HRS Corrugated Tube Heat Exchangers: Achieving and Delivering Optimal Heat Transfer Efficiency for hassle-free operations in pharmaceutical, chemical, fertilizer, oil and fats, cement, steel and power generation Process Industries.
HRS is a pioneer in bringing corrugated tube technology to heat exchangers. Our Ecoflux* Corrugated Shell And Tube Heat Exchangers (CTHE) are available in a range of models and materials, designed to increase the efficiency of processes. The use of corrugated tubes instead of smooth tubes ensures compact and economical equipment with a substantial reduction in fouling.
The development of corrugated tube design in shell and tube heat exchangers is perhaps the most exciting advancement in heat transfer technology. Corrugations induce turbulence in the media and ensure a high Reynolds number even at low velocity. Such construction of shell and tube heat exchanger is made with specially designed patterns and in a manner where there is no tube wall thinning and the strength of the tube remains intact.
Corrugation imparts different flow regimes – spiral at the core and eddy’s at the periphery. The helical flow contributes to the situation that the fluid particles are alternatively in the vicinity of the tube wall and then in the main flow. Between the helical impressions, around the circumference of the tube, secondary flow, typically in the form of eddies occur in this type of tubular heat exchanger.
Tube corrugation creating turbulant flow
Efficient condensation in Ecoflux* corrugated tube vs conventional plain tubes
Uniform Thermal Processing
The roughness elements need to have a minimum height so as to influence the flow and thus the heat transfer. To ensure that the heat transfer is improved by roughness elements, the flow must be influenced by the heat conduction layer.
The key to enhanced efficiency in corrugated tube heat exchangers is the design of the tubes with minimal boundary layer resistance. This determines the various styles of tube corrugation: continuous spiral indentation or an intermittent spot indentation.
The continuous disturbance of the boundary layer of the tube side fluid increases the amount of turbulence within the fluid as described mathematically by the “Nusselt number” and, providing the tube side fluid has a higher resistance to heat flow, will increase the overall rate at which heat is transferred.
There are three types of corrugations – Soft, Hard and Dimpled. These are based on the corrugation depth, pitch and angle. The number of starts also affects the pattern of corrugation.
 |  |  |
|---|---|---|
| Hard | Soft | Dimpled |
HRS Corrugated Tube Technology Features
The design of heat exchanger depends primarily on the process or application for which it is to be used; whether for industrial, food processing and further factors such as product and utility properties such as density, viscosity, corrosion factor, pressure, temperature, capacities and so on.
Thermal design
Ecoflux* Corrugated Tube Heat Exchangers are designed with specific formulae as a result of detailed study and research. This is the proprietary, specialized heat exchanger thermal design program developed by HRS.
Mechanical design
Ecoflux* Corrugated Tube Heat Exchangers are designed and manufactured according to standards including TEMA, ASME Sec. VIII Div.I, BS5500, AS1210, PED and other comparable standards. We deploy high-end design/ drawing software which enables the accurate design of the equipment.
Material of construction
Ecoflux* Corrugated Tube Heat Exchangers are manufactured in all grades of Materials of Construction:
Stainless Steel AISI 304/316, SS304L, SS316L, 904L, 321, AL6XN, C22, C276, C2000, Titanium, Tantalum, Duplex, Super Duplex, Alloy 20, Copper, Cu-Ni, alloys, Inconel, Monel. SMO and other special materials can be offered.
‘K’ Series – Multitube for Industrial Heat Exchange applications
The ‘K’ Series Ecoflux* heat exchanger is a multitube shell and corrugated tube unit with mechanical design tailored for industrial use. The product normally flows through the tubes and the service fluid over tubes.
The ‘K’ Series is manufactured from welded / seamless tubes and is of a fixed tube sheet construction featuring heat transfer enhancing corrugated tubes available in dimple, hard or soft corrugation. Standard units of lengths between 0.5m and 6m are available as well as a range of shell diameters. ‘K’ Series can be designed to withstand high temperature and pressure conditions.
These are designed to TEMA & ASME Standards, including all TEMA configurations.
Features
Applications
Heating, cooling, condensing, sub-cooling, pasteurizing, sterilizing, heat recovery, evaporation, etc. for the process industry – chemical, pharmaceutical, biotechnology, power generation, food, drink, brewing, environmental processes.
Vapour Condenser, Effluent cooler, Exhaust Gas, Glycols, Latex, Paint, Process Water, Steam, Varnish, Water, Alcohol, Vegetable/ Industrial Oil, concentrate, Sugar Juices/ Syrups and many more.
‘MI’ Series – Multitube for Food Applications
The Ecoflux* ‘MI’ Series is manufactured from welded/seamless tubes and is of a fixed tube sheet construction featuring heat transfer enhancing corrugated tubes available in dimpled, hard or soft corrugation versions. Standard units of length between 0.5m and 6m are available as well as a range of shell diameters. ‘MI’ Series heat exchangers can be designed to withstand high temperature and pressure conditions. The type of corrugated tube used for is dependent on fluid viscosity and particulate matter.
The ‘MI’ Series heat exchanger is a multitube corrugated shell and corrugated tube unit and has been designed for the food processing, dairy, dairy products and pharmaceutical industries. The product normally flows through the tubes and the service fluid over tubes.
Features
Applications
Heating, cooling, pasteurizing/sterilizing, cooking, concentration for the food and dairy industries; heating and cooling for sludge environmental and sanitary hot water processes as well as for the power generation and latex industries.
