Shell and tube heat exchangers are special type of unit operation which is needed for high-pressure applications; they are durable products, which can withstand the demands of many working environments. Their design plays a large part in ashell and tube exchanger’s ability to endure exceedingly-challenging situations. The gaskets are normally spiral wound gaskets made of stainless steel.

Shell and tube heat exchangers are made from a series of tubes, which can be made of durable material such as fluoropolymers. Fluoropolymers are highly-durable plastics such as PTFE, FEP, and PFA. Fluoropolymers, like heat exchangers, have a place in a variety of industries such as the automotive, medical, and aeronautical.

In a heat exchanger’s shell, one set of tubes contains fluid, which is either heated or cooled. Another set of tubes also contains liquid, which facilitates the heating or cooling of the primary set of tubes. A tube set is referred to as the tube bundle and can take on a variety of shapes depending on what is most conducive for the intended job.

Engineers of shell and tube heat exchangers need to consider several components of construction, among them are:

• A smaller tube diameter enables the shell and tube exchanger to be economical and compact, yet a tiny diameter can facilitate malfunction and difficulty of cleaning. Larger tubing can be instituted to eradicate potential flow and cleaning problems. Engineers must factor cost, space, and the propensity of liquids to foul when constructing a heat exchanger.
• Tube thickness is important to make sure there is room for corrosion; vibration existing in the product has resistance; and, the shell and tube exchanger can withstand pressure coming from both in and outside of its internal tubes.
• Folding or wrinkling the inner tubes increases the flow of the liquid, which facilitates the transfer of heat, producing better performance from the exchanger.
• Designers also consider the layout of the inner tubes. Tubes can be fashioned in a triangular, square, rotated square, or rotated triangular fashion. Particular, internal designs are conducive to specific jobs and the elimination of potential problems such as fouling of the liquid.
• Shell and tube heat exchangers also host baffle components. Baffles serve several purposes such as holding the tube bundles in place; making sure tubes do not sag or vibrate; and, facilitating fluid flow.

More information regarding this report:Power Boiler and Heat Exchanger Manufacturing Industry in the U.S. and its International Trade

http://www.reportlinker.com/p0206939/Power-Boiler-and-Heat-Exchanger-Manufacturing-Industry-in-the-U-S-and-its-International-Trade.html#utm_source=LivePR&utm_medium=pr&utm_campaign=LivePR

This June edition of Power Boiler and Heat Exchanger Manufacturing Industry report is the comprehensive market research guide for the industry. It publishes the latest information on the industry’s key financial data, competitive landscape, cost and pricing, and trends during the current economic environment.

In 2009, the value of imported products within this industry into the U.S. has been relatively high, at approximately 40% of U.S. production. Because of this reliance on imports, the report covers the foreign trade statistics including the top 25 countries the U.S. imports from and their respective import values. This industry exhibits a high amount of trade activity, because in 2009, the value of exported products within this industry into the U.S. has also been relatively high, at approximately 30% of U.S. production. This reliance on exports is also covered in the report’s foreign trade statistics.

At 162 pages with over 150 charts and tables, the report’s extensive coverage includes topics such as current macroeconomic trends, granular product data, global trade, channel mix, government demand, and labor structure. It relies on over a decade of historical data and enhanced forecasting to project industry trends through 2014 on the domestic market, global market and overseas growth opportunities. This current report contains shipment data, inventory levels, international trade volume, and industry specific price indices through April 2010. Industry analysts and Fortune 500 customers rely on this quarterly report to make accurate forecasts and planning in today’s uncertain economy.

In this report, you will find industry data on the following major categories:

Executive Summary

• Quick Industry Statistics: 2-page overview for the CEO on the run
• Supply & Demand with Capacity Utilization
• 2010-2014 Forecast

Industry Income Statement

• All relevant financial data including: Revenue, Cost of Materials, Labor Costs, Gross Profit, SG&A, Net Income, etc.
• 4-year Financials Comparison and Trends

Industry Balance Sheet

• Traditional key elements of Assets, Liabilities, and Equity
• Inventory fabrication stages
• Calculated balance sheet ratios

Capital Expenditure

• Plant additions and expansions
• Computer and IT investments
• Machinery and Equipment for production and material handling

