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Heat Exchanger

Air Cooled Heat Exchanger

Gelan Air Cooled Heat Exchanger is the top choice. It provides excellent and best service for you. It has super quality strengths. One can simply clean the interior of this exchanger. For specific environments, their scale and bold design make them perfect. Gelan Air Cooled Heat Exchangers are robust and suitable for tough places.

  • Application industries: petroleum, chemical, pharmaceutical, food processing
  • Certificate: ISO, ASME, CE
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shell and tube heat exchanger 2

Structure and Work Principle

Air-cooled heat exchangers help calm things down using air. They are used when there isn’t enough water or when water costs too much. Many big factories like oil plants, power plants, and gas factories use them. It saves money and helps keep the Earth safe. Tubes are like pipes. The hot liquid goes inside the tubes. The air blows on them to make the hot liquid cool. Then Fins make the air touch more of the tubes. Fans blow air on the tubes. The air helps cool the hot liquid. The plenum is like a box that helps the air go to all the tubes. And headers help the hot liquid move in and out of the tubes quickly. And the frame holds all up. It keeps all the parts in the right place and makes sure they stay safe.

Air-cooled heat exchangers (ACHEs) are used to cool process fluids by transferring heat to ambient air. They are commonly utilized in industries such as oil and gas, petrochemical, power plants, and chemical processing, where water for cooling may be scarce or expensive. Here are the key specifications of ACHEs:

Basic Components

  • Tube Bundles: Comprise finned tubes that increase the surface area for heat transfer.
  • Fans: Provide the airflow necessary for cooling, either forced or induced draft.
  • Headers: Distribute the fluid evenly across the tubes, with configurations such as plug, cover plate, and bonnet headers.
  • Plenum Chamber: Connects the fan to the tube bundle, ensuring even airflow.
  • Fan Drives: Include motors and variable speed drives to control fan operation.

2Tube Material and Type

  • Material: Commonly stainless steel, carbon steel, copper alloys, and titanium, depending on the fluid’s corrosiveness and temperature.
  • Tube Types: Plain, finned (extruded or embedded fins), and different coatings for enhanced heat transfer.

Cooling Method

  • Forced Draft: Fans blow air over the tube bundles; suitable for environments where there is limited space.
  • Induced Draft: Fans draw air through the bundle; reduces recirculation and allows for more uniform cooling.

Design Temperature and Pressure

  • Designed to handle a wide range of operating pressures and temperatures, often up to 450°C (842°F) or higher and pressures up to 200 bar, depending on process requirements.

Heat Transfer Capacity

  • Measured in kilowatts (kW) or British Thermal Units (BTU/hr), determined by tube material, surface area, airflow, and fluid properties.
  • ACHEs typically range from small units (less than 100 kW) to large units exceeding several thousand kW.

Fan Specifications

  • Fan Diameter: Often ranges between 1.5 to 10 meters depending on the system’s scale.
  • Fan Speed: Typically between 200-1200 RPM, affecting the airflow rate.
  • Motor Power: Can vary from 5 to 200+ kW, depending on fan size and airflow needs.

Noise Level

  • Noise considerations are crucial for industrial compliance, with noise reduction techniques such as using lower fan speeds, sound dampening materials, and noise barriers.

Mounting Options

  • Can be horizontal or vertical. Horizontal units are more common and easier to maintain, while vertical options may be used where space is limited.

Control and Monitoring

  • ACHEs often integrate temperature and pressure sensors, fan speed controls, and programmable logic controllers (PLCs) for automated operation and efficiency.

Efficiency and Performance Standards

  • Must comply with industry standards such as API 661 (Air-Cooled Heat Exchangers for General Refinery Services) and ASME Section VIII for pressure vessel design.

Air-cooled heat exchangers are advantageous due to their low water consumption and environmental resilience. However, ambient conditions like temperature and humidity can impact performance, requiring careful design to optimize efficiency.

Features

1. Air as a Cooling Medium

  • ACHEs use ambient air as the cooling medium, making them highly suitable for areas where water is scarce or costly.

2. Tube Bundles

  • ACHEs have tube bundles where the hot fluid flows inside, and air passes outside to cool the fluid. The tubes are often finned to increase surface area and enhance heat transfer efficiency.

3. Fans and Motors

  • Large fans driven by electric motors blow air across the tube bundles, ensuring efficient cooling. Variable speed fans can adjust airflow based on temperature requirements, saving energy.

4. Adjustable Louvers

  • Louvers control the airflow by adjusting the direction and volume of air reaching the heat exchanger, allowing for temperature regulation and efficiency.

5. Environmentally Friendly

  • Since they don’t rely on water, ACHEs reduce water consumption and environmental impact, making them an eco-friendly choice in arid regions.

6. Modular Design

  • ACHEs often feature a modular design, which allows for easy customization and expansion to meet the specific cooling needs of different processes.

7. Reduced Operational Costs

  • Using air as a cooling medium and requiring minimal maintenance, ACHEs often lead to lower operational costs compared to water-cooled systems.

8. Corrosion Resistance

  • Many air-cooled heat exchangers are built from corrosion-resistant materials like stainless steel, extending their lifespan and reducing the frequency of replacements or repairs.

9. High Thermal Efficiency

  • With advanced tube designs and efficient fan systems, ACHEs offer high thermal efficiency, maintaining the desired temperatures even in challenging conditions.