Fruit Pulps/Juices, Grain Slurry, Pet Food, Tomato Puree, Dye-House Effluent, Digestion Sludge, Effluent Water and many more
‘DT’ Series – Tube in Tube Heat Exchangers
The Ecoflux* ‘DT’ Series heat exchanger is a tube-in-tube heat exchanger, manufactured from concentric corrugated tubes. The Product normally flows through the inner tube and the service fluid through the annulus between the tubes.
Supplied as standard in lengths of three and six meters with tube diameters ranging from 1” to 4.5”. The DT Series is capable of handling large particulates up to 50 mm. Three versions of the corrugated tube are available for this unit including hard corrugation designed to generate maximum turbulence for an optimum pressure drop and soft and dimpled corrugation designed to increase wall velocity with minimum pressure drop.
Features
Applications
Heating, cooling, pasteurizing/sterilizing, cooking, concentration for the food and dairy industries; heating and cooling for environmental and sanitary hot water processes as well as for the power generation and latex industries.
Fruit Pulps/Juices, Fruit Slices, Grain Slurry, Pet Food, Tomato Puree, Dye-House Effluent, Digestion Sludge, Effluent Water and many more…
‘AS’ Series- Tripletube for Food & Pharma Applications
The Ecoflux* ‘AS’ Series annular Space heat exchangers are made from three concentric tubes, which give three annular spaces. The product fluid channel is surrounded on both sides by the service fluid.
The ‘AS’ Series is a tube in a tube in the tube heat exchanger. With this type of heat exchanger, the smaller inner tube and larger outer tube carry the service media whilst the process media passes through the annulus between the two tubes. The tube diameters range from 1” inner tubes to 6” outer tubes as standard, with unit lengths available in three or six meters. Three types of corrugation are available, dimple for low Reynolds numbers, hard corrugation for high Reynolds numbers and soft corrugation for medium Reynolds numbers.
Features
‘AS’ Series- Tripletube for Food & Pharma Applications
Applications
Heating, cooling, pasteurizing/sterilizing, cooking and concentration for the food and dairy industries.
High Viscosity like Dairy Products, Sauces, Fruit Pulps/Juices/Slices, Tomato Products and many more…
The flow regime in Ecoflux* Corrugated Shell and Tube Heat Exchanger ensures that the rate of decrease in boundary layer resistance exceeds the rate of increase in pressure loss. In other words high heat transfer coefficients with minimum increase in pressure drop.
An increase in heat transfer coefficient brings the temperature of the tube wall closer to the temperature of the bulk fluid on the tube.
Comparison of heat exchanger types
Key parameters to compare Ecoflux*Corrugated Tube Heat Exchangers with other two types of heat exchangers – Smooth Tube Heat Exchangers and Plate Heat Exchangers.
| PARAMETERS | Ecoflux* CTHE | Shell & Tube Heat Exchanger | Plate Heat Exchanger |
| Heat Transfer Coefficient | High | Low | High |
| High Pressure applications | Yes | Yes | NO |
| High Temperature applications | Yes | Yes | No |
| Temperature Distribution | Uniform | Non Uniform | Uniform |
| Two Phase Application | Excellent | Good | Poor |
| Aseptic Processing applications | Yes | Yes | No |
| Product Burn-out | No | Yes | Yes |
| Dead Areas / spots | No | No | Yes |
| Products with Solid Particles | Yes | Yes | No |
| Products with High Viscosity | Yes | Limited | No |
| Product Hold-up / tosses | Low | High | Low |
| Leakage Risk | Low | Low | High |
| Overall Size | Low | High | Low |
| Response to Cleaning In Place (CIP) | High | Medium | Low |
| Extension of Units / Modules | Yes | i4o | Limited |
| Ease of Inspection | High | Medium | Low |
| Maintenance Cost / Spares Cost | Low | Medium | High |
Ecoflux* Corrugated Shell and Tube Heat Exchanger take the best features of Smooth Tube Heat Exchangers and Plate Heat Exchangers to provide innovative heat transfer solutions.
Ecoflux* Corrugated Shell and Tube Heat Exchanger are used across process industries for a host of applications. Thermal and mechanical designs, material of construction is determined as per process and product compatibility to give optimal energy-efficient solutions.
In chemical, pharmaceutical, fertilizer, cement, biotechnology, power generation, food, drink, brewing, and environmental processes Ecoflux* Corrugated Shell and Tube Heat Exchanger are used as vapour condenser, effluent cooler, exhaust gas cooler etc.
In the food processing sector, a range of heating, cooling, condensing, sub-cooling, pasteurization, sterilization, evaporation, continuous cooking, heat recovery, etc. applications are enabled with corrugated tube heat exchanger-based systems and turnkey lines for fruit pulp, beverage, dairy, nutraceuticals, probiotics, ready-to-eat foods, purees and concentrates and diced food processing.
In environmental and sanitary hot water processes, effluent treatment, digestion sludge, effluent water, along with power generation and latex industries, corrugated tube heat exchangers are used in various heating, cooling applications.
In the pharmaceutical and chemical industries where custom-made Ecoflux Corrugated Tube Box Condensers used in certain processes are involved. This is a single condenser that comes with two utilities, so it can act as a combination of the main condenser and vent condensers. Box condensers can also be fitted with multi-pass headers to improve heat transfer efficiency to suit pharma/Chemical industry-related applications. HRS has the expertise to manufacture box condensers in Hastelloy and all grades of SS materials as suited to the processes
For industries such as chemical, agrochemical HRS brings ECOFLUX corrugated tube Tank top condensers. This is the most effective heat exchanger designed to condense vapours in low-pressure gas, typically released from storage tanks, also to eliminate pollution that occurred due to solvent emission. This can be designed and manufactured in all grades of materials. Tank top condensers can be designed based on the process requirement.
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