Industry Cost Analysis

• Upstream Industries and the cost allocations towards producer, wholesale, retail, and freight
• Materials and their percentage share of total material costs

Industry Pricing Analysis

• Producer Pricing Indices at industry, wholesale, and retail levels for comparison and trend forecasting
• Pricing Distribution among Downstream Industries differentiated at producer, wholesale, retail, and freight categories

Industry Foreign Trade

• Detailed Import/Export Data by commodities and by countries
• Mode of Shipment and insurance and freight costs

Industry Structure

• Labor and Compensation Structure: productivity indices, hourly wages, production hours, output index, HR structure
• Establishments: Trends, Employee Statistics, State by State numbers
• Valued added statistics: industry GDP contribution

Competitive Landscape

• Industry Concentration: HHI, number of companies, size distributions, market shares
• Major Players: company profiles and market size ranges

__________________________________________

Definition & Classification

This industry comprises establishments primarily engaged in manufacturing power boilers and heat exchangers. Establishments in this industry may perform installation in addition to manufacturing power boilers and heat exchangers. This 6-digit NAICS industry (332410) is under the hierarchy of Boiler, Tank, and Shipping Container Manufacturing Industry Group (3324), Fabricated Metal Product Manufacturing Subsector (332), and the Manufacturing Sector (31-33). Its SIC equivalent codes are: 3443 – Fabricated Plate Work (Boiler Shops) (power boilers and heat exchangers); and 3559 – Special Industry Machinery, NEC (nuclear control rod drive mechanisms).

Revenue, Profitability & Foreign Trade Preview

The industry’s revenue for the year 2009 was approximately $4.8 billion USD, with an estimated gross profit of 27.65%. Import was valued at $2.0 billion USD from 64 countries. The industry also exported $1.3 billion USD worth of merchandise to 141 countries. Adding import value to and subtracting export value from the industry’s shipment value, the total domestic demand for the industry in 2009 was $5.5 billion USD.

Report Summary

This industry report contains 162 pages of in-depth market research with over 150 charts and tables. Current and forecasted industry sales and shipment data within the U.S. and its international trade are presented. For financial analysis, the report presents industry level income statements, balance sheets, and capital expenditure figures. In the cost analysis section, 48 upstream industries are analyzed to offer insight into the supply chain cost structure. For the channel and pricing structure, 63 downstream industries are analyzed. The competitive landscape section provides the number of companies and their respective revenue share, the market concentration, and a list of major players. Furthermore, products within the industry are listed with their respective market sizes and import and export data. The appendices contain relevant resources to additional trade statistics, U.S. State statistics, and industry trade associations.

Our clients include Fortune 500 companies, manufacturers, international top consulting firms, major retailers and wholesalers, professional trade associations, financial corporations, universities, governmental entities, start-ups and individuals. We are committed to providing the highest level of quality to all our clients and assure your satisfaction in the report delivering as promised.
(rlk1-2010-07-24) plp

