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Heat Exchangers
A Heat Exchanger is equipment designed to transfer heat between two or more fluid streams without direct mixing. These fluids can be liquid, gas, or a combination of both. Heat exchangers are used in refineries, chemical industries, petrochemicals, and even building HVAC systems.
The most widely used type in petrochemicals. Consists of a large shell and a bundle of tubes; one fluid flows inside the tubes and another flows around them (inside the shell).
- Advantages: Resistant to high pressure and temperature, easily maintainable
- Application: Condenser, reboiler, inter-stage coolers

Consists of thin metal plates between which fluids flow. The heat transfer surface area is very high due to the large number of thin plates.
- Advantages: High efficiency, compact size
- Disadvantages: Limited to high pressure and temperature
- Application: Low-pressure cooling systems, food and pharmaceutical industries

In this type, air is used instead of water to cool the fluid. Fans force air over finned tubes.
- Advantages: Suitable for water-scarce regions
- Application: Refineries and petrochemicals in arid areas (e.g. Abadan)
The simplest type; consists of one pipe inside another. Hot fluid flows in one pipe and cold fluid in the other.
- Advantages: Simple design, suitable for low flow rates
- Application: Auxiliary services or low-capacity applications

Consists of two spiral channels in which fluids flow.
- Advantages: Resistant to fouling, compact design
- Application: Fluids with suspended particles or sludge

Used to convert vapor to liquid. Mostly of shell & tube or air-cooled type.
- Application: Distillation and separation units
Provides heat at the bottom of distillation columns to vaporize liquid.
Essentially a specialized shell & tube heat exchanger.
- Application: All petroleum and chemical distillation units
- Cooler: Reduces temperature of process fluids (e.g. gas before compressor)
- Heater: Increases fluid temperature to reach reaction conditions
Can be of shell & tube or air-cooled type
Heat Exchanger Selection Criteria:
- Fluid flow rate
- Inlet and outlet temperature difference
- Operating pressure and design temperature
- Fluid type (corrosive, clean, or containing suspended particles)
- Maintenance cost and service life
