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.
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:
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:
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:
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.
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).
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 -
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.
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.
U-tube, removable bundle or suction-heater (open-end shell) construction.
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.
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.
ii. Medium Size Sanitary Heat Exchangers for CIP
iii. Compact Sanitary Heat Exchangers in SS316 or Titanium for Dairy
Maximum Working Pressure:
Maximum Working Temperature:
e. Corrugated Tubes Shell and tube heat Exchangers
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.
C. OTHER HEAT EXCHANGERS:
a. Trombone Gas Condensers:
b. Cement Kins: