Design of Shell and Tube Heat Exchangers for Steam Heating of Heavy Oil

1. Determination of operating parameters

Fluid properties:

Understand the physical and thermodynamic properties of heavy oil and steam, including viscosity, density, specific heat capacity, etc.

Operating Temperature and Pressure:

Determine the inlet and outlet temperatures and pressure ranges of heavy oil and steam, which will affect material selection and design specifications.

2. Selection of heat exchanger type

Shell and tube design:

Determine the type of shell-and-tube (e.g., single-tube, double-tube, or multi-tube design), each of which has different heat transfer efficiencies and application scenarios.

3. Calculate heat exchange area

Calculation of heat exchange volume:

Calculate the required heat exchange area using the heat transfer equation.

4. Selection of materials

Material selection:

Select the appropriate material according to the working temperature and chemical properties, commonly used stainless steel, carbon steel and alloy materials.

5. Design details

Pipe diameter and length:

According to the flow rate and flow rate requirements to select the appropriate pipe diameter, to ensure that the fluid flow characteristics in the pipe (such as flow velocity, turbulence, etc.).

Shell design:

Ensure that the shell structure is strong enough to withstand the internal pressure and perform thickness calculations if necessary.

Connection methods:

Design suitable inlet and outlet and vapour connections to ensure good sealing and prevent leakage.

6. System control

Temperature and pressure monitoring:

Design the installation location of temperature sensors and pressure gauges for real-time monitoring and automatic adjustment.

Safety devices:

Design safety valves, venting valves, etc. to prevent overpressure and other safety hazards.

7. Maintenance and cleaning

Easy-to-maintain design:

Considering the cleaning and maintenance needs of the equipment, the design should be easy to disassemble and clean.

8. Simulation and Testing

Computational Fluid Dynamics (CFD) Simulation:

CFD simulations are performed prior to final design to optimise fluid flow and heat transfer.

Prototype Testing:

Prototypes are built for field testing to ensure that the design meets the expected performance criteria.

The above steps lead to the design of an efficient and reliable shell and tube heat exchanger for steam heating of heavy oil.