Comparing Different Types of Heat Exchanger Tubes for ...

Author: Helen

Jun. 24, 2024

Comparing Different Types of Heat Exchanger Tubes for ...

Heat exchanger tubes are a critical component in various industrial processes and systems where heat transfer is essential. Choosing the right type of heat exchanger tube for a specific application depends on factors such as the nature of the fluids involved, operating conditions, and the desired heat transfer efficiency. Here, we'll compare different types of heat exchanger tubes for specific applications:

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1. Carbon Steel Tubes:

- Applications: Carbon steel tubes are commonly used in low-temperature heat exchangers, such as HVAC systems and some industrial processes.

- Advantages: They are cost-effective and readily available. Carbon steel can withstand moderate temperatures and pressures.

2. Stainless Steel Tubes:

- Applications: Stainless steel tubes are suitable for applications where corrosion resistance is crucial, such as chemical processing, food and beverage, and pharmaceutical industries.

- Advantages: They offer excellent corrosion resistance, making them ideal for aggressive or corrosive fluids. Stainless steel tubes also have good mechanical strength.

3. Copper Tubes:

- Applications: Copper tubes are commonly used in residential and commercial HVAC systems, refrigeration, and heat pumps.

- Advantages: Copper has excellent thermal conductivity, making it an efficient choice for heat transfer. It's also corrosion-resistant in many environments.

4. Aluminum Tubes:

- Applications: Aluminum tubes are used in automotive radiators, air conditioning systems, and some industrial heat exchangers.

- Advantages: Aluminum is lightweight and has good thermal conductivity. It is often used where weight is a concern.

5. Titanium Tubes:

- Applications: Titanium tubes are used in highly corrosive environments, such as marine applications, chemical processing, and desalination plants.

- Advantages: Titanium is extremely corrosion-resistant and has excellent strength at high temperatures.

6. Inconel Tubes:

- Applications: Inconel tubes are suitable for applications involving high temperatures and aggressive environments, such as aerospace and petrochemical industries.

- Advantages: Inconel offers excellent resistance to oxidation and high-temperature strength.

7. Duplex Stainless Steel Tubes:

- Applications: Duplex stainless steel tubes are used in applications that require both corrosion resistance and high strength, such as offshore oil and gas platforms and chemical processing.

- Advantages: Duplex stainless steel combines the benefits of austenitic and ferritic stainless steels, offering superior corrosion resistance and strength.

8. Tube-in-Tube Heat Exchanger Tubes:

- Applications: Tube-in-tube heat exchangers are used in applications where it's essential to prevent mixing between the two fluids, such as in pharmaceuticals or food processing.

- Advantages: They allow for efficient heat transfer while keeping the two fluids separate.

9. Finned Tubes:

- Applications: Finned tubes are used in air-cooled heat exchangers, such as in power plants and HVAC systems.

- Advantages: The finned design increases the surface area for heat transfer, making them efficient for air-to-fluid heat exchange.

10. Corrugated Tubes:

- Applications: Corrugated tubes are employed in applications requiring high turbulence and improved heat transfer efficiency, such as shell-and-tube heat exchangers.

- Advantages: The corrugated design enhances heat transfer by creating turbulence and disrupting laminar flow.

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Selecting the appropriate heat exchanger tube material and design depends on factors such as temperature, pressure, fluid properties, and environmental conditions. Consulting with a materials engineer or heat exchanger specialist is often necessary to make the best choice for a specific application, ensuring optimal heat transfer efficiency and long-term reliability.

Heat Exchanger tube switching material from CS to SS

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Heat Exchanger tube switching material from CS to SS

Heat Exchanger tube switching material from CS to SS

abehong

(Mechanical)

(OP)

3 Dec 12 18:31

Got a request to evaluate the mechanical integrity assessment for changing the tubes of two exchangers ( AXM and NEN type) from carbon steel to stainless steel. Because of difference in heat transfer coefficients of CS and SS, our process group wants to reduce the SS tube wall thickness from that for the CS. Currently, the carbon steel tube that we need to replace is size at 3/4" with 0.083" thickness. The process engineer propose to offset heat transfer change by decreasing the wall thicknesses from 0.083" to 0.065" of SS material ?. But this need to be confirm by mechanical engineer if there is any issue on mechanical strength. I did verify the minimum required tube wall thickness due to internal and external pressure. It turns out that the thickness of 0.065" 316 SS tube material is acceptable . But for fixed end tube design, I am not sure how to justify tube to tube sheet joint load because SS tube obviously will experience higher thermal expansion stress than CS. In addition to tube to tube sheet joint load, Do I need to verify tube sheet design as well because of tube material change ?

It will be appreciated if you can give me quick response.

RE: Heat Exchanger tube switching material from CS to SS

SNORGY

(Mechanical)

3 Dec 12 23:34

It's worth looking into in light of the additional consideration that you will also have more mechanical strength lost in the tube-to-tubesheet joint (assuming expanded tubes) after you achieve the 8% to 10% (I think that's about where it will end up) wall reduction after rolling.

RE: Heat Exchanger tube switching material from CS to SS

SnTMan

(Mechanical)

5 Dec 12 11:04

abehong as these are both fixed tubesheet exchangers you absolutely need to evaluate the proposed designs with Part UHX calculations or something similar. Due to the change in metallurgy differential expansion may present problems that did not exist before the change. There is more involved that the tube wall and tube-tubesheet joint. Tubesheet thickness, stresses in integral cylinders, tube and joint strength all come into play. As for categorizing the joint strength Appendix A contains factors to account for different coefficients on thermal expansion. For stainless tubes in CS tubesheets, I would not normally consider the joint strength to decrease due to thermal effects.

Regards,

Mike

RE: Heat Exchanger tube switching material from CS to SS

davefitz

(Mechanical)

5 Dec 12 14:28

issues are:
worse thermal expansion, worse thermal stress+ lower yiled stress= more fatigue damage
better corrosion resistance
lower youngs modulus may imply vibration worsens- may need closer spaced supports, ditto thinner wall + lower section modulus
may need to anneal tube bends
dissimilar metal weld at tube sheet

RE: Heat Exchanger tube switching material from CS to SS

EdStainless

(Materials)

7 Dec 12 16:49
I am a bit concerned about galvanic corrosion of the tubesheets.
This is actually a very common change.

The only risk of vibration is from the thinner walls, the modulus is about the same.

The biggest issue is that you are lowering the back pressure on the system.
If there are centrifugal pumps used the pressure/flow will change.

What material are the current tubesheets? and what is their condition?I am a bit concerned about galvanic corrosion of the tubesheets.This is actually a very common change.The only risk of vibration is from the thinner walls, the modulus is about the same.The biggest issue is that you are lowering the back pressure on the system.If there are centrifugal pumps used the pressure/flow will change.

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RE: Heat Exchanger tube switching material from CS to SS

TD2K

(Chemical)

8 Dec 12 18:52

I would doubt that going to CS from SS will have much effect on the overall heat transfer coefficient when you look at film and fouling coefficients effects in addition to the effect of the tube material. Reducing the wall thickness in terms of maintaining overall heat transfer doesn't make sense to me.

I have typically seen wall thicknesses for SS tubes less than that of CS tubes because of the higher corrosion resistance for SS. That depends however on the fluids in question and expected corrosion rates.

RE: Heat Exchanger tube switching material from CS to SS

Guest

(Materials)

11 Dec 12 15:30

Austenitic SS is implied by the CTE concern, but is ferritic SS possible?

Beware of SCC lurking in the bushes whenever 300 SS is proposed as a magic bullet.

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