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Heat Exchangers

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Heat Exchangers

Enersys offers high quality efficient and cost effective heat exchangers for an extensive range of processing applications across a diverse spectrum of industries like chemical, petrochemical, food & beverage, paper & pulp, pharmaceutical, edible oil & fats, bio diesel, oil & gas, textile, steel, cement, rubber, power, effluent treatment, automotive, space heating, refrigeration, air conditioning, and various other process Industries.

We use clinical approach to evaluate your plant / process for energy efficiency and offer most optimum heat exchange solutions, thereby delivering quality solutions that ensure sustainability with a competitive edge.

Our product range includes :

A. Finned Tube Heat Exchangers

Enersys supplies heat exchangers with finned tubes of various designs and material combinations.

  • Rectangular fin twin-tubes
  • Spiral (helical) wound fin tubes
  • Fins materials: Aluminum, SS 304 / SS 316, MS (G.I.), Copper
  • Tube Material: SS 304 / SS 316, MS (G.I.), Copper, Brass, Cupro-nickel.
  • Casing Material: Stainless steel or Carbon steel
  • Some of our standard designs are-

    a) Process Air heaters with Steam / Hot Water / Thermal Fluid

    Enersys supplies fin tube type hot air generators required in various industrial process heating and drying operations. Heat sources may be steam, thermal fluid, pressurized hot water, electricity and combinations of these.

    Some of the major applications are-

    Spray Drying Plant for production of dried milk products, such as ordinary skim milk, whole milk, whey powder and baby foods.

    Note: Special design “L- Footed” fins give optimum contact pressure of the foot of the fin on to the base tube thus maximizing the heat transfer properties. The foot of the fin considerably enhances the corrosion protection of the base tube. Maximum operating temperature for this fin type is 250°C for Steel (SS / CS) and 200°C for Aluminum fins.

    Fin material: Stainless Steel, Carbon Steel, Aluminum or copper
    Tubes and Casing: SS material are used for dryers in food, pharmaceutical and milk powder plants

    b) Process Air and Gas Dehumidifiers

    Enersys has many years of experience in thermal dehumidifying (drying) of process air and process gas. The Enersys Dehumidifiers offers a total conditioning of the process air with respect to temperature and humidity, which is important in many drying systems - especially spray-drying systems.

    Enersys Dehumidifiers are efficient and suitable for sanitary applications e.g. to prevent organic deposits and to prevent wet outer surfaces. The units are easy to access and to clean efficiently - both mechanical and by CIP. Therefore they are widely used within food industry and pharmaceutical industry.

    Enersys supplies a large range of capacities of Dehumidifiers. They are adapted to many available coolant e.g. brine, low temperature thermal fluid, ice water or refrigerants. For the re-heater section, any heating fluid can be used i.e. steam, thermal fluid, hot water or electrical heating.

    Standard design includes gas tight execution, all parts in stainless steel except fins, pull-out drip-catcher, condensate reservoir, drain with trap, supporting adjustable legs, air flanges and counter flanges. Re-heater section is optional (reheating should always be established).

    c) Acetone / Methanol Condensers for Pharmaceutical

    MOC: Stainless Steel
    Tubes, Fins and Casing: SS 316 (for all Contact parts)
    Support Frame and Cladding: SS 304

    d) Air Cooled Heat Exchangers

    The air cooled heat exchangers are used in utilities and industrial applications; such as petroleum, chemical, gas processing, electrical power generation, environment and steel industries.

    The applications include air fin coolers for:

  • Refinery Services, Oil And Gas (Gaseous and liquid hydrocarbons)
  • Hot Water, Quench Oil, Transformer Oil and Lube Oil closed circuit system
  • Forced and induced draft air coolers
  • Exhaust Gas Recirculation Cooler
  • Air Cooled Heat Exchanger For Power Sector
  • Refrigeration Air Fin Products
  • Inter Cooler / After cooler / Oil Cooler
  • Spirally Wound Fin-tube Coils
    MOC: Galvanized Carbon Steel, Stainless Steel, Copper, Aluminum fins with SS / CS tubes

    The advantages of closed loop air cooled heat exchangers are:

  • No need of cooling water or other cooling media
  • No problem arising for thermal and chemical pollution of cooling fluids
  • Flexibility for any plant location and plot plan arrangement (installation over other units)
  • Reduction of maintenance costs (cleaning limited, when needed, to the inside of exchanger tubes)
  • No need of over sizing of the equipment due to tube fouling
  • e) Finned Tube Economisers For Gas Fired Boilers

    In case of boiler system, economizer can be provided to utilize the flue gas heat for pre-heating the boiler feed water. On the other hand, in an air pre-heater, the waste heat is used to heat combustion air. In both the cases, there is a corresponding reduction in the fuel requirements of the boiler. An economizer is shown in Figure below.

