Introduction

Heat exchangers are essential components in a wide range of industries, including power generation, chemical processing, HVAC systems, and petroleum refining. These devices are used to transfer heat between fluids, and their design is crucial for optimizing energy efficiency, minimizing costs, and improving system performance. As industries strive for greater efficiency and sustainability, advancements in heat exchanger design are critical for meeting modern demands.

This advanced course is aimed at providing participants with in-depth knowledge and hands-on experience in the design, operation, and optimization of heat exchangers. We will explore various types of heat exchangers, advanced materials, modern design methodologies, and innovative technologies used to enhance performance and durability.

Objectives

By the end of the course, participants will be able to:

1. Understand the fundamentals of heat exchanger operations and the principles of heat transfer (conduction, convection, and radiation).
2. Design and optimize shell-and-tube heat exchangers, plate heat exchangers, and air-cooled heat exchangers.
3. Apply computational fluid dynamics (CFD) for simulating and analyzing heat exchanger performance.
4. Evaluate the performance of heat exchangers under varying operating conditions (temperature, pressure, flow rates).
5. Learn advanced heat transfer enhancement techniques, including heat transfer fluids, surface modifications, and phase change materials.
6. Optimize heat exchanger designs for energy efficiency and sustainability, considering environmental impact and cost-effectiveness.
7. Understand maintenance, cleaning, and troubleshooting techniques to ensure long-term reliability and performance.
8. Explore the application of heat exchangers in energy recovery systems, waste heat recovery, and industrial processes.

Who Should Attend?

This course is designed for:

• Mechanical Engineers and Thermal Engineers working in heat exchanger design and optimization.
• Process Engineers involved in designing and operating thermal systems in industries such as chemical, petrochemical, and power generation.
• HVAC Engineers focusing on energy-efficient heating and cooling systems.
• Energy Consultants and Sustainability Experts working on energy recovery and green technologies.
• Students and Graduates in Mechanical Engineering, Thermal Engineering, or Chemical Engineering looking to specialize in heat exchanger technology.
• Plant Engineers and Maintenance Engineers responsible for heat exchanger maintenance and performance evaluation.
• R&D Engineers exploring new heat exchanger technologies and materials.

Course Outline

Day 1: Fundamentals of Heat Exchanger Design

• Morning Session:

  1. Introduction to Heat Exchangers: Types, Applications, and Importance in Industrial Systems
  2. Basic Principles of Heat Transfer: Conduction, Convection, Radiation, and Their Role in Heat Exchanger Design
  3. Key Parameters in Heat Exchanger Design: Thermal Resistance, Heat Transfer Coefficient, Pressure Drop, and Flow Arrangement
  4. Overview of Heat Exchanger Types: Shell-and-Tube, Plate, Air-Cooled, Double Pipe, and Heat Pipes

• Afternoon Session:

  1. Shell-and-Tube Heat Exchanger Design: Construction, Performance Calculation, and Sizing
  2. Plate Heat Exchangers: Advantages, Applications, and Detailed Design Calculations
  3. Heat Exchanger Materials: Selection of Materials Based on Thermal, Mechanical, and Corrosion Resistance Properties
  4. Hands-On Exercise: Shell-and-Tube Heat Exchanger Sizing and Performance Evaluation

Day 2: Advanced Heat Transfer Enhancement Techniques

• Morning Session:

  1. Heat Transfer Enhancement Techniques: Active and Passive Methods for Improving Heat Transfer Efficiency
  2. Surface Modifications: Finned Tubes, Textured Surfaces, and Nano-coatings for Enhanced Heat Transfer
  3. Heat Transfer Fluids (HTFs): Selection and Use of Fluids for High-Efficiency Heat Exchange
  4. Use of Phase Change Materials (PCMs) in Heat Exchangers for Energy Storage and Load Shifting

• Afternoon Session:

