What is a fin tube heat exchanger? Heat exchangers heat or cool buildings, improve the efficiency of engines and machines. Refrigerators and air conditioners use heat exchangers to cool elements; radiators use them to warm environments. It's all about controlling heat energy ' either removing it or adding it, depending on the goal and function.
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At Energy Transfer, we manufacture fin tubes, as well as enhanced surface and formed and dimpled tubes, for tube fin and tubular heat exchangers. We sell both to original equipment manufacturers as well as people looking to repair existing heat exchangers.
When it comes to building or repairing a tube fin or tubular heat exchanger, how do you determine which tube is right for your heat exchanger? Which one will provide the best thermal solution? What do you need to know to ensure superior heat transfer capability?
It pays to do your homework. Thoroughly researching a manufacturer's product offerings and capabilities invariably results in a more suitable fin tube to meet your goals and ambitions.
Energy Transfer manufactures a diverse range of fin tube pipes to serve a variety of heat exchanger needs. All options are on the table. We're ready to meet any need ' turn your vision into a reality of superior performance.
This guide will walk you through the selection process of how to choose the optimal finned tube for your heat exchanger. [/vc_column_text][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]
What is a Fin Tube Heat Exchanger?
[/vc_column_text][vc_empty_space][/vc_column][/vc_row][vc_row][vc_column width='1/2'][vc_column_text]By definition, a heat exchanger is a device used to transfer thermal energy between two or more fluids ' it allows heat from a liquid or gas fluid to pass to a second liquid or gas without the two fluids mixing together or coming into direct contact.
The objective of a heat exchanger may be to recover or reject heat, or to sterilize, pasteurize, fractionalize, distill, crystallize, or control a fluid or process fluid.[/vc_column_text][/vc_column][vc_column width='1/2'][vc_single_image image='' img_size='full' alignment='center' style='vc_box_border_circle' border_color='black'][/vc_column][/vc_row][vc_row][vc_column][vc_empty_space][vc_column_text]Tubular heat exchangers consist of small tubes located within a cylindrical shell. These finned pipes are positioned within a cylinder as a bundle, allowing various gases or liquids to circulate in a process of heat exchange that either warms or cools an element.
One fluid or gas flows through a set of metal tubes while a second fluid or gas passes through a surrounding sealed shell. The fluids can flow in the same direction (a parallel flow) or opposite directions (counterflow or counter-current), or at right angles (crossflow).
To increase heat transfer capabilities, fin tube pipes can either have fins that are applied as a second material (as is the case of applied fin tubes), or raised out of the material of the tube itself (such as low fin, medium-high fin, and high finned tubes).
For tubular heat exchangers where there are no fins but just a smooth tube, the tubes can have enhanced surface or formed dimples to mitigate flow and increase heat exchange capabilities.
Conventional Tube-Fin heat exchangers are most commonly used in gas-to-liquid applications. Round fins on the outside of the tube are used on the gas side of the heat exchanger to increase surface area. The liquid side of the heat exchanger consists of a tube bundle of Finned Tubes supported by a sheet metal frame with common headers on each end of the bundle.[/vc_column_text][vc_empty_space][vc_column_text]
Determining Required Heat Transfer for Finned Tubes
The first step is to determine how much heat transfer is required and how much heat transfer surface you'll need. This will help decide which type of fin tube pipe is the optimal thermal solution, including necessary fin surface requirements and the ideal material. What fin tube geometry is required in order to accomplish your vision?
You also should determine the necessary rate of flow, which will affect the required diameter of the fin tube. This is affected by tube size.
How much pressure drop is needed?
What size of hydraulic diameter is required?
What is the flow length of each fluid side of the heat exchanger?
What is the minimum free flow area?
What do you need in the frontal area?
What is the flow length of each fluid side of the heat exchanger?
Heat transfer can be improved by increasing the number of tubes or by increasing the length of the finned tubes.
These factors are all measured by heat transfer calculation software that boils down the necessary physics of the tube through well defined computed science. You can then determine if you'll need a smooth tube, a formed and dimpled tube, or a finned tube to achieve the required heat exchange capabilities. [/vc_column_text][vc_empty_space][vc_single_image image='' img_size='full' alignment='center' style='vc_box_shadow_circle'][vc_empty_space][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]
How to Optimize Heat Transfer Performance
The potential heat transfer you can achieve is baked into the thermal properties of the fin pipes themselves. The amount of heat transfer can be controlled through surface dimension: fin count, the length of tube, and enhanced or formed and dimpled tube shapes.
Heat transfer is also affected by the thermal conductivity of the metals used to make the fin tubes. Copper fin tubes, for example, are nearly twice as conductive as aluminum fin tubes, and nearly 6 times the thermal conductivity of steel fin tubes. Copper finned tubes are more than 25 times the conductivity of stainless steel finned tubes.
Material corrosiveness or acidity is also a determining factor in material selection, depending on the nature of the gas or fluid that will flow through the heat exchanger.
When choosing materials, you naturally face 2 concerns:
Availability of Materials
Cost of Materials
Is the material going to be readily available or will it take time to get? How will this affect manufacturing deadlines?
What is the cost of each material? These are precious materials with an inherent value based on fair market prices. Copper fin pipe will generally cost more than aluminum, but it maintains the best heat transfer among common alloys. Copper's chemical properties are ideal for many heat exchanger applications ' it's easily formed and can be readily enhanced for heat exchanges.
Ask yourself:
Are the desired heat exchange properties and corrosion advantages worth the cost?
Can the materials be accessed within an acceptable time frame?
Thermal solution advantages must be weighed against cost and material procurement concerns to determine the best path forward.[/vc_column_text][vc_empty_space][vc_single_image image='' img_size='full' alignment='center' style='vc_box_border_circle' border_color='black'][vc_empty_space][vc_column_text]
Proactive Material Procurement in the Age of COVID-19
The cost of materials is naturally affected by the metals market ' which can ebb and flow even in normal times. But in the headwinds of COVID-19, it's a perfect storm.
The pandemic has had a radical impact on the tube mill industry and its ability to respond to demand. Many mills have limited production of certain materials; some mills have stopped production completely.
To navigate these challenges, we've had to be more thorough in our planning of material procurement. We need to think further ahead and be more proactive in future planning needs.
To optimally meet material needs as we accommodate the challenges of today's 'new normal,' flattening demand is essential.
Anything you can do to ensure consistency and avoid spikes or drops in demand will result in a smoother procurement process. Fluctuations in demand prove challenging, but consistency can be planned and optimally accommodated. This will result in a smoother, streamlined manufacturing process that's more predictable with fewer hiccups.
By planning for consistency, you'll stay ahead of demand ' and maintain an even flow of the fin tubes you need.[/vc_column_text][vc_empty_space][vc_column_text]
Our Unsurpassed Variety in Fin Tube Potential
There is a wide range of fin tubes, enhanced surface tubes, and formed and dimpled tubes available to accommodate an eclectic array of challenges and functions.
Energy Transfer just happens to have some of the largest varieties of finned tubes on the market. And because of our versatile market position, we can accommodate nearly every style of heat exchanger design and fin tube application you can come up with.
To optimize the heat transfer capabilities of your heat exchanger, take some time to learn what we have available. Take a close look at our product pages, our sales brochure, and the engineering dimensions outlined in detail. [/vc_column_text][vc_row_inner][vc_column_inner width='1/2'][vc_single_image image='' img_size='full' alignment='center'][/vc_column_inner][vc_column_inner width='1/2'][vc_column_text]After all, creativity is largely fueled by option availability. You can either look at the different finned tube products we have available and pick one ' or you can learn about our capabilities and come up with your own configuration based on existing products.
Having that information will streamline the selection process for which products will work best. It will also give you a rich understanding of our full potential ' and help to leverage the advantages of Energy Transfer's superior performance.[/vc_column_text][/vc_column_inner][/vc_row_inner][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]Once you've taken a detailed look at what finned tubes we have available, talk to one of our sales engineers to see what's truly possible.
The beauty of variety is unleashed potential. That's the advantage of working with a highly qualified company with a rich diversity in product offerings. Energy Transfer has the tooling, mechanical engineers, and development teams ready on hand to make your vision a reality ' whatever form that might take.[/vc_column_text][vc_empty_space][vc_separator color='black' border_width='3'][vc_empty_space][vc_column_text]
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Want to build a seamless fin tube? Our FREE GUIDE tells you everything you need to know. Download yours today![/vc_column_text][vc_empty_space][/vc_column][/vc_row][vc_row][vc_column][vc_column_text] [/vc_column_text][/vc_column][/vc_row]
Want to learn more about heat exchangers? What they are used for and how they work? This FAQ page is a good introduction to the subject.
The company is the world’s best Industrial Finned Tube Heat Exchanger supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
Frequently Asked Questions Index;
Put simply, a heat exchanger is a device which transfers heat from one medium to another, a Hydraulic Oil Cooler or example will remove heat from hot oil by using cold water or air. Alternatively a Swimming Pool Heat Exchanger uses hot water from a boiler or solar heated water circuit to heat the pool water. Heat is transferred by conduction through the exchanger materials which separate the mediums being used. A shell and tube heat exchanger passes fluids through and over tubes, where as an air cooled heat exchanger passes cool air through a core of fins to cool a liquid.
There are many different types of heat exchanger available, the three main types that Thermex supplies are;
Shell and Tube; Shell and Tube Heat Exchangers consist of a large number of small tubes which are located within a cylindrical shell. The tubes are positioned into the cylinder using a tube bundle or "tube stack" which can either have fixed tube plates (permanently fixed to the body) or, in the case of Thermex Heat Exchangers a floating tube stack which allows the tube bundle to expand and contract with varying heat conditions as well as allowing the tube bundle to be easily removed for servicing and maintenance.
Plate Type; Plate Heat Exchangers operate in very much the same way as a shell and tube heat exchanger, using a series of stacked plates rather than tubes. Plate heat exchangers are usually brazed or gasketed depending on the application and fluids being used. Their compact stainless steel construction makes them an ideal choice for use with refrigerants or in food and beverage processing.
Air Cooled; Air Cooled Heat Exchangers are commonly used in vehicles or other mobile applications where no permanent cool water source is available. Thermex designs and supplies combination cooling packs (or combi-coolers) which combine an engine jacket water cooler, oil cooler and charge air cooler into a single unit reducing space requirements and improving efficiency. Cool air is provided either by a fan or by air flow caused by the movement of the vehicle.
To be able to select a heat exchanger, we need to know;
The fields above are only the basics. When putting an enquiry together you should also make Thermex aware of any pressure loss limitations and any other special requirements.
Please click here to download the Thermex data sheet template which highlights the required fields for heat exchanger selection. The data sheet should also be saved and sent to us if you require a quotation for a heat exchanger.
Please feel free to contact us if you need assistance with the form.
The operating principles of a marine heat exchanger are the same as a cooler designed for fresh water use, the main consideration for the designer however is that the marine heat exchanger must be resilient to erosion or corrosion caused by sea water. This means that materials that come in to contact with the sea water must be suitable, such as 90/10 Cupro-Nickel, 70/30 Cupro-Nickel, Bronze and Titanium.
There are other factors which need to be taken in to consideration when a marine heat exchanger is being designed. One is the velocity, if it is too low then there is a risk that sand and other particles will block the tubes. If it is too fast on the other hand then those same particles can rapidly erode the tube plate and tubes.
Additional protection can be provided by installing a sacrificial anode which Thermex can include upon request. This will be installed in to the threaded hole normally used for a drain plug and is in direct contact with the sea water flow.
The suitability of a fluid with a heat exchanger will depend on the type of heat exchanger being used and the materials which are available. Standard Thermex Heat Exchangers are suitable for most fluids including Oil, Water, Water Glycol and Sea Water. For more corrosive fluids such as chlorinated salt water, refrigerants and acids other materials such as Stainless Steel and Titanium will need to be used instead.
Temperature cross over is a term used to describe the scenario where the temperatures of both circuits in a liquid cooled heat exchanger begin to cross over. This can be an important factor in a heat exchanger design as the efficiency of a cooler will be significantly reduced when the temperatures cross over. In many cases a plate heat exchanger is the best option for applications where temperature cross over can't be avoided.
Oil
Water
Inlet Temperature
80 30Outlet Temperature
50 51.5Flow Rate
25 L/min 15 L/minThe table above demonstrates that the cooling water outlet temperature is slightly higher than the outlet temperature of the oil. One simple way to combat this and increase the efficiency of the oil cooler is to increase the flow rate of the coolant. In this particular example increasing the water flow rate to 25 L/min would reduce the water outlet temperature to 43°C
A Heat Exchanger Pass refers to the movement of a fluid from one end of the heat exchanger to the other. For example, when referring to the "through tubes" circuit (usually the coolant); · Single Pass ' Fluid enters one end of the heat exchanger, and exits at the other end. · Double Pass ' Fluid enters and exists the heat exchanger at the same end. · Triple Pass ' Fluid travels the length of the heat exchanger body three times before exiting. The images below will help to demonstrate this;
Heat exchanger efficiency can be defined in many ways, in terms of thermal performance there are several key factors to consider;
Temperature differential - As discussed in point 3 (temperature cross-over) the difference between the hot fluid and coolant is very important when designing a heat exchanger. The coolant always needs to be at a lower temperature than the hot fluid. Lower coolant temperatures will take more heat out of the hot fluid than warmer coolant temperatures. If you had a glass of drinking water at room temperature for example, it is much more effective to cool it down using ice rather than just cool water, the same principle applies to heat exchangers.
Flow rate - Another important factor is the flows of the fluids in both the primary and the secondary side of the heat exchanger. A greater flow rate will increase the capability of the exchanger to transfer the heat, but a greater flow rate also means greater mass, which can make it more difficult for the energy to be removed as well as increasing velocity and pressure loss.
Installation - The heat exchanger should always be installed based on a manufacturers' guidelines. Generally speaking the most efficient way to install a heat exchanger is with the fluids flowing in a counter-current arrangement (so if the coolant is travelling left to right, the hot fluid travels right to left) and for shell and tube heat exchangers the coolant should enter at the lowest inlet position (as shown in the diagrams above) to ensure that the heat exchanger is always full of water. For air cooled heat exchangers it is important to consider the air flow when installing a cooler, any part of the core which is blocked will compromise cooling capacity. To find out more about counter-flow and why it is more efficient, please read our blog post "Why counter flow heat exchangers are more efficient"
Sometimes, a specific heat exchanger type can be selected based on the industry it will be used for. Some examples include;
The correct method of heat exchanger installation varies depending upon the exact type of unit and the environment of operation. For installations instructions please refer to one of our Installation and Operation Manuals
Heat exchangers are manufactured from robust materials, have no moving parts and operate at a variety of different pressures and temperatures, therefore if a heat exchanger is used in the correct way then there is no reason why it shouldn't be able to remain operational for many years. To help increase the operational lifetime of a heat exchanger there are several steps that should be taken;
Make sure the design data is accurate - If you are sending data to our engineers for heat exchanger selection, then it is best to make sure that it is as accurate as possible. Not only will this ensure that your heat exchanger is thermally efficient but also that it will be able to operate for a long period of time. If the flow rates are too high then erosion could be a problem, if the pressures are too high then leaks could occur and if there are any unusual chemicals in the fluids (such as acids in coolant water) then please contact us to check the compatibility. If our standard materials aren't suitable then we can usually supply an alternative which is.
Commission and Installation - When installing your heat exchanger, make sure that correct fittings and pipe work are used. If unsure, please check the Thermex Installation and Operation Manual for details. For heat exchangers on applications which use polluted, shallow or brackish sea water as the coolant and have copper alloy tubes, it is recommended to run the heat exchanger in clean sea water for several weeks first, this creates a protective layer over the tube material which helps to protect against corrosion. More information regarding this subject can be found on www.copper.org. Where possible, filters should also be used where fluids may contain solid particles to prevent tube erosion from occurring.
Regular Maintenance and Servicing - All Thermex shell and tube heat exchangers are designed to allow for easy maintenance and servicing. The end caps can be removed allowing the internal tube bundle to be removed for cleaning. New seal kits can also be provided from stock and are available to purchase on our Web Shop. For information and tips on servicing your heat exchanger, please see the Thermex Installation and Operation Manual.
There are many possible causes for heat exchanger failure, some examples for shell and tube include;
Symptom
Possible Cause
Possible Solution
Prevention
Oil and Water Mixing
O Ring failureErosion on the tube plate face
Water velocity is too high Check water flow rate and advise Thermex. In some cases a higher grade of material such as 70/30 CuNi or Titanium may be required. When using sea water, make sure that the flow rate doesn't exceed the Heat Exchanger's capabilities. Contact us for advice.Header / End cap split
Frozen water expanding within the heat exchanger / Oil Cooler. New header kit and Seal Kit will be required. Drain the water system during the winter if the cooler isn't being used.Insufficient thermal capacity, or reducing performance.
Below are some abbreviations and terms often used in the heat exchanger industry;
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