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ASTM A178 Pipe and SA178 Grade A Boiler Tubes Suppliers
SA179tubes.com is leading ASTM A178 Tubes manufacturer in India. We are dealing Tubo ASTM A178 Tubes Gr A, A178 Tubing & ASTM A178 tubes at best price due to reasonable man hours in India and good source of high quality ASTM A178 Tubes at best price available in Mumbai, India. SA179tubes.com is Exporter of Norma ASTM A178 approved by Saudi Aramco. We maintain good stock of ASTM A178 Tubes. SA179Tubes.com stock complete range or scope of Carbon Steel ASTM A178 Tubes, and A178 Steel Pipe in Stock in various sizes.
If you are looking to buy ASTM A178 Tubes at the best price in India, check our price of SA178 Material including Tubo ASTM A178. SA179TUbes.com is supplying ASTM A178 Pipes Gr B Pipe to Canada, UK, Turkey, USA, Russia, Australia, Indonesia, Israel, Bahrain, Sri-Lanka, Italy, Qatar, Egypt, Malaysia, Singapore, Germany, France, Thailand, Iran, Kuwait, Oman, Sweden, UAE, & Saudi Arabia. We can supply ASTM A178 tubes at best price as we are one of the largest Supplier & Franchisors of Sa 178 Gr A in India.
We have our stocking distributors in Surat-(Gujarat), Pune-(Maharashtra), Bangalore, Chennai, Hyderabad, Delhi & Tamil Nadu. Check once our ASTM A178 tubes price before buying ASTM A178 Boiler Tube from India or China. also, mail for our live stock of Tubo ASTM A178 Gr A to check types & sizes with our ready stock we can give you the best price of Sa178 Steel Pipe. We can also provide free sample of ASTM A178 tubes , SA179tubes.com is having our Dealer & Distributor in Karnataka, Karnataka, Chennai(Madras), Bangalore, Rajkot, Gujarat, Maharashtra, Chhattisgarh, Bhosari, Jaipur, , Madhya-Pradesh, Raipur,
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How To Repair Boiler Tube
In a boiler, the work – in this case, heat transfer – is carried out by the boiler tubes. The type of boiler (firetube, water tube, etc.) may affect the orientation and layout of the boiler, but the tubes are still transferring heat from the fire side to the water side. It is for this reason that boiler tube maintenance and repair are essential.
As a result of the large temperature gradients, boiler tubes are subjected to a great deal of stress, so the tube design, material, and thickness have been chosen carefully for optimum and efficient operation. As boiler tubes may be the most crucial component of most boilers, the importance of proper operation, maintenance, and repair cannot be understated.
To ensure compliance with all rules and regulations, boilers built to ASME Boiler & Pressure Vessel Code (BPVC) must be repaired by a National Board certified company.
On board the ship, some of the common repairs made to the marine boiler are plugging of the tubes and replacing the leaky manhole joints. The dry dock must also be used for other major repairs, such as replacing damaged tubes and rebuilding the furnace. To fire the boiler, a temporary repair must be made to the leaky boiler tube. Regardless of the situation, and regardless of the condition, the boiler must run.
Boiler tube repair method
A method for the fast and efficient repair of tubes in a furnace boiler water wall involves milling elongated slots at each end of a damaged tube section. This damaged tube section is then cut away and replaced with a new tube section having elongated slots milled at each end and which is cut to mate with existing tubes.
In order to secure the replacement tube section, the existing tubes and the replacement tube section are aligned to form elongated slots through which interior welds are made. To complete the repair, the elongated slots are then closed with covers made from a second section of replacement tubing, and the water wall web is attached to the replacement tube section.
In addition to the milling machine used to mill the elongated slots, drill and saw fixtures are also disclosed to assist in cutting away damaged tube sections. The improved method and apparatus make boiler tube repairs more precise and uniform, increase the possibility of performing internal welds in boiler tubes, and allow prefabrication of some repair parts, thus reducing furnace downtime.
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Solitaire Overseas is a well-known supplier of Corten steel, also known as weathering steel. Corten steel is a high-strength steel alloy that has the ability to form a protective layer of rust on its surface when exposed to the elements. This protective layer not only adds to the aesthetic appeal of the steel but also helps to protect it from further corrosion.
Solitaire Overseas is based in Mumbai, India, and has been in the steel industry for over 25 years. We specialize in the supply of high-quality Corten steel products such as plates, sheets, coils, pipes, and fittings. Their products are widely used in industries such as construction, architecture, and engineering.
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Carbon steel is a type of steel that contains mainly carbon as the primary alloying element, with small amounts of other elements such as manganese, silicon, and copper. The carbon content in carbon steel typically ranges from 0.05% to 2.0%.
Carbon steel is widely used in various industries because of its low cost, high strength, and durability. It is used in the manufacturing of machinery, tools, construction materials, and many other products. It is also used in the automotive and aerospace industries, as well as in the production of pipes, tanks, and other structures that require high strength and resistance to corrosion.