10. Applications Across Industries

  • ACHEs are widely used in industries such as power generation, petrochemicals, and refineries, where cooling processes are essential for operational safety and efficiency.

Appications

Shell and tube heat exchanger has a wide range of applications in chemical, petroleum, pharmaceutical, food, metallurgy, electric power and other industries. It can be used for heating, cooling, condensation, evaporation and other processes, is to realize the heat transfer and energy conversion of the important heat transfer equipment.

Chemical Industry

Improve the heat transfer in the chemical process and reaction.

Petroleum Industry:

It has high value in the recovery of heat during refining.

Pharmaceutical Sector:

Maintain proper temperature for the production of drugs.

Metallurgy

Optimization of management for heat transfer in processing of metals.

Electric Power

Cools the generation system in power.
Hvac

Air Cooled Heat Exchangers Types

Forced Draft Air-Cooled Heat Exchangers

Inside, there are fans at the bottom. The fans push the air up. The air cools the tubes with hot fluid inside. These fans are easy to reach, so fixing them is easy. They do not make too much noise. But sometimes, the fans blow warm air, and it doesn’t cool very well.

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Induced Draft Air-Cooled Heat Exchangers

It has fans at the top. These fans pull the air through the machine. This cools the fluid. Because the fans are far from the hot parts, they last longer. But these fans make more noise, and they are hard to reach if you need to fix them.

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Natural Draft Air-Cooled Heat Exchangers

 

This one has no fans. They let the hot air move up by itself. When the air moves up, it takes the heat away. These kinds of heat exchangers are very quiet because they have no fans. But they need a lot of space and are not cool as well as other types.

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Our SUCCESSFUL Projects

Product Advantages of Gelan Air Cooled Heat Exchangers

  • ISO and ASME Compliance: Manufactured based on ISO and ASME standards so that the CE and FDA are highly obtained in order to achieve excellent quality of manufacture up to 80% without having a high failure rate, hence little or no maintenance cost.


  • Precision Engineering: Gelan has 415 international-grade plate and gasket molds and 31 CNC precision machines which are able to produce high quantities in both standard and custom applications. The gaskets are very tough, withstanding up to 69 disassemblies without leakage, far above the national requirements.


  • Enhanced Materials: New items make High-Efficiency Air Cooled Heat Exchangers better. These chemicals stop corrosion and hastens heat transmission. Their longevity, strength, and effectiveness are secrets only found in this regard.  Light and vital items like aluminum are used. Their heat-transporting power is exceptional.


  • Compact Design: There are few significant new treaties. Their sizes are smaller. This is quite a good pick in limited areas. Small Air Cool Heat Exchanger Design: Simple Installation and Maintenance. Space is preserved and performs quite well. The rate is lower even with the smaller lodging.


  • High Pressure Resistance: The advanced designs of the surface ensure that the Gelan plate heat exchangers could bear pressures of up to 2.5 MPa.


  • Extended Service Life: The exchangers are of quality and from the best manufacturers. The high quality materials ensure it prevents rust and lasts for a long time. In a Gelan heat exchanger they also ensure durability.


  • Reliable and Leak-Free Operation: For dependable and leak-free operation, Gelan’s two-channel closing structure doesn’t bend much and is remarkably resilient. This means that the Exchanger ages slowly. Gelan’s two-channel closing structure makes sure that the seal is firm and stops any leaks in a plate heat exchanger. 

 

Appications

Air-cooled heat exchangers (ACHEs) are widely used across industries for efficient heat management without the need for water-based cooling systems. Here are four main applications:

  1.  

Power Generation:

ACHEs are commonly used in power plants (like gas turbines, steam turbines, and combined cycle plants) to cool exhaust steam and other fluids. They help improve plant efficiency by maintaining optimal temperatures, especially in areas where water scarcity makes traditional cooling systems impractical.

Oil and Gas Industry:

In refineries, petrochemical plants, and gas processing facilities, ACHEs play a critical role in cooling gases, oils, and other process fluids. This helps regulate process temperatures, ensuring safe operations and efficient heat recovery.

Chemical and Petrochemical Processing:

These facilities use ACHEs to cool down a wide variety of process fluids and gases after chemical reactions, aiding in temperature control to avoid excessive heating or reactions within equipment.

HVAC Systems and Data Centers:

ACHEs are used in large HVAC systems and data centers to dissipate heat generated by electronic equipment and cooling systems. They help maintain optimal temperatures, which is essential for continuous operation and protecting sensitive equipment.

FAQ

A heat exchanger moves heat between two liquids or gases without mixing them. It has plates or tubes that let heat pass from one fluid to another.

There are different kinds: shell and tube, plate, air-cooled, and double pipe. Each one works in a slightly different way to move heat between fluids.

They are used in heaters, coolers, fridges, factories, power plants, and cars. They help control heat in many places.

Think about the fluid temperatures, materials, size, and cost. Make sure it is easy to clean and works for your needs.

They use the best quality materials to make it. Also, they ensure safety, and their items are durable and of high quality. 

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Jiangsu Gelan Environmental Technology Co.,Ltd

  • Grand (Shenzhen) Petrochemical Equipment Co.,Ltd
  • Mobile : +86-15961057777
  • E-mail : herman@lyngou.com
  • Website : www.gelanpetro.com
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  • Address : No.01, Jianxin Road, Xinqiao Inudstrial Area, Jingjiang City, Jiangsu Province, China.
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