  1. Enhanced Heat Exchanger Designs: Compact Heat Exchangers, Microchannel Heat Exchangers, and High-Performance Tubes
  2. Heat Exchanger Fouling: Causes, Effects, and Mitigation Strategies
  3. Case Study: Optimizing Heat Exchanger Designs for Energy Efficiency in a Chemical Plant
  4. Hands-On Exercise: Implementing Heat Transfer Enhancement Techniques in Heat Exchanger Design

Day 3: Computational Fluid Dynamics (CFD) and Simulation in Heat Exchanger Design

• Morning Session:

  1. Introduction to CFD for Heat Exchanger Analysis: Basics of Simulation, Governing Equations, and Boundary Conditions
  2. CFD Modeling of Heat Exchangers: Geometry, Mesh Generation, and Flow Simulation
  3. Using CFD for Thermal Performance Prediction: Heat Transfer, Pressure Drop, and Flow Distribution
  4. CFD Software Tools: Overview of Popular Software (ANSYS, COMSOL, Fluent)

• Afternoon Session:

  1. Optimizing Heat Exchanger Design Using CFD Simulations: Geometry Refinements, Performance Optimization, and Cost Reduction
  2. Thermal-Hydraulic Design: Combining Heat Transfer and Fluid Flow Simulations for Accurate Results
  3. Hands-On Exercise: Simulating Heat Exchanger Performance Using CFD Software and Analyzing Results

Day 4: Heat Exchanger Optimization and Sustainability

• Morning Session:

  1. Energy Efficiency in Heat Exchanger Design: Improving Heat Recovery, Minimizing Energy Loss, and Reducing Operating Costs
  2. Exergy Analysis: Understanding the Thermodynamic Efficiency of Heat Exchangers
  3. Waste Heat Recovery: Techniques for Capturing and Reusing Waste Heat in Industrial Systems
  4. Sustainable Design: Green Technologies, Eco-friendly Materials, and Low-Carbon Solutions in Heat Exchanger Design

• Afternoon Session:

  1. Performance Optimization: Balancing Heat Transfer, Pressure Drop, and Flow Rate for Optimal System Design
  2. Life-Cycle Costing: Evaluating Capital and Operating Costs to Achieve Cost-Effective Designs
  3. Case Study: Optimizing Energy Recovery Systems in a Power Plant Using Advanced Heat Exchanger Technologies
  4. Hands-On Exercise: Optimization of Heat Exchanger Design for Energy Savings and Performance Improvements

Day 5: Maintenance, Troubleshooting, and Future Trends in Heat Exchanger Design

• Morning Session:

  1. Maintenance Strategies for Heat Exchangers: Regular Inspection, Cleaning, and Monitoring Techniques
  2. Troubleshooting Common Heat Exchanger Problems: Leaks, Fouling, Vibration, and Efficiency Losses
  3. Heat Exchanger Cleaning: Methods for Effective Cleaning, Removing Fouling, and Restoring Efficiency
  4. Corrosion Prevention in Heat Exchangers: Materials Selection, Protective Coatings, and Cathodic Protection

• Afternoon Session:

  1. Future Trends in Heat Exchanger Design: Innovations in Materials, Micro-channel Technology, and Smart Heat Exchangers
  2. Digital Twin and IoT in Heat Exchanger Monitoring: Real-Time Data, Predictive Maintenance, and Performance Optimization
  3. Emerging Technologies: Phase Change Heat Exchangers, Microfluidics, and Nano-enhanced Heat Transfer
  4. Final Project: Design and Optimize an Advanced Heat Exchanger for a Hypothetical Industrial Application

Certification

Upon successful completion of the course, participants will receive a Certificate of Completion in Advanced Heat Exchanger Design. This certification will recognize the participant’s advanced understanding of heat exchanger design, optimization, and simulation, equipping them with the necessary skills to tackle complex challenges in the field.

For those who excel in the course exercises and final project, a Certification of Excellence will be awarded.