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Introducing high-quality stainless steel pipes from Solitaire Overseas, your trusted supplier of raw materials in metals. Our stainless steel pipes are made from durable and corrosion-resistant materials, ensuring long-lasting performance and reliability. Perfect for a wide range of applications, including plumbing, construction, and industrial projects. With our commitment to quality and customer satisfaction, you can trust Solitaire Overseas to deliver the finest stainless steel pipes and other metal products to meet your needs. Contact us today to learn more!
#stainlesssteelpipe#pipingsolutions#steeltube#industrialpipe#corrosionresistant#metalpiping#stainlesssteelfitting#seamlesspipe#weldedpipe
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What Is a Boiler Tube ? How They Made It
Boiler tubes are seamless tubes made of carbon steel or alloy steel. In steam boilers, power plants, fossil fuel plants, industrial processing plants, electric power plants, etc. They are widely used. A boiler tube can either be a medium-pressure boiler tube or a high-pressure boiler tube.
In a boiler, boiler tubes are metal tubes that heat water in order to create steam. Tube boilers come in two major types: water-tube boilers and fire-tube boilers.
With the advent of high-pressure water tubes, it has become possible to heat water in tubes externally by means of gases. Fuel is burned within the furnace, generating hot gas that heats water in the tubes to produce steam. Smaller Boiler tubes are isolated by external heating tubes, while larger Boiler tubes rely on water-filled tubes that run along the walls of the furnace to create steam.
There are two major types of tube Boiler tubes: water-tube Boiler tubes and fire-tube Boiler tubes
Water-tube Boiler tubes. …
Fire-tube Boiler tubes. …
Materials used for Manufacturing of Boiler Tubes.
In water-tube boilers, water circulates inside the tubes and is heated externally by hot gases created by the furnace. In fire-tube boilers, hot gas is passed through one or more tubes which, through thermal conduction, heat the water surrounding them. Certain mechanisms can damage boiler tubes, including:
boiler feed water corrosion
graphitization
thermal fatigue
corrosion fatigue
The heat treatment methods used in boiler pipes
Heat treatment involves heating and cooling a high pressure boiler pipe to change its physical properties. The microstructure of a high pressure boiler pipe can be improved by heat treatment to meet the required physical requirements. By heat treating, toughness, hardness and wear resistance can be obtained. Quenching, annealing, tempering, and surface hardening are required to achieve these characteristics.
A. Quenching
In hardening, also called quenching, a high-pressure boiler pipe is heated evenly to the appropriate temperature, quickly immersed in water or oil for rapid cooling, and cooled in the air or in the freezing zone. In order for the high pressure boiler pipe to achieve the required hardness.
B. Tempering
After hardening, high pressure boiler pipes become brittle. By quenching, the high pressure boiler pipe can be broken and tapped. Brittleness can be eliminated by tempering. While the hardness of the high pressure boiler pipe is reduced, the toughness can be increased to reduce the brittleness.
C. Annealing
Annealing is a method of removing the internal stress from a high-pressure boiler pipe. In the annealing process, steel parts are heated to the critical temperature, then placed in dry ash, lime, asbestos or enclosed in a furnace and allowed to cool slowly.
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Working Principle Of Plate Heat Exchanger
The law of physics always allows the driving energy in a system to flow until equilibrium. Heat dissipates when there is a temperature difference.
A heat exchanger follows the equalisation principle. With a plate heat exchanger, heat cuts through the surface and separates the hot medium from the cold. Thus, heating and cooling fluids and gases use minimal energy levels.
The theory of heat transfer between mediums and fluids happens when:
Heat is always transferred from a hot medium to a cold medium.
There must always be a temperature difference between the mediums.
The heat lost from the hot medium is equal to the amount of heat gained by the cold medium.
Generally, these plates are corrugated in order to increase the turbulence, the thermal exchange surface and to provide mechanical rigidity to the exchanger. Corrugation is achieved by cold forging of sheet metal with thicknesses of 0.3mm to 1 mm.
The most frequently used materials for the plates are stainless steel (AISI 304, 316), titanium and aluminium.The corrugation on the plates forces the fluid on a tortuous path, setting a space between two adjacent plates b, from 1 to 5 millimetres.
The fluids can cross the channels in series (a less common solution) or in parallel by making counter-current or current configurations.The serial configuration is used when there is a small flow rate for each fluid but high heat jump; the greatest problem is with a high pressure drop and an imperfect counter-current.
The parallel configuration with countercurrent channels is used for high flow rates with moderate temperature drops, and is the most widely used.When there is a great difference between the flow rates (or between the maximum permissible pressure drop) of the two fluids, the exchanger can run twice by the fluid with a lower flow (or higher losses) to balance the values of pressure drops or specific flow rates in the channels.
The working principle of a plate heat exchanger is determined by its construction, function, and application. A plate heat exchanger is a class of heat exchangers for transferring heat between two fluids using metal plates.
The plate heat exchanger has a notable advantage over conventional heat exchangers because the fluids are exposed to a much broader surface area as the fluids are spread over the plates. This facilitates heat transfer and considerably incToday, plate heat exchangers are common, and very tiny brazed ones are applied in the hot-water parts of millions of combination boilers. The high efficiency of such small dimensions leads to an increase in the Domestic Hot Water (DHW) flow rate of combination boilers. The small plate heat exchanger has a great influence on domestic heating and hot water supply. Larger commercial plate heat exchangers employ gaskets between the plates, while smaller ones can be brazed.reases the rate of the temperature change.
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How To calculate the efficiency of a plate heat exchanger ?
Plate heat exchangers are efficient heat recovery units in commercial, industrial and residential settings. Plate heat exchangers can reduce a building’s energy costs and environmental impact by extracting sensible energy from exhaust air and using it to cool or heat incoming air.
Simple engineering principles are used to build them. A heat exchange core consists of layers of aluminium or polymer plates with gaps between them that allow air to flow freely. The exhaust air is funnelled between some of the layers. In the meantime, incoming air is funnelled in the other direction between the other layers.
Depending on the climate, the exhaust air heats or cools the plates. This sensible energy is then transferred to the incoming air. Modern plate heat exchangers can recover the vast majority of sensible energy, so their impact is significant.
What Is Heat Exchanger Efficiency?
Comparison of real-world performance with ideal performance is efficiency; it is the ratio between the heat transferred in an actual heat exchanger and the heat transferred in an ideal heat exchanger. Optimal performance is determined via modelling and includes the limitations imposed by factors such as the second law of thermodynamics, which states that more energy is wasted each time it is transferred or transformed.
Defining the levels involved in optimal plate heat exchanger efficiency, which transfers the maximum amount of heat and generates the least entropy, provides a benchmark against which existing plate heat exchangers can be measured.
Ideal Heat Exchanger System
In most cases, the mean temperature difference is given. UA is the product of surface area and heat transfer coefficient and determines the heat transfer rate. A new heat exchanger design or a larger heat exchanger can always be improved on the UA. Therefore, we do not have a practical definition of an ideal heat exchanger.
Overall heat transfer equation
For any heat exchanger system, the overall heat transfer rate (Q) is defined as –
Q = U×A×ΔT
where, U is the overall heat transfer coefficient
A is the overall heat transfer surface area
and ΔT is the mean temperature difference between hot and cold side
There are two main models for calculating the performance efficiency of a plate heat exchanger. Calculating the rate of heat transfer using the log-mean temperature difference method (LMTD) is as follows:
Q = UA(FΔTlm)
This equation defines U as the overall heat transfer coefficient, A as the total area of heat transfer, *Tlm as the log-mean temperature difference, and F as the log-mean temperature difference correction factor. LMTD is most commonly used when the inlet and exit temperatures are known, but the size of the heat exchanger is not. In contrast to the LMTD method, the thermal effectiveness method compares the real-world heat transfer inside the heat exchanger with the maximum possible heat transfer. The ratio is then calculated.
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Difference between Different Heat Exchanger Systems
A heat exchanger is a device for transferring heat between two fluids, such as liquids, gases, or vapours, of different temperatures. Depending on the type of heat exchanger being used, the heat is transferred from gas to gas, liquid to liquid, or liquid to liquid through a solid separator, which prevents mixing of the fluids or direct fluid contact.
Frame Aand Plate Heat Exchanger
Corrugated parallel plates are separated from each other by gaskets that control the alternating flow of hot and cold fluid over the surface of the plates.
By tightening bolts, a frame plate and a pressure plate compress gasketed plates together. Two upper bars and a lower guiding bar suspend the gasketed plates and the pressure plate. By removing or adding plates, it is easy to clean and change the capacity of this device.
As heat transfers from the warmer to the cooler channel, hot and cold media flow in alternate channels with processed fluids.
Heat Exchanger For Shells And Tube
A heat exchanger transfers heat between two or more liquids or gases of different temperatures. The heat transfer process can be gas-to-gas, liquid-to-gas, or liquid-to-liquid, and usually does not involve direct contact between the two fluids. A liquid to gas heat exchanger, and more specifically a water to air heat exchanger, is discussed in this article.
Heat Exchanger For Scraped Surface
Applications involving highly viscous and/or sticky products require heat transfer. Because the blades on scraped surface heat exchangers prevent the product from settling on the interior surfaces, they are the best choice for heat transfer in those applications.
In order to ensure uniform heat transfer to the product, blades inside the product channel remove product from the channel walls.
The scraping blades are made from a variety of materials to meet different processing requirements, and are designed specifically for gentle product handling to avoid compromising product quality and consistency.
Scraped surface exchangers can be mounted vertically or horizontally. Inside, an electric motor turns a rotor fitted with scraping blades.
In order to prevent product damage, rotors turn and product flows through the heat exchanger in the same direction, with product entering at the bottom and exiting at the top.