• Preface
• Introduction
  • Definition
  • Related Industries
  • Comparison to U.S. Manufacturing Sector
  • Scope
  • History
• Executive Summary
  • Quick Statistics
  • Supply, Demand and Capacity Utilization
  • 2010-2014 Forecast
    • Shipments
• Industry Income Statement
  • Revenue (Value of Shipments, Net Sales)
  • Compensation (Payroll and Fringe Benefits)
    • Salaries
    • Wages
    • Fringe Benefits
    • Compensation Distribution
  • Cost of Materials
    • Materials Cost Excluding Fuel and Energy
    • Electricity Cost
    • Fuel Costs
    • Materials Consumption Breakdown
  • Gross Profit
  • Other Costs
    • Administrative, Sales and Marketing Expenses
    • Current and Deferred Taxes
  • Net Income
    • Income (or Loss) From Operations (EBIT)
    • Other Non-Operating Income
    • Income (or Loss) Before Income Taxes (NIBT)
    • Income (or Loss) After Income Taxes
    • Earnings before Interest, Depreciation and Taxes (EBIDT)
• Industry Balance Sheet
  • Assets
    • Cash and Government Securities
    • Accounts Receivable
    • Inventories
    • Inventories Stage of Fabrication Ratios
    • Total Current Assets
    • Current Assets Distribution Chart
    • Property and Other Non-Current Assets
  • Liabilities
    • Current Liabilities
    • Total Liabilities
  • Equity
    • Stockholders’ Equity
    • Profit on Stockholders’ Equity before Income Tax
    • Profit on Total Assets before Income Tax
    • Total Current Assets to Total Current Liabilities
    • Total Cash and Government Securities to Total Current Liabilities
• Capital Expenditures
  • Building and Structure
  • Machine and Equipment Expenditures (including Automobile and Computers)
  • Computers
  • Automobile and Highway
  • Other Machine and Equipment
• Product Market Sizes
• Cost Analysis
  • Upstream Industries
• Pricing Analysis
  • Producer Price Indices
    • Industry-Level Producer Price Indices
    • Manufacturing Sector PPI
    • Producer Price Index – Wholesale Sector
    • Producer Price Index – Retail Sector
    • Consumer Price Index – All Items
    • Consumer Price Index – Durable Goods
    • Consumer Price Index – Non-Durable Goods
    • Consumer Price Index – Electricity
    • Consumer Price Index – Gasoline
  • Pricing Distribution
  • Downstream Industries
• Industry Foreign Trade
  • Import
    • Import Process
    • Harmonized Tariff Schedule
    • Top Import Commodities Analysis
    • Ranking – Countries US Imported From
    • Top 5 Countries US Imported From
    • Top 25 Countries US Imported From
    • Importing Insurance and Freight Cost Index by Country
    • Import Total Value from 2000 to 2012
    • Import Total Quantity from 2000 to 2012
    • Import Export Total Value Comparison from 2000 to 2012
    • Import Export Total Quantity Comparison from 2000 to 2012
    • Import Price Indices from 2000 to 2012
    • Comparison of Import and Export Price Indices from 2000 to 2012
  • Export
    • Domestic Exports
    • Foreign Exports (Re-exports)
    • Export Statistics Summary
    • Top Export Commodities Analysis
    • Ranking – Countries US Exported To
    • Top 5 Countries US Exported To
    • Top 25 Countries US Exported To
    • Export Total Value from 2000 to 2012
    • Export Total Quantity from 2000 to 2012
    • Export Price Indices from 2000 to 2012
• Industry Structure
  • Labor and Compensation
    • Trend
    • Production Workers
    • Production Workers to Total Employees Ratio
    • Hourly Wages
    • Production Hours Trend
    • Contribution (Revenue) per Production Worker
    • Annual Wage per Production Worker
    • Production Worker Contribution (Revenue) Ratio
    • Revenue to Number of Workers
    • Labor Productivity (output per hour)
    • Labor Input Index (total labor hours)
    • Output Index
    • Unit Labor Cost Index
    • Labor Compensation Index
    • Output per Worker Index
    • All Worker Index
    • Human Resources – Occupations
  • Establishments
    • Trend
    • Average Number of Employees per Establishment
    • Contribution (Revenue) per Establishment
    • Establishment Sizes by Number of Employees
    • Establishments by U.S. States
  • Value-Added
  • Sustainability
• Competitive Landscape
  • Industry Concentration
  • Industry Aggregate
  • Major Players
• Appendix A – Additional Foreign Trade Statistics
  • Trading Countries’ Rank
  • Top 5 US Trading Countries and Other
  • Top 25 US Trading Countries
• Appendix B – Industry U.S. States’ Statistics
  • Production Workers Ratio
  • Average Hourly Wage
  • Average Annual Salary
  • Cost of Materials Ratio
  • Capital Expenditure Ratio
  • Industry Shipment Ratios
  • Electricity Consumption and Environmental Impact
  • Fuel Consumption and Environmental Impact
• Appendix C – Additional Links
  • Trade Associations
  • Trade Publications
  • Trade Shows
  • Industry Standards
  • Legislation, Regulation, Tax and Environmental Related Issues
    • Industry Specific Regulatory Agencies
    • Non-Industry Specific Regulatory Agencies
• Appendix D – Industry’s 4-Year Financial Statement
• Appendix E – Report Methodology

