Manufacturing processes produce much waste heat that needs to be removed to maintain equipment and fluids at appropriate temperatures. If processes are not maintained at optimum temperatures, efficiency can be reduced, additional maintenance required, and additional strain put on connected equipment. If an AirEx Heat Exchanger is chosen correctly, it can remove this unwanted heat and allow processes to be maintained at a more stable temperature.
Why Industrial Temperature Control Matters
Temperature control is vital in a number of industrial operations where a fluid must be kept within a temperature range to allow operation of the system or ensure stability of the process.
When temperatures rise beyond the desired operating range, several problems can occur, including:
- Performance degradation of equipment
- Higher thermal strain
- More work to maintain:
- Variations in fluid characteristics
- Lowered efficiency of process as a whole
- Problems in the regulation of the operating conditions
The function of a heat exchanger is to effectively and controlledly transfer heat from one fluid stream or process stream to another heat receiving fluid.
How AirEx Heat Exchangers Support Heat Removal
Managing Excess Process Heat
Heat can be generated in significant quantities during the running of industrial systems. It may be necessary to cool elements such as pumps, compressors, vacuum equipment and other process machinery to limit excessive temperatures.
It‘s also possible to have heat exchangers installed within these systems, these remove heat from the fluids which are being pumped around, taking excess heat from the process thus allowing the machinery to be operated within the correct temperature limits.
Maintaining More Stable Conditions
Not only is the elimination of heat of importance but the temperature must be kept reasonably constant. The fluctuation of temperature can have adverse effects on the operation of an industrial process, not to mention the machinery used in the process.
If appropriately sized, a heat exchanger can offer a more reliable means of extracting heat. Performance is governed by such variables as; fluid temperature, flow rate and pressure; cooling medium temperature and heat transfer capacity requirement.
Important Factors When Selecting a Heat Exchanger
Process Temperature
When a heat exchanger has to be chosen the temperature of operation of the process should be taken into account. It should be kept in mind what is the normal operating temperature and the likely temperature range.
Knowing how much heat will be taken away can indicate what capacity to specify.
Flow Rate
The rate of flow will have an effect on the speed at which the heat is transferred throughout the system. A unit should be chosen that matches the fluid characteristics.
The alteration of the flow rate could affect the heat transfer performance, the pressure drop and the overall operating characteristics of the system.
Fluid Characteristics
Characteristics of the fluids to be handled should be evaluated as well. Viscosity, density, corrosive properties, fouling characteristics etc will affect the choice of heat exchanger.
The awareness of these properties ensures the correct choice of equipment rather than depending only on the temperature.
Installation Requirements
Selection can also be affected by the space available and the way connection is to be made. Industrial equipment might need to be accommodated within an established process flow system and space available might be at a premium.
Consequently, site, piping and installation aspects, and accessibility and maintenance, must be considered prior to its installation.
Improving Equipment Performance Through Temperature Control
Supporting Continuous Operation
Industrial operations can often run for extended periods and as a result temperature control is an issue that requires continual attention. If too much heat is not removed, its effects on the equipment and operation will occur over time.
Effective application of heat exchanger helps in stabilizing the temperature of the fluid that is being circulated during its operation. This can aid in the reliability and prevent it from undergoing operational issues due to temperature variations.
Reducing Unnecessary Thermal Stress
Excessive temperatures applied to a piece of equipment can cause further thermal stress. This could, in turn cause wear or add to maintenance requirement.
This aids the maintenance of the operational conditions near to the desired value. Such use is beneficial when pump, vacuum equipment or other parts have to work constantly.
Heat Exchanger Maintenance and Performance
Proper maintenance is the other side of ensuring effective temperature control through suitable equipment selection. Regular check and maintenance should also be carried out.
Monitor Operating Conditions
During operation the temperature, pressure and flow must be monitored. Deviations from normal may indicate impaired heat-transfer or a malfunction in the system.
Check for Fouling
The rate of heat transfer is decreased by a deposit/accumulation of a material onto the heat transfer surface. Fouling is or is not possible according to the fluids and process.
The routine inspections allow you to spot potential problems before they start to impact greatly.
Review System Changes
If modifications are made to the production rate, fluid properties, flow rate or operating temperatures, it may also be the case that the existing heat exchanger is no longer adequate for this revised service. If there is a major process modification the cooling system should be examined to confirm the suitability of the design.
Choosing the Right Approach for Industrial Cooling
The needs for different industrial applications are varying. The same heat exchanger may perform excellently in one application, while failing to meet expectations in other applications.
Before selecting equipment, it is useful to review:
- Heat transfer required:
- Operating and design temperature
- Flow rates of fluids
- Fluid properties
- Maximum pressure drop
- Cooling medium characteristics
- Area for installation:
- Maintenance needs
Considering these issues also simplifies design of the cooling system to fit the specific application.
Conclusion
Proper temperature control can also have a role in industrial stability. Excessive heat can be detrimental to equipment performance, process repeatability, and maintenance demands. Efficient removal of this heat is therefore critical.
In summary, AirEx heat exchangers are considered as a component of an industrial cooling system in which the process involves controlled transfer of heat. A decision to use should be made on the basis of actual operating parameters of a process, that are, temperature, flow rate, fluid properties, pressure, installation constraints, etc. Collaboration with a reliable and experienced heat exchanger supplier may assist the industry to estimate their cooling requirements and find an appropriate heat transfer solution.