The inner surface of the heating surface is polished to a high gloss.
Carbon mechanical seals, carbon flushed/aseptic seals, hard face seals and hard face flushed/aseptic seals are available. Suitable materials will be selected for special applications.
Typical scraped surface heat exchanger applications include:
There are viscous products such as ketchup, mayonnaise, hummus, peanut butter, puddings, salad dressings, bread dough, gelatine, baby food, skin lotions, and shampoos.
Heat-sensitive produce: Egg products, fruit purées, cream cheeses, and fishmeal.
The following products crystallise and phase change: coffee/tea extracts, icings and frostings, sugar concentrates, margarines, shortening, spreads, gelatine broth, lard, fondant, beer and wine.
Meat, poultry, pet foods, jams, preserves, and rice puddings constitute particulate products.
Caramel, cheese sauces, processed cheese, gums, gelatine, mascara, and toothpaste are sticky products.
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Difference between heat exchangers and interchanger
The design of a heat exchanger and an intercharger is very different. Cooling is provided by refrigeration units in chiller systems, while temperature regulation in heat exchangers is achieved by direct fluid heat transfer.
Exchanger Heat
A It is an apparatus used for heat recovery, which means it is used to transfer heat from two fluids. A heat exchanger and a condenser differ by the purpose of the state change of the substance (liquid or vapour).
Heat Interchanger
Using heat Interchanger, whether as an aid to performance or as a solution to a problem, has been custom and practised in the commercial refrigeration industry for many years, often without much consideration for either theoretical or practical concepts. ASTM A106 Pipe And ASME SA106 Pipe Is Main Elements of Heat interchanger. They are used in refrigerant systems in many different ways and for many different reasons. Here we cover the most common uses of these refrigerant heat exchangers. Heat Exchanger Consist Of ASTM A106 Pipe And ASME SA106 Pipe Which Help Heat Exchanger To Work Properly.
Conventional Application
Almost all refrigeration systems will benefit from a heat exchanger, provided it is not undersized so that the suction side pressure drop nullifies the advantages or oversized, on low temperature applications, so that the suction superheat and the discharge temperature is too high. The heat exchanger in this application has two effects: to increase the gas temperature (superheat) as it enters the compressor suction and to increase the liquid subcooling as it enters the expansion valve.
Increasing the suction gas temperature
In order to achieve this rating, refrigeration compressors are rated at suction gas temperatures significantly above freezing point. This heat is extracted from the evaporator to reach this rating. The evaporator is rarely able to meet this requirement in low-temperature applications, so consequently there can easily be a 5% shortfall in the compressor rating and consequently system capacity. The only way that this superheat can be achieved, albeit indirectly, is from a heat interchanger which can be sized to restore and, sometimes, slightly increase the system evaporator capacity. This is achieved by superheating the suction gas and subcooling the refrigerant liquid in an exchange of heat, this sub heating then being usefully employed in the evaporator and fulfilling the requirements stated in the first paragraph.
Classification of heat exchangers
Direct transfer type: The hot and cold fluids are separated by a metal wall through which heat is transferred from the hot to the cold fluid. For example, a shell and tube heater.
Storage type: A hot fluid is flowed through a porous solid to heat it, then a cold fluid is flowed through the hot solid to extract heat. This type of heat exchanger is not used by the pharmaceutical industry.
Direct contact: In this case, hot and cold fluids are not physically separated, since hot fluid passes through cold fluid. For example, steam bubbles through a cold liquid.
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Graphite block heat exchanger
Graphite block heat exchangers are suitable for the heating, cooling, evaporation, condensation, and absorption of highly corrosive liquid chemicals. It is one of the most versatile types of impervious graphite heat exchangers. The process and service channels are formed by drilling rows of holes horizontally and vertically through graphite blocks. Heat is transferred by conduction through the impervious graphite left between the rows of holes that separate the media. Graphite block heat exchangers consist of a stack of blocks enclosed in a steel shell.
Why Use Graphite in Heat Exchangers?