Source: http://www.live-pr.com/en/power-boiler-and-heat-exchanger-manufacturing-r1048523622.htm

Four different types of steel used for high-temperature service:

• Carbon steels – for most usage up to 750 degrees F (400 degrees C). Carbon steels are cheaper, very strong, with highest thermal conductivity. Above 750 degrees F, their creep increases; above 950 degrees F (510 degrees C) they get oxidized too.
• Chromium-molybdenum steels – resist oxidation up to 1200 degrees F (650 degrees C). But their thermal conductivity is lower; and chromium-molybdenum steels are more expensive than carbon steels.
• Ferritic stainless steels – can be used up to 1500 degrees F (820 degrees C).  Ferritic stainless steels have higher thermal conductivity, lower thermal expansion coefficient, and less expensive than other materials for the same service. Ferritic stainless steels can resist oxidation as well as attack from sulfur- and carbon-containing flue gases. Coefficient of thermal expansion of ferritic stainless steels is lower than for austenitic stainless steels. Loose strength after a very long usage at high temperatures.
• Austenitic stainless steels – the strongest among steels for use at high temperatures and do not loose strength after very long usage at high temperatures. Austenitic stainless steels resist oxidation at high temperatures and are widely used in boilers, super-heaters, refinery services, etc., where chlorine is not present.

These are part of the steels that can be used for the manufacturing of various heat exchanger including shell and tubes, spiral heat exchanger and plate heat exchanger.

This information is credited to http://brazedplateheatexchangers.wordpress.com/2010/07/01/which-types-of-steel-can-be-used-for-high-temperature-service/

1.  Is there a phase change involved in my system?

2.  How many “zones” are involved in my system?

3.  What are the flowrates and operating pressures involved in my system?

4.  What are the physical properties of the streams involved?

5.  What are the allowable pressure drops and velocities in the exchanger?

6.  What is the heat duty of the system?

7.  What is the estimated area of the exchanger?

8.  What geometric configuration is right for my exchanger?

9.  Now that I have a geometry in mind, what is the actual overall heat transfer coefficient?

10.  What is the actual area of the exchanger using the ‘actual’ heat transfer coefficient?

11. What are the materials of Construction, ease of maintenance, cost of exchanger and overall heat integration

Think of the questions…

We’ll provide answers for it in latter posts.

There are various types of heat exchangers and the function depends very much on its dedicated applications. Among them are:

• Inter-coolers and heaters
• spiral heat exchanger
• shell and tube heat exchanger
• plate and frame heat exchanger
• Regenerators – refrigeration units
• Automobile radiators
• Milk chiller of a pasteurizing plant
• Condensers and boilers in steam plant
• Evaporators
• Oil coolers of heat engine

CLASSIFICATION
Heat exchangers may be classified according to the following main criteria:

1. Nature of heat exchanger process
2. Flow arrangement
3. Physical state of fluids
4. Geometry and construction

1. Classification based on Nature of heat exchanger process

(i) Direct contact:
Heat transfer will occurs by direct mixing of two fluids. This is preferred when the direct mixing is harmless or desirable.
Ex: cooling towers
(ii) Indirect contact:
Heat transfer will occurs through a separating wall between two fluids
Ex: Regenerators and Recuperators

2. Classification based on Flow arrangement

According to the relative directions of two fluid streams the heat exchangers are classified into the following three categories:

(i) Parallel flow or co-current flow heat exchangers
(ii) Counter-flow heat exchangers
(iii) Cross-flow heat exchangers

(i) In a parallel or co-current flow heat exchanger

As the name suggests, the two fluid streams (hot and cold) travel in the same direction. The two streams enter at one end and leave at the other end. The flow arrangement and variation of temperatures of the fluid streams in case of parallel flow heat exchangers, are shown in the below figure. It is evident from the figure that the temperature difference between the hot and cold fluids goes on decreasing from inlet to outlet.

In parallel flow, it is not possible to bring the outlet temperature of the cold fluid nearly to the inlet temperature of the hot fluid. This type of heat exchanger needs a large heat transfer area, so, it is rarely used in practice.
It is particularly useful when sudden cooling or sudden heating is required.
Examples: Oil coolers, oil heaters, water heaters etc.

