Heat Exchanger Modification and Re-Rating for Improved Performance
We recently performed modifications to a feed cooler shell & tube heat exchanger to improve its performance in a polypropylene manufacturing facility for a Texas Gulf Coast customer.
Following a detailed analysis of the heat exchanger's thermal and hydraulic performance, we determined reducing the number of tube side passes would decrease the overall pressure drop, improve flow rate, and enhance pumping efficiency—reducing overall energy consumption, and potentially lowering operational costs.
This project included updates to the existing channel design from a 6-pass to a 4-pass configuration and also called for re-rating of the heat exchanger to reflect related changes. In addition to channel modification, the scope of work for this project included tube bundle stripping and retubing, and both tube sheet and baffle assembly replacement.
Reducing tube side passes also simplifies the internal design, making the heat exchanger easier to clean and maintain—reducing maintenance time and costs, and supporting improved long-term performance and reduced downtime.