Due to its thermal and physical properties, graphite is an excellent heat transfer medium. These are some of its advantages:
Exceptional thermal conductivity
Easily machined
Capable of withstanding system stresses
Superior corrosion resistance
Low coefficient of thermal expansion (CTE)
High operational safety
Long service life
Benefits Of Graphite Block Heat Exchanger
High corrosion resistance of Graphilor® 3
Compactness
Robustness
Modular design
Easy maintenance
Long lifetime
Service and maintenance in the US with two strategically located facilities
Manufacturing plant in the US
Materials
Impervious graphite: GAB GPX1, GPX1T or GPX2
Shell, Pressure plates and flanges: carbon steel or stainless steel
Tie rods, nuts, bolts, washers, springs: stainless steel
PTFE gaskets between the blocks
Design
Totally modular design: number of blocks, size of blocks and number of passes can be adjusted
Different drilling diameters on process and service sides
Maximum block diameter: 900 mm
Graphite nozzles on product side
Thermal expansion compensation ensured by tie rods and helical springs
Key Features
Design pressure: -1 barg (full vacuum) to +10 barg (145 psig)
Design temperature: -60 to +200°C (-76 to 392°F)
Heat transfer area: up to 163 m2 (1755 ft2)
Design: according to European PED, ASME code, Chinese Pressure Vessel code and other national pressure vessel codes on request
Key Benefits
Outstanding corrosion resistance on one side or on both sides
Good heat transfer performance thanks to adjustable cross sections on both sides
Large transfer areas and comparatively low pressure drop on the product side
Easy disassembly and ability to mechanically clean each block
Impregnation before machining ensures resin free surfaces
Single or double-row drillings on product side
High operational safety
Sturdy and modular design
Short lead time
Long lifetime
Optional features
Removable headers for easy mechanical cleaning
Rubber lined, glass lined or PTFE lined shell for corrosive fluids on shell side
Protection against abrasion
Sight glass
Main applications
Cooling, condensation, heating, evaporation and absorption of ultra-corrosive chemicals
Heat transfer between two ultra-corrosive chemicals
Best suited for single purpose units
Types of Graphite Heat Exchangers for Corrosive Environments
Graphite heat exchangers are available in many designs and configurations to suit different heat transfer processes. These include:
Shell and Tube Graphite Heat Exchangers
Imperative shell and tube heat exchangers are engineered for superior reliability and longevity. When compared to other graphite heat exchangers, they offer exceptional performance and a low initial cost, resulting in an excellent lifetime return on investment. The large cross-sectional area makes them ideal for low pressure and fouling applications.
Multi-Blox Graphite Heat Exchangers
Our Multi-BloxTM heat exchanger features some of the longest graphite composite blocks in the industry. The design reduces the need for gaskets, eliminates leak paths, and minimises point loading. With a maximum operating pressure of 150 PSIG, they are designed for non-stop service.
Cubic Block Graphite Heat Exchangers
The most efficient cubic block heat exchangers on the market with the highest heat transfer capabilities in the smallest area are available from us. They are easy to clean and maintain, and they are exceptionally durable. They are therefore ideal for interchange service and high-fouling applications.
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Plate Heat Exchanger Working Principle
Plate Heat Exchangers were first produced in the 1920s and have since been widely used in a great number of sectors. Plate exchangers are composed of parallel plates that are stacked one on top of the other so that fluid can flow between them. Fluid flows between adjacent plates in the space between them.
Through holes at the corners of the plates, hot and cold fluids can alternately flow through the exchanger, so that a plate is always in contact on one side with the hot fluid and on the other with the cold fluid.
Plate sizes can range from a few square centimetres (100 mm x 300 mm side) to 2 or 3 square metres (1000 mm x 2500 mm side). From a few square centimetres (100 mm x 300 mm) to 2 or 3 square metres (1000 mm x 2500 mm).
Generally, these plates are corrugated to increase turbulence, the surface for thermal exchange and provide mechanical rigidity to the exchanger. Metal sheets of 0.3 mm to 1 mm thick can be cold forged into corrugated shapes by cold forging. Stainless steel (AISI 304, 316), titanium, and aluminium are the most commonly used materials for the plates.
Corrugations on the plates cause the fluid to travel on a tortuous path, creating a space between two adjacent plates B of 1 to 5 millimetres.
You can cross the channels in series (a less common solution) or in parallel by making counter-current or current configurations. This configuration is used when the flow rate for each fluid is small, but the heat jump is high; the greatest problem is with a high pressure drop and an imperfect counter-current. Parallel configurations with countercurrent channels are most common for high flow rates with moderate temperature drops.
Anytime there is a large difference between the flow rates (or maximum permissible pressure drop) of the two fluids, the exchanger can be run twice by the lower flow fluid (or higher losses) to balance pressure drops or specific flow rates in the channels.
The most common problem with plate heat exchangers is the irregular supply of all channels in parallel. Due to the pressure drop, fluid tends to distribute more in the first channels than in the last. When the number of plates increases, even distribution decreases, resulting in a decrease in the performance of the exchanger as a whole.
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Heat Exchanger VS Dual Boiler
A Dual boiler espresso machine has two boilers, whereas a heat exchanger machine only has one. Although this is the most obvious difference between the two types of machines, both can produce extremely high steam temperatures and temperature below boiling for quality espresso.
Heat Exchanger
In a heat exchanger espresso machine like the Rocket Appartamento, water is kept at a temperature high enough to produce steam, approximately 255 – 265 degrees Fahrenheit. Water from the reservoir is fed into the steam boiler where it is flash heated before being channelled into the group to make the coffee. The steam boiler is half filled with water and has a heat exchange tube inside.
The steam valve above the water and heat exchanger tube is where steam is drawn from to create steam and make your milk-based drinks. Dual boiler machines do not require cooling flushes when the machine sits idle for a period of time, as is the case with heat exchangers.
But how does this principle apply to an espresso machine, and what does it mean for its performance?
Heat exchanger boilers in espresso machines differ from standard boilers in how they heat and control the water. Standard boilers pull water directly from the boiler for both steam and brew, but heat exchangers separate this process. The water temperature difference between steaming and brewing is over 40 degrees Fahrenheit. You’ll have to wait for temperature changes between brewing and steaming. The vast majority of commercial machines use heat exchangers or dual boilers to steam. This is why the vast majority of commercial machines have a heat exchanger or dual boiler. A912 Tube & SA 192 Tubes Are Used In Both Heat Exchanger & Dual Boiler.
The first thing we need to understand is what a heat exchanger actually is. Simply put, this is a boiler that transfers heat from one fluid to another without contacting the fluids. Imagine a pool of water with a tube running through it.
Water in the pool will affect the temperature of the water in the tube, and vice versa, despite the tube’s material separating them. Thousands of homes, businesses, and industries use these types of boilers. It’s likely you have at least one heat exchanger in your home, whether it’s your water heater, coffee machine, or some other appliance!
Dual Boilers
Dual boiler machines are just what they sound like: they have multiple boilers. Instead of a single boiler with multiple water paths, dual boilers have separate brew and steam boilers. The boiler can be ready at all times for either task.
The end result is that temperature is no longer a factor in shot inconsistency. In a machine like this, it’s nearly impossible for a barista’s shot preparation to outrun brew boiler recovery. As with a heat exchanger, a dual boiler allows you to steam and brew at the same time. Both boilers are temperature stable within the required ranges for both brewing and steaming, providing excellent consistency in both processes.
In high steam volume situations, such as steaming 10-20 oz. of milk, this can only change. Several lattes at once. With a Dual boiler, however, brew temperatures will not fluctuate and will result in consistent espresso.
What’s the problem? Cost, as you might have guessed. Dual boiler machines tend to be more expensive than heat exchangers because they pack in more material. Heat exchangers take up the same amount of space as a single boiler, functionally. Dual boiler machines, however, require double the materials. Over time, this means double the components that could fail. This also means double the space needed. This is another problem with dual boiler machines, as they tend to run larger.
Taking these caveats into consideration, dual boilers are powerful solutions for high volume cafés, especially when you actually have multiple baristas using the same espresso machine.
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6 Maintenance Tips For Plate Heat Exchanger
Maintenance and inspection schedules for plate heat exchangers depend on a variety of factors, including the environment (time, temperature, and concentrations), frequency of use, and regulatory mandates. Different industries have different maintenance requirements, and different processes will affect your heat exchanger differently. The best way to maximise uptime is to establish a preventative maintenance schedule.
Online and Offline Cleaning :
Cleaning online prevents fouling and scaling without interrupting operation or shutting down the heat exchanger. Online cleaning can be used as a standalone approach or in conjunction with chemical treatment to prevent any reduction in the heat exchanger performance and to extend the service life of the tube. Online cleaning techniques include the recirculating ball type system and the brush and basket system.
Offline cleaning is another effective cleaning technique for improving heat exchanger efficiency and reducing operating costs. Pigging involves the use of a bullet-like piece of equipment placed inside the tube and pushed down the tube with high air pressure. Other offline cleaning methods include chemical cleaning, hydro-blasting, and hydro-lancing.
As a result of both methods, the heat exchanger is restored to its optimal efficiency before scaling and fouling begin to creep in and negatively impact its efficiency.
Maintaining Heat Exchanger :
Maintaining plate heat exchangers to avoid fouling, blockages, and leaks is the best way to boost efficiency and output. In the absence of periodic maintenance, heat exchanger efficiency is bound to be compromised, resulting in reduced heat transfer, potentially higher energy costs, fluid cross-contamination, and erosion. It can be safely concluded that all heat exchanger performance problems can be avoided by implementing an appropriate maintenance program.
Periodic Cleaning :
It is most effective to flush out all the dirt and debris that degrade heat exchanger efficiency over time with periodic cleaning-in-place. Draining both sides of the PHE and isolating it from the system fluid is required for this technique. The water should be flushed out from both sides until it runs clear. Flushing should be performed in the opposite direction of regular operations.
As soon as this is done, a cleaning agent is passed using a solution tank and a circular pump, while making sure the agent is compatible with the gaskets and plates of the PHE. Lastly, the system should be flushed with water until the discharge stream is clear.
Cleaning the PHE Manually :
You must follow the manufacturer’s instructions when cleaning manually. Ideally, the plates should be cleaned without being separated from the frame, so when installing a PHE, it is essential that there is enough space for manual cleaning.
In the next step, a cleaning agent is applied to eliminate dirt and debris, followed by a thorough rinsing with a soft bristle and pressurised water. It is not recommended to use metal pads or brushes, as they may irritate or dislodge the plates.
Minimising the Fouling Factor :
Heat exchanger efficiency is highly affected by the velocity of the operating fluid, so it is recommended that the flow rate be increased periodically. Turbulence retards fouling, which otherwise impacts heat exchanger performance and impedes fluid flow. The duration and frequency of preventive maintenance and periodic cleaning will, however, vary depending on the velocity of the fluids being processed and the foundering tendencies of the medium.
Analysing and Addressing Issues in Heat Exchanger Efficiency :
Efficiency issues with heat exchangers may not always appear as leaks, fouling, or blockages. While many problems are minor, if left unchecked, they can cause irreparable damage to expensive equipment, resulting in unplanned downtime and emergency repairs.
The process data documented around maintaining heat exchangers offers valuable insight into various important factors, such as flow rate, pressure, and channel inlet and outlet temperatures. Using this data, we are alerted to impending issues that may become uncontrollable if not addressed on time.
If you are not using energy optimally, you are losing money every minute. Follow these tips to improve heat exchanger efficiency and save fuel in almost any application.
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Difference Between Heat Exchanger and Condenser
Heat Exchanger
Heat exchangers transfer heat from one place to another.
In a refrigerator, the heat exchanger separates hot and cold air, while the condenser cools it.
A heat exchanger transfers heat energy from one fluid to another by utilising the temperature difference between two different fluids.
An evaporator uses a heat exchanger to separate hot and cold liquids. A condenser is a device used to cool liquid from one or more heat exchangers.
Heat exchangers do not use refrigerants, so they are environmentally friendly.
In any situation where there is a temperature difference of more than 100 degrees Fahrenheit between two fluids, a heat exchanger can be used.
A heat exchanger uses the same amount of energy as a condenser, but installation takes longer since they are larger and require more components.
Heat exchangers are typically used in industrial settings where large amounts of energy are needed for heating and cooling.
Higher pressures can be handled by heat exchangers.
The advantage of a heat exchanger over a condenser is that the former is more cost-effective and less prone to damage. This is because it does not have moving parts, unlike a condenser.
Condenser
Heat is transferred from a cool to a hot area by the condenser.
Condensers are usually found in HVAC applications such as air conditioning and refrigeration systems.
A condenser is an apparatus that evaporates and condenses fluids in order to cool them.
Condensers change the phase of fluids from liquid to gas.
Generally, condensers are more efficient than heat exchangers since they transfer all the heat in one direction (instead of two).
Condensers are typically smaller and more compact than conventional systems.
A condenser requires less maintenance than a conventional system.
Heat exchangers require more energy to operate than condensers.
Condensers are more durable and reliable because they are designed precisely.
Because condensers are smaller in size and simpler in configuration, they require less installation time.
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How to calculate the heat duty for heat Exchangers ?
In order to understand exactly what we are calculating, let’s define the term “Heat duty.”. It is the amount of heat required to transfer from a hot side to a cold side over a period of time. The calculation is important to all engineers and one of the most common calculations you’ll need to know in your career if you’re a process engineer. There are two ways to calculate heat duty.
Speaking of Heat Exchangers, specialised boiler tubes are utilised in proper functioning of such exchangers.
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Fluids that are suitable for sensible heat transfer, that is, fluids that do not undergo phase changes.Latent heat transfer, on the other hand, occurs when a fluid undergoes a phase change. i.e. condenses.
How to calculate the heat duty for heat exchangers?
A210 Tubes And SA 210 Tubes Play Important Role In Heat Exchanger. To begin understanding exactly what we are calculating, let’s define the term “Heat duty”. Heat duty can be defined as the amount of heat that has to be transferred from a hot to a cold side over the course of a unit of time.
A process engineer needs to know this calculation because it’s one of the most common ones. There are normally two ways to calculate heat duty.
Fluids that can be used for sensible heat transfer, meaning they do not undergo phase change.
In order to solve a thermal problem, we need to know several parameters. From there, further data can be determined.
The six most important parameters include:
The amount of heat to be transferred (heat load)
The inlet and outlet temperatures on the primary and secondary sides
The maximum allowable pressure drop on the primary and secondary sides
The maximum operating temperature
The maximum operating pressure
The flowrate on the primary and secondary sides
The heat load can be calculated if the flow rate, specific heat and temperature difference on one side are known.
Calculation method
The heat load of a heat exchanger can be derived from the following two formulas:
1. Heat load, Theta and LMTD calculation
Where:
P = heat load (btu/h)
m = mass flow rate (lb/h)
cp = specific heat (btu/lb °F)
δt = temperature difference between inlet and outlet on one side (°F)
k = heat transfer coefficient (btu/ft2 h °F)
A = heat transfer area (ft2)
LMTD = log mean temperature difference
T1 = Inlet temperature – hot side
T2 = Outlet temperature – hot side
T3 = Inlet temperature – cold side
T4 = Outlet temperature – cold side
LMTD can be calculated by using the following formula, where ∆T1 = T1–T4 and ∆T2 = T2–T3
2. Heat transfer coefficient and design margin
The total overall heat transfer coefficient k is defined as:
α1 = The heat transfer coefficient between the warm medium and the heat transfer surface (btu/ft2 h °F)
α2 = The heat transfer coefficient between the heat transfer surface and the cold medium (btu/ft2 h °F)
δ = The thickness of the heat transfer surface (ft)
Rf = The fouling factor (ft2 h °F/btu)
λ = The thermal conductivity of the material separating the medias (btu/ft h °F)
kc = Clean heat transfer coefficient (Rf=0) (btu/ft2 h °F)
k = Design heat transfer coefficient (btu/ft2 h °F)
M = Design Margin (%)
Combination of these two formulas gives: M = kc · Rf
i.e the higher kc value, the lower Rf-value to achieve the same design margin.
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Condenser vs vented vs heat pump. Which one Is Useful?
Condenser
Dryers with condenser coils are the most popular. The tumble drums are heated by blowing air over an electric coil. Heat and moisture are emitted into a container as vapour and condensed into water.
Condenser dryers are closed systems. The air passes over a heating coil and into the drum. The air is expelled into a condenser chamber, where water is extracted, and the dry air is heated and returned. Collecting water needs to be emptied regularly.
Condenser dryers are generally slower and less energy efficient than vented dryers. Additionally, they often have a “quick dry” feature, which is generally inefficient.
Condenser dryers generally come with medium (7-9kg) or large drums (10kg and up). Additionally, they are usually heavier and are not really suitable for mounting on a wall.
Upside: closed system – no venting
Downside: Fast, needs to empty a water reservoir, weighs a lot and cannot be wall-mounted. Poor energy $ per kg/minute drying time ratio.
Vented
Emptying the water reservoir weighs a lot. A fan draws external air over a heating coil, blows it through the drum and expels hot, moist air out a vent. Air should vent to the outside.
It is fast, requires a water reservoir to be emptied, weighs the clothes before they are dried, and starts on a delayed timer to prevent over-drying or using low-price electricity. These are better and stretching to this level will get you the best heater/dryer.
A disadvantage is that it is slow, needs to be emptied regularly, is heavy,rating as low as £150. Here, air here is blown over a heating coil into the tumble drum and expelled through a large pipe, much like that used on a portable air-conditioning unit.
Negatives: Slow, must empty a reservoir, very heavy, cannot be mounted on a wall. either through a window or permanently fitted through an external wall.
Also a disadvantage is that it is slow, needs to be emptied regularly, is heavy,and mid. Thus, vented dryers are trickier to place in a room, with their installation a more complicated
It needs to empty a water reservoir, and needs the help of a professional.
extra programmes makes them more efficient and gentler on clothes, but this usually comes at a higher price. A reverse-action setting – which changes the direction of the drum towards the end of washing – is useful for avoiding tangled or crumpled clothing.
Upside: Cheaper to make and buy. Quick-drying. Stackable or wall mount. Good energy $ per kg/minute drying time ratio.
Downside: hot, moist air needs to go somewhere so vent if you can or open a window in the laundry. Shorter replacement cycles. Not as gentle on clothes as one heat/time fits all. Can ‘ball’ clothes leaving damp patches inside.
Heat Pumps
Condenser dryers without heating coils are heat pumps. The mini-air conditioner/fridge is a closed-system model. When a compressor compresses refrigerant gas, hot air is extracted and blown into the tumble drum during the process of blowing air through the coils. From the coils, water is collected. That’s why it’s cold inside the fridge and hot outside.
The energy efficiency of a compressor is much higher (7-9 stars) than that of a heating coil, but humidity and temperature can affect the performance of a compressor. Additionally, heat pumps require periodic draining of water reservoirs.
They are the gentlest on clothes since they use far lower temperatures. However, they can also take longer than condenser systems.
Operating costs for heat-pump dryers are the lowest. Although they are the most expensive at first, they also represent a larger investment. They’re particularly suitable as a long-term solution for those who frequently tumble-dry their clothes.
The heat-pump dryer is similar to a condenser dryer in that it has a water tank, but the heat is reused. A condenser dryer, on the other hand, does not have a heating coil, so it works like a refrigerator and air conditioner.
Tumble dryers also send hot air into the drum, but here the warm vapour is compressed and passed through the evaporator. The extracted water is pumped into a tank (or directly into a drain if you’ve attached the optional hose). The difference is that the warm air is recycled and reused, not dumped outside.
Since condenser tumble dryers repurpose the hot air, they are more energy efficient than any other type of dryer, but they can take longer to operate. Newer models, however, are offering faster cycles. Similarly to other tumble dryers, the best models tend to be on the more expensive end with features such as smartphone controls and extra programs. Generally speaking, they tend to be the quietest and gentlest on textiles because of their lower temperatures.
Their size is only available in medium (7-9kg) or large (10kg or more), and they cannot be wall-mounted.
Upside: low energy use. Said to be gentler on clothes.
Downside: Long time to dry. Cannot be wall-mounted. Need to empty a water reservoir. A lot of tech goes wrong.
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