(II) Counter-flow heat exchangers

In a counter-flow heat exchanger, the two fluids flow in opposite direction. The hot and cold fluids enter at the opposite ends. The flow arrangement and temperature distribution for such a heat exchanger are shown schematically in the below figure.

In this flow, it is possible to bring the outlet temperature of the cold fluid nearly to the inlet temperature of the hot fluid. This type of heat exchanger needs a small heat transfer area, so, it is widely used in practice.
Examples: Oil coolers, oil heaters, water heaters etc.

(iii) Cross-flow heat exchangers

In cross-flow heat exchangers, the two fluids (hot and cold) cross one another in space, usually at right angles. The flow arrangement and temperature distribution for such a heat exchanger are shown schematically in the below figure.

Source: enggyd.blogspot.com/2010/03/description-of-heat-exchange-equipment.html

In industry, specifically process or manufacturing plants there are other types of heat exchanger such as plate heat exchangers, spiral heat exchangers and shell and tube heat exchangers. All of these heat exchangers are special and have their dedicated purpose or function when being employed. The price, size, specification, purpose and design varies within each other.

Heat exchanger must be properly maintained in order for it to be working efficiently and effectively. Energy is being transferred from one side to the other, thus it acts like an energy saver. When the heat exchanger is no longer efficiently transferring heat, it is time for cleaning. Hence, the heat exchanger will be stopped and cleaned from scale sticking on the surface of the wall. Failing to clean the heat exchanger will result to tremendous lost of energy.

The answer to who invented the electric water heater begins around 1850 with an experiment that was created in which both water and bath, on the underneath side, were heated by gas jets. An Englishman Benjamin Maughan, however in 1868 invented the first instant water heater called “The Geyser”, a device where the water was heated as it flowed into the bath. They were known to be quite dangerous.

Maughn’s invention influenced the designs of a Norwegian mechanical engineer by the name of Edwin Ruud, who immigrated to Pittsburg. Ruud who invented the electric water heater (automatic storage) in 1889, founded the Ruud Manufacturing Company, which is still in operation today, and pioneered the advancement of them, in both the residential and commercial market.

The Water Heater is still sometimes referred to as a geyser in the UK. Other terms include: an electric water boiler, electric dispensing pot, or electric water urn.

There are various kinds of water heaters. The most common of them are the storage water heaters. Instantaneous (tankless) heaters are newer on the market, and newer still, solar heaters.

Storage Tank Water Heaters:

This is typically the kind of water heater you saw growing up, the big white tank often beside the furnace. Tank type heaters come in different varieties – gas, oil & electric. This refers to the type of burner used to heat the water. Energy efficiencies between the different types of burners on the tank water heaters can differ greatly. In this tank, cold water is used to fill the tank, and an element, usually near the top & bottom inside the tank is used to heat it. In between the inside tank and the outer shell is often insulation to help keep the water hot, without the elements having to do all of the work.

Instantaneous Water Heaters:

Instantaneous Water Heaters, also called Tankless are just that. They do not have a tank, and therefore are thought to be more energy efficient. Sometimes they are called an in-line heater, as it only heats the water it needs as it passes through, and therefore energy is not wasted by heating extra water all day that is not in use.

Other terms for Tankless are Combination, Combi Boilers, Continuous Flow, Inline, Flash, On-Demand or Instant-On Water heaters.

These particular Water Heaters are rapidly gaining in popularity and will soon become the standard. Often, one main Tankless Water Heater will be installed near the furnace, and supplemental smaller Tankless ones will be situated in tactical spots, such as a far reaching bathrooms, etc to be located right where the water is being used. This strategy saves water as well as energy, thereby making this option one of the most efficient, as well as saving on space.

Solar Water Heaters:

If you’re fortunate enough to live someplace sunny most of the year around, a solar powered water heater may be an option for you. Solar collectors are typically installed on the exterior of the building on the roof or nearby. If insufficient sunlight or at night, an automatic sensor turns off and keeps the remaining water from cooling.

For colder climates, you’re not out of luck. The evacuated tube collector solar powered heater is an alternate type of solar water heater, smaller and deemed more efficient, also roof mounted, is said to work very well in cold climates.

True to its name, the evacuated tube collector solar powered heater has a row of glass tubes which contain heat conducting rods. Inside the heating rods is antifreeze, which is in a circulating loop. The heat is captured and transferred into a heat exchanger. The result is excellent, with very low heat loss due to the fact that once the inside coating has absorbed solar radiation, the air has been evacuated from the glass tubes to create a vacuum.

Stephan Bevan writes for the Toronto Plumbing contrator: Draincom.com. If you need a water heater repair or installation please give us a call at: 416-989-5757.

There are different home-heating systems that can save you more money on fuel costs. Those of you that are using wood stoves can get even better use of your burn time by the following methods.

Before every heating season, have chimney stacks adequately cleaned to aid drafting and prevent stack fires. Green and unseasoned wood causes greater creosote buildup, which results in other problems. It reduces combustion and increases the hazard of a fire.  Layers of soot inside the stove reduce heat transfer to your home. Cleaning out the inside of your wood stove improves heat transfer. Chimney brushing can take from 20 minutes to several hours depending on stack length and complexity.

Install a “wetback” or water-jacket system to your wood stove. Heating household water through your woodstove is a good money saver. Some stoves come with accessories to attach water pipes. Installation time depends on distance between the stove and hot water heater.

Fuel-efficient heating systems are another way to save. Small forced air space heaters such as Monitors are excellent for smaller homes. They use minimal amounts of fuel to heat spaces. Remember to always use with surge protectors to protect electronic components. For hot water heating, Toyotomis, solar hot water heating and boilers with at least a three-pass heat exchanger will bring the greatest fuel economy. Toyotomis are on-demand water heaters. They are very durable because of simpler components and also have very low fuel consumption.  Solar hot water heating can reduce fuel consumption 65 percent and even higher.  New technologies make solar more usable even with minimal light levels.Viessmann has new solar technology available to connect with existing hot water systems.

•Lastly, boilers are the most multi-purpose. They can be used in large homes and complex floor plans. They are useful for in-floor heating, baseboard heating and solar heating. They can be 90 percent efficient if installing a three-pass boiler. Single pass boilers tend to block up more readily.

Jennie Grimwood has been married to a plumbing and heating contractor for 20 years.  Chris Grimwood has more than 30 years experience in plumbing and heating in New Zealand, the Lower 48 and Alaska and operates Kiwi Mechanical Plumbing and Heating.

The above article is adopted from www.thecordovatimes.com. Please refer to their site for other good information on various other subjects.

A heat exchanger is a device that is used to transfer heat from one fluid to another fluid and at the same time preventing the two fluids from coming in contact with one another. There are three main types of heat exchanger. They are as follows:

• air-cooled
• shell and tube
• plate heat exchangers

Dividing the two fluids is usually a metal wall, which acts as a conductor. On one side of the wall is a hot solution, which, while flowing transfers its heat to the cooler solution that is flowing on the other side of the wall.

If the surface area of the heat exchanger is larger then it will create a faster heat transfer. Thermal energy will only flow from a hotter area to a cooler area in order to reach a point of equilibrium.

A heat exchanger can be known by other names as well. For example, in a car, the radiator that acts as an exchanger. The radiator cools the hot fluid by using the airflow over the surface of the radiator.

Other examples of some uses for these devices are swimming pool heating, air conditioners, refrigerators and hot water radiators.

Whether a heat exchanger is used in an industrial or a commercial setting, they are considered very important energy saving devices.

A heat exchanger is usually constructed of cast iron, aluminum, and steel, titanium, bronze or copper. Manufacturers find that one of the biggest problems with these devices is corrosion. This is due to the constant flowing of liquid in these devices.

Manufacturers are always looking for ways to prevent this from happening. The manufacturers are using tubing that is resistant to basic corrosion. They have been creating heat exchangers that feature fins to provide better thermal conductivity. They have found that this has been helping prevent some corrosion.

You will find a heat exchanger in many different types of industry. This would include pulp and paper, pharmaceutical, steel industries, marine, automotive and water treatment plants.

Your guide to everything you have ever wanted to know about a heat exchanger. We also provide information on various types and brands of heat exchangers. Visit our site today! http://www.theheatexchangers.com

By M. Applebaum