Course Details

Objective

• Understand Heat Transfer Principles: Gain a strong foundation in the basic principles of heat transfer, including conduction, convection, and radiation, as applied to heat exchangers.
• Design Heat Exchangers: Apply thermal and hydraulic design methodologies to design various types of heat exchangers (e.g., shell-and-tube, plate, air-cooled) for diverse industrial applications.
• Evaluate Performance: Assess the performance of heat exchangers using techniques like effectiveness and NTU methods, and calculate the overall heat transfer coefficient (U-value).
• Optimize Efficiency: Utilize advanced methods and tools, such as Computational Fluid Dynamics (CFD), to troubleshoot and optimize heat exchanger systems for improved thermal and hydraulic performance.
• Address Operational Issues: Identify and solve common operational problems like fouling, corrosion, and scaling that affect heat exchanger performance.
• Understand Sustainability: Incorporate sustainability considerations, energy recovery, and the latest advancements in materials and technologies into heat exchanger design.
• Apply Knowledge to Real-World Scenarios: Use case studies and hands-on exercises to apply learned concepts to practical design and troubleshooting challenges in industrial settings.

Content

Following topics will be covered in 5 days.

Day 1: Introduction to Heat Exchangers and Heat Transfer Fundamentals

• Overview of Heat Exchanger Types and Applications
• Fundamental Heat Transfer Principles: Conduction, Convection, Radiation
• Heat Exchanger Terminology and Classification
• Basic Thermodynamics for Heat Exchangers
• Flow Arrangements: Counterflow, Parallel Flow, Shell-and-Tube, Plate Heat Exchangers
• Practical Exercises: Identifying Heat Exchanger Types and Flow Patterns

Day 2: Heat Exchanger Design Fundamentals

• Thermal Design of Heat Exchangers: Heat Transfer Coefficients, Temperature Profiles
• Hydraulic Design: Pressure Drop, Flow Velocity, and Distribution
• Material Selection and Corrosion Considerations
• Heat Exchanger Sizing and Calculations
• Case Study: Designing a Shell-and-Tube Heat Exchanger
• Group Exercise: Basic Design Problem Solving

Day 3: Performance Evaluation and Advanced Calculation Methods

• Evaluating Heat Exchanger Performance: Effectiveness, NTU Method
• Calculating Overall Heat Transfer Coefficient (U-value)
• Using CFD for Heat Exchanger Design Optimization
• Performance Measurement Techniques and Field Testing
• Troubleshooting Common Issues: Fouling, Scaling, and Leakage
• Hands-On Exercise: Performance Evaluation Using Software Tools

Day 4: Operational Issues and Troubleshooting

• Operational Problems: Fouling, Corrosion, and Maintenance
• Predictive Maintenance and Performance Monitoring
• Design Modifications to Address Operational Challenges
• Case Studies: Identifying and Solving Real-World Heat Exchanger Problems
• Group Activity: Troubleshooting Heat Exchanger Issues in Small Teams
• Discussion: Operational Best Practices for Longevity and Efficiency

Day 5: Advanced Design Concepts and Practical Application

• Heat Exchanger Network Design: Pinch Analysis and Energy Recovery
• Sustainable Design Practices: Reducing Environmental Impact and Energy Use
• Emerging Technologies and Materials in Heat Exchanger Design
• Final Project: Design, Evaluate, and Optimize a Heat Exchanger System
• Group Presentation of Final Project Results
• Q&A, Course Wrap-Up, and Certification

NOTE:

Pre & Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day Review & Assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of the multiple-choice type will be made available on a daily basis to examine the effectiveness of delivering the course.

All presentations are made in excellent colorful power point. Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions