Heat Exchangers
These equipments, examined under the heading of Heat Exchangers, are primarily designed to transfer the heat of one fluid to another without allowing them to mix with each other. This process is usually carried out through a solid wall (surface). The efficiency of heat transfer depends on the thermal conductivity coefficient of the material used, the type of fluids, the amount of turbulence, and the surface area.
Among the most commonly used types in industry are shell-and-tube heat exchangers, plate heat exchangers, and air-cooled systems. Each has a different intended use, pressure resistance, and efficiency capacity. For example, shell-and-tube systems are preferred in environments with high pressure and aggressive chemicals, while plate systems stand out where space is limited and high efficiency is expected. Asem Process determines the most suitable heat transfer model for the enterprise by performing engineering analyses during this selection stage.
What is a Heat Exchanger and How Does It Work?
Heat exchangers work based on the second law of thermodynamics; that is, heat always flows from the hot side to the cold side. Inside an exchanger, the hot fluid leaves its energy on the metal surface, and this metal surface conducts the energy to the cold fluid. In this process, they can function as a condenser, evaporator, or a simple cooler/heater.
One of the most important factors determining the efficiency of a heat exchanger is what we call the “fouling factor.” Over time, lime, rust, or particles accumulating on metal surfaces prevent heat transfer. Systems produced by Asem Process are manufactured using stainless steel or special alloys, taking into account easy cleanability and low fouling risk.
Asem Process and Industrial Solutions
Asem Process, as one of Turkey’s leading names in the field of industrial manufacturing and engineering, produces critical equipment particularly for cryogenic systems, pressure vessels, and the maritime sector. The company’s expertise is not limited to standard production but is reinforced by its ability to perform custom process design for the client.
The management of heat in industrial facilities directly affects production capacity and product quality. At this point, Asem Process steps in to design heat recovery systems and enables businesses to lower their energy bills by reusing waste heat. By manufacturing in accordance with global standards (ASME, EN 13445, etc.), the company is a reliable solution partner in high-pressure tanks and complex process piping works.
What Should Be Considered When Choosing a Heat Exchanger?
Choosing the right equipment in an industrial facility is critical for long-term operational success. Here is what to consider:
- Fluid Type: Whether the fluid is corrosive or not directly affects material selection. Asem Process offers titanium or high-alloy steel solutions for aggressive liquids.
- Pressure and Temperature Values: The maximum values the system must withstand determine the shell thickness and gasket type.
- Efficiency Expectation: Designs with a high heat transfer coefficient can achieve greater tasks in smaller volumes.
- Ease of Maintenance: The system must be accessible for cleaning and parts replacement.
What are the Differences Between Plate and Shell-and-Tube Heat Exchangers?
This is one of the most frequently asked questions in the sector. Shell-and-tube heat exchangers are generally used at very high pressures and extreme temperature differences. Their durability is quite high. On the other hand, plate heat exchangers provide high efficiency in small areas by offering a much wider heat transfer surface. However, their pressure limits are more restricted compared to shell-and-tube systems. Asem Process determines which model is more cost-effective for you by analyzing your facility’s technical data.
Usage Areas and Sectors of Heat Exchangers
It is possible to encounter an exchanger in every corner of industrial life. Heat management is used not only to heat a liquid but also to liquefy a gas or cool a machine.
Maritime (Marine) Sector
On ships, these devices are of vital importance as engine cooling water, oil coolers, and fuel heaters. Due to the corrosive effect of seawater, the use of copper-nickel alloys or titanium is common in equipment used in this sector. Asem Process produces high corrosion-resistant equipment suitable for the harsh conditions of the maritime sector.
Cryogenic and Gas Industry
Heat must be managed very precisely during the storage and transportation of gases such as LPG, LNG, or liquid oxygen. At this point, Asem Process provides cryogenic exchanger solutions, ensuring a safe and efficient working environment even at extremely low temperatures. The vacuum-insulated technologies used in these systems minimize heat loss.
Energy and Petrochemicals
Massive heat exchangers are used in refineries during the processing stage of crude oil. Here, the aim is to preheat the cold raw material going to another tower while cooling the hot product from one tower. This is the most fundamental application for energy efficiency.
Ways to Increase Efficiency in Heat Transfer
Just installing a system is not enough; performance optimization is a continuous process. Heat Exchangers can lose efficiency over time. To prevent this, the following methods should be followed:
Creating Turbulent Flow
Turbulent flow instead of laminar flow significantly increases heat transfer. Special patterns on the plates or turbulators inside the tubes are used for this purpose. In Asem Process designs, maximum turbulence is targeted with minimum pressure drop.
Regular Maintenance and Chemical Cleaning
Scaling creates an insulation layer on the heat transfer surface. Regularly performed CIP (Clean-in-Place) systems or mechanical cleaning ensure the system operates at its initial efficiency.
What are the Advantages of Cryogenic Heat Exchangers?
Cryogenic processes cover temperatures below -150 degrees. In these extreme conditions, standard materials become brittle and break. The cryogenic systems developed by Asem Process are manufactured using special stainless steels and aluminum alloys that maintain structural integrity even at these temperatures. Advantages include obtaining high-purity gas, safe storage, and low operating costs.
Quality Control in Engineering and Manufacturing Processes
The manufacture of a heat exchanger is not just the shaping of metal; it is a process of calculation and testing. Within Asem Process, every product is simulated with thermal calculation software during the design stage. Then, it undergoes the following tests during the manufacturing stage:
- Hydrostatic Pressure Test: The leak-tightness and durability of the system are checked.
- Radiographic Test (RT): The internal structure of the weld seams is examined.
- Helium Leak Test: Used to detect the smallest leaks, especially in cryogenic equipment.
Asem Process documents its production quality with ISO certificates and approvals from internationally recognized inspection bodies. This way, every unit installed in your facility is guaranteed to provide trouble-free service for many years.
How are Industrial Heat Exchanger Prices Determined?
Pricing varies according to the capacity of the device, the stock market value of the material used (for example, 316L stainless steel or hastelloy), design complexity, and required certifications. Asem Process, with its engineering-oriented approach, aims to offer its customers not just the cheapest solution, but the one with the lowest total cost of ownership.
Conclusion: Energy Systems of the Future
As the world focuses on green energy and reducing carbon footprints, Heat Exchangers will continue to be at the center of this transformation. Efficient heat management means less fuel consumption and fewer emissions. Asem Process ensures that industrial facilities are ready for the standards of the future today with its innovative R&D studies.
If you would like to optimize the heat transfer processes in your facility or receive professional support regarding pressure vessels or cryogenic solutions, Asem Process is by your side at every stage of your project with its expert staff. When heat is brought under control, production turns into power.