Heat exchangers are critical elements of energy managements systems and are often where the most straight-forward and effective optimisation can take place. Most industrial systems use one form or another of heat exchangers, including oil & gas, energy generation and most chemical processes. Heat exchangers aim to transfer heat between the flows of working fluid either directly, which involves mixing, or indirectly, which involves separation of the fluids via pipes or panels. Depending on geometric constraints and applications, the flow of hot and cold fluids can be parallel (co-flow), perpendicular (cross flow) or counter flow. The latter being most efficient for most applications in light of the greater average temperature difference. The flows can present a single or multiple passes of working fluids, offering a balance between pressure loss and efficiency of the heat transfer. This quickly results in fairly complex thermodynamic interdependency of the flows which is best captured by the use of numerical methods. Tresconhave developed a range of tools, of varying complexity, to provide cost-effective simulation of classical heat exchangers as well as more complex local effects or mechanical behaviour . The two most common types of industrial heat exchanger types are plate heat exchangers and shell and tube heat exchangers. 

SHELL AND TUBE HEAT EXCHANGERS

>>  CFD optimisation: Fluid flow and thermal performance

>>  Code compliance (ASME, TEMA, API, PD:5500 and EN): Stress and fatigue analysis

>>  Phase change modelling: Condensers and boilers

>>  Plenum and baffles configuration optimization: Fluid dynamics assessment

>>  Thermal shocking modelling: Transient Computational Fluid Dynamics (CFD) analysis

>>  Thermal expansion for tubes and tubesheets: FEA stress calculation

PLATE HEAT EXCHANGERS

>>  Plate-and-frame and plate-and-fin fluid flow modelling

>>  Plates pattern optimization: Chevrons and grooves

>>  Code compliance (ASME, API, PD and EN): Stress and fatigue analysis

>>  Manifold design assessment

OTHER HEAT EXCHANGER EQUIPMENT

>>  Heat recovery steam generator (HRSG) thermal analysis

>>  Recuperators and economisers thermal assessment

>>  Underhood thermal management studies

>>  Lighting and electrical equipment heat sink modelling