., acidic fluids) require corrosion-resistant materials like titanium alloys or duplex stainless steel13.
     • For fluids with particulates or high viscosity, widen flow channels or adopt a wide-gap design to prevent clogging8.

2. ‌Thermal Load & Efficiency‌

   • Calculate ‌heat load‌ ($Q=\Delta T\times \text{Flow Rate}\times \text{Specific Heat}$) to determine the required heat transfer area. Include a 10–20% safety margin for fouling48.
   • Prioritize designs with higher ‌Logarithmic Mean Temperature Difference (LMTD)‌. Optimize tube passes (e.g., 4–6 passes) to enhance thermal efficiency7.

2. ‌Structural Design Considerations‌

1. ‌Thermal Stress Management‌

   • For tube-shell temperature differences >50°C, install expansion joints or use a floating head design7.
   • Fixed tube sheet designs are suitable for small temperature differences (≤50°C) and clean shell-side fluids (e.g., cooling water systems)7.

2. ‌Tube Sheet & Shell Connections‌

   • Welded tube sheets offer compactness and cost savings but require clean shell-side fluids (no fouling risk)7.
   • For high-pressure applications (e.g., 600 bar), use forged steel tube sheets and validate strength via finite element analysis (FEA)4.

3. ‌Maintenance & Cost Balance‌

1. ‌Maintainability‌

   • Fixed tube sheet exchangers cannot be mechanically cleaned on the shell side; use only with clean fluids (e.g., softened water)7.
   • Reserve 20% extra length for tube replacement and maintenance access7.

2. ‌Cost Optimization‌

   • Standardized designs reduce costs by 30–50%. Custom solutions require cost evaluation for special materials (e.g., Inconel)36.
   • Follow TEMA standards (Class R/B/C). Class B (general-purpose) balances performance and cost for most industrial applications7.

4. ‌Application-Specific Guidelines‌

‌Note‌: For extreme conditions (>500°C or highly corrosive media), collaborate with manufacturers for CFD simulations and material testing to prevent premature failur.