    For every 220C reduction in flue gas temperature by passing through an economizer or an air pre-heater, there is 1% saving of fuel in the boiler. In other words, for every 60C rise in feed water temperature through an economizer, or 200C rise in combustion air temperature through an air pre-heater, there is 1% saving of fuel in the boiler.

    B. SHELL AND TUBE TYPE HEAT EXCHANGERS (TEMA DESIGN)

    Enersys designs and manufactures all types of Shell & Tube Heat Exchangers either according to classification as per TEMA standards or custom designed units for special applications.

    TEMA (Standards of Tubular Exchanger Manufacturers Association), classifies all types to be recognizable at a glance according to each component’s name and shape of Shell & Tube type Heat Exchangers, and stipulates all types of standards and technical matters in detail in order to efficiently and safely manufacture the Heat exchanger. Therefore, TEMA is widely applied in the design and production of Shell & Tube type Heat Exchangers.

    The types shown below are representative examples of Heat Exchangers according to the TEMA.

    The shell-and-tube heat exchanger is the most common type of heat exchanger used in any industry. These heat exchangers can be used in almost all process heat transfer applications. It can be fabricated from a wide range of materials. The shell-and-tube design is more rugged than other types of heat exchangers. It can stand more (physical and process) abuse.

    The following nomenclature is normally used:

  • Heat Exchanger: Both sides single phase and process streams (as opposed to utility)
  • Cooler: One stream a process fluid and the other cooling water or air
  • Heater: One stream a process fluid and the other a hot utility such as steam or hot oil
  • Condenser: One stream a condensing vapour and the other cooling water or air
  • Chiller: One stream a process fluid being condensed at sub-atmospheric temperature and the other a boiling refrigerant or process stream
  • Construction Details
    Tubes

    Tubing may be seamless or welded. Welded tubing is usually more economical. In standard designs normal tube diameters are 5/8, 3/4 and 1 inch. Tubes of larger diameter are sometimes used either to facilitate mechanical cleaning or to achieve lower pressure drop. The normal tube wall thickness ranges from 12 to 16 SWG (from 2.77 to 1.65 mm thick).

    Twisted / corrugated type tubes are also available which provide more heat transfer surface.

    Tube sheets

    Holes are drilled in the tube sheet normally in either of two patterns, triangular or square. Normally the tube pitch is 1.25 – 1.3 times the outside diameter of the tubes. Other tube pitches are frequently used to reduce the shell side pressure drop and to control the velocity of the shell side fluid as it flows across the tube bundle. Triangular pitch is most often applied because of higher heat transfer and compactness it provides. Square pitch facilitates mechanical cleaning of the outside of the tubes.

    The tubes are held firmly in the tube sheets either by welding or by mechanical expansion. Tubes can also be welded to the inboard face of the tube sheet. Strength welding designates that the mechanical strength of the joint is provided primarily by the welding procedure and the tubes are only lightly expanded against the tube sheet to eliminate the crevice that would otherwise exist. Seal welding designate that the mechanical strength of the joint is provided primarily by the tube expansion with the tubes welded to the tube sheet for better leak protection. The seal-welded joints have increased reliability, reduced maintenance costs, and fewer process leaks. Seal-welded joints are required when clad tube sheets are used, when tubes with wall thickness less than 16 BWG (1.65 mm) are used, and for some metals that cannot be adequately expanded to achieve an acceptable mechanical bond (titanium and Alloy 2205 for instance).

    Channels (Heads)

    The channel type is selected based on the application. Most channels can be removed for access to the tubes. The most commonly used channel type is the bonnet. It is used for services which do not require frequent removal of the channel for inspection or cleaning. The removable cover channel can be either flanged or welded to the tube sheet. Flanges are usually not provided for units with larger shell diameters. The removable cover permits access to the channel and tubes for inspection or cleaning without the need to remove the tube side piping. Removable cover channels are provided when frequent access is required.

    The rear channel is often selected to match the front channel. For example a heat exchanger with a bonnet at the front head (B channel) will often have a bonnet at the rear head (M channel) and will be designated as BEM. However, in some cases they are different such as when removable bundles are used.

    Pass partitions are provided in channels when multiple tube passes are used to maximize tube side heat transfer within the pressure drop constraint. Typically, heat exchangers with liquid as the tube side fluid have multiple tube passes. Most heat exchangers with large tube side volumetric flow rates have a single tube pass.

    Common Markets/Applications:

    • Hydraulics                                                                          • Digester Heating/Cooling
    • Compressor After-cooler                                             • Heat Recovery
    • Engines                                                                                • Effluent Gas
    • Lube Oil Coolers                                                              • Petrochemical
    • Steam / vapour Condensers                                      • Refinery
    • Condensate Cooler                                                        • Pulp and Paper
    • Evaporators                                                                       • Metal/Ore Processing
    • Re-boilers                                                                           • Fuel Oil Heater/Cooler
    • Pharmaceutical                                                               • Marine Heat Exchanger
    • Distillery                                                                             • Gearbox Cooler
    • Manufacturing Plants                                                   • Process Heating/Cooling
    • Seal Water Cooler Wastewater Treatment          • Drilling Platforms On / Off shore

    Applications: Heating / cooling in -

  • Oil - water coolers and heater
  • Steam - Oil heater
  • Steam condensers
  • Heat Recovery steam generator
  • Transformer oil cooling systems
  • Food and Beverages
  • Refinery Services (liquid hydrocarbons)
  • IC Engine Jacket Hot Water, Quench Oil, Transformer Oil and Lube Oil
  • Enersys sets the industry standard for heat exchangers. Quality is the cornerstone of our products from start to finish. Our engineering specialists work closely with you to custom design the most efficient, cost effective heat exchanger for your thermal transfer requirements.

    From the documentation of raw materials in compliance with ASME code, to the precision machining of tube-sheets and bonnets, to final finishing, testing and documentation, Enersys Heat Exchangers are manufactured to deliver superior performance and trouble-free operation, even in the most demanding processing environments.

    Enersys supplies all versions of these shell and tube heat exchanger designs with pressures range from full vacuum to 150 kg/cm2 and design temperatures range from -50oC to 500oC with following features.

  • Straight tubes, U-tube or Coil designs
  • Multi-pass on either or both sides
  • Floating head construction
  • TEMA recommended design guidelines
  • Mechanical design fully compliant with ASME Sec-VIII, Div-1
  • Excess surface area is added to every design
  • a. Floating Head Design For Petroleum Processing

    The floating head heat exchanger is the most versatile type of shell-and-tube heat exchanger, and also is the costliest. In this design, one tube sheet is fixed relative to the shell, and the other is free to float within the shell. This permits free expansion of the tube bundle, as well the cleaning of both the insides and outsides of the tubes. Thus floating head heat exchangers can be used for services where both the shell-side and the tube-side fluids are dirty - making this the standard construction type, such as used in petroleum refineries.

    There are various types of floating head constructions. The two most common are the pull-through with backing device (TEMA S) and pull-through (TEMA T) designs. The TEMA S design is the most common configuration in the chemical process industries. The floating head cover is secured against the floating tube sheet by bolting it to an ingenious split backing ring. This floating head closure is located beyond the end of the shell and is contained by a shell cover of a larger diameter. To dismantle the heat exchanger, the shell cover is removed first, then the split backing ring, and then the floating head cover, after which the tube bundle can be removed from the floating end.

    b. ‘U’ Bend Shell And Tube Heat Exchangers

    Enersys has many years’ of experience in supplying ‘U’ Bend Shell and Tube Heat Exchangers. We have in-house tube bending facility to enables us to maintain the quality and the precision required for manufacturing of the U bend coils. Our constructions comply with ASME Code, Section VIII Div. 1, TEMA Standards, type BEU/AEU.

    Materials: Steel, Stainless Steel, Copper Alloys - Other material options available.
    Applications: For heating or cooling oil, water and process fluids or condensing process steam or vapour. Design allows wide variation in fluid temperature, withstands thermal shock better.
    CODE: TEMA Type AEU or BEU can meet TEMA “B”, “C” and “R”, ASME Section VIII Div.1.

    DETAILS
    U-tube, removable bundle or suction-heater (open-end shell) construction.

  • Multi-pass tube arrangements for maximum efficiency over a variety of tube side flow volumes.
  • Special tube layout for tank suction heating applications.
  • Custom designs up to 1500 mm shell diameter and 12000 mm shell length.
  • Available for horizontal or vertical mounting.
  • ADVANTAGES:

  • Allows for differential thermal expansion between shell and tubes as well as between individual tubes.
  • High heat transfer surface area for given shell and tube size.
  • Capable of withstanding thermal shock.
  • The most economical of all shell-and-tube exchangers, and the least expensive of all basic designs.
  • Shell side can be steam or mechanically cleaned.
  • Bundle can be removed for shell side cleaning and maintenance.
  • LIMITATIONS:

  • Individual tube replacement is difficult.
  • Cannot be made single-pass on tube side, so true counter current flow not possible.
  • Draining tube side is difficult in vertical (head-up) position.
  • Tube side can be cleaned by chemical means only.
  • d. Special Design Heat Exchangers: for Food, Pharmaceutical, Sanitary

    i. Large Heat Exchangers for Chemical, Food & Beverages

    Our applications specialists can offer custom-made heat exchangers, and help you choosing technical and economical solutions optimized as per your process energy saving requirements.

    Salient Features:

  • Heat Transfer area ranges from 1.0 m² to 100 m²
  • Available in both options – Plain Tube & Corrugated Tube.
  • Ideal for Projects in Chemical & Pharmaceutical Industry.
  • Designs as per TEMA Class ‘B’,'C' AND ‘R’ as well as ASME Sec-VII, Div.1
  • Precision drilled baffles & minimum gap between baffle OD to shell ID to minimize fluid by-pass & ensure maximum heat transfer.
  • Tube to Tube sheet joint is strength welded & light expansion.
  • Designed to provide excellent gasket sealing.
  • Expansion bellow can be provided as per design requirement.
  • Available with Vertical or Horizontal orientation.
  • Inspection under any Agency of customer’s choice.
  • SS or Copper materials used as per compatibility with fluid media
  • Polished surfaces are provided as required for sanitary applications
  • A new series of heat exchangers designed and engineered for the pharmaceutical and food industries and suitable all applications requiring compliance with FDA specifications. This advanced design also ensures correct operation in applications requiring the highest standards of cleanliness. Our team of dedicated professionals are committed to provide you with products that deliver very good performance and dependability, along with the responsive customer service you need.

  • SS 316 materials used as standard
  • Highly Polished surfaces are provided as required for sanitary applications
  • ii. Medium Size Sanitary Heat Exchangers for CIP

    iii. Compact Sanitary Heat Exchangers in SS316 or Titanium for Dairy

    Applications:

  • Pharmaceutical, Biotech, Clean Steam, Blood Plasma
  • Food Processing, Beverage, Dairy, Brewery, Juice
  • Cosmetics, Fragrances
  • Semiconductor
  • Maximum Working Pressure:

  • Up to 10 bar in Tubes
  • Up to 16 bar in Shell
  • Maximum Working Temperature:

  • Up to 284°F (140°C) Tube Side (Viton seal)
  • Up to 250°F (121°C) Tube Side (Silicon seal)
  • Up to 397°F (203°C) Shell Side
  • e. Corrugated Tubes Shell and tube heat Exchangers

    Features:

  • Higher heat transfer co-efficient: Corrugated tubes increase the turbulence in the flow that enables a more effective mixing and agitation that generates a higher heat transfer coefficient compared to smooth tubes at the same conditions.
  • Compact heat exchanger: The heat transfer area of corrugated tube heat exchanger is 30% to 50% less than plain tube heat exchanger (% depends on case to case design)
  • Economical: The cost of Corrugated tube heat exchanger is 25% To 50% less than the cost of a plain tube heat exchanger for the same duty. When exotic materials are used significant savings can be made on the overall cost of the unit.
  • Reduced Fouling: Corrugation carries a self-cleaning effect that reduces fouling on the tube surface. Less fouling means smaller heat exchanger and longer production cycles.
  • Low maintenance & operating cost: Small product and service hold up volumes due to the compact size of the Heat Exchanger.
  • Longer running times without stopping for cleaning. Higher response to CIP cleaning.
  • Homogenous Thermal treatment due to the mixing capacity.
  • Smaller footprint due to smaller sizes.
  • Efficient: In condensing applications, are more efficient than the plain tube heat exchanger. The thin film formed over the tube by the condensing vapors breaks off due to the corrugation there by exposing fresh surface of the tube for heat transfer, hence making them more efficient.
  • Versatile: These are versatile since they are able to process different products in the same installation.
  • Wide range of Material of Construction. Full SS 316 L Tubes and body for extra hygiene and food products and pharmaceuticals.
  • f. Hair Pin Heat Exchangers

    The Process Advantage
    Hairpin heat exchangers utilize true counter-current flow. Unlike multi-pass shell-and-tube designs where correction factors are used to account for inefficiencies resulting from co-current passes, this process maximizes temperature differences between shell side and tube side fluids. When a process calls for a temperature cross (hot fluid outlet temperature is below cold fluid outlet temperature), a hairpin heat exchanger is the most efficient design, with fewer sections and less surface area. Double-pipe heat exchangers utilize a single pipe-within-a-pipe design and are commonly used for high fouling services such as slurries where abrasive materials are present, and for smaller duties. Common shell diameters range from 2” to 6”. Multi-tube heat exchangers are used for larger duties.

    APPLICATIONS:

  • FOOD
  • PHARMA
  • CRITICAL PROCESS
  • DAIRY
  • AUTOMOBILE
  • C. OTHER HEAT EXCHANGERS:

    a. Trombone Gas Condensers:

    b. Cement Kins: