HELIXCHANGERTM

SK
 HELIXCHANGER

1. HELIXCHANGER Historical Overview

2. Conventional versus Helical Baffle Concepts

3. HELIXCHANGER Advantage

4. HELIXCHANGER Guidelines

5. Typical Industry Applications

6. HELIXCHANGER References
 HELIXCHANGER

Milestones : S&T Heat Exchanger Development

Year Milestone
1980 Vuchz invents Helical Baffles
1994 LHT-exclusive license: HELIXCHANGER

2000 HTRI IST-Helixchanger calculation engine
2002 Joint SK, SUNGJIN and ABB
2003 Joint SK, SUNGJIN,DKME and ABB
Shell & Tube Heat Exchanger
Conventional Baffle Arrangements
Single Double Triple No Tubes In
Segmental Segmental Segmental Window
Bundle
1 1
1 1 Int.
suppt.
2 2
2 2
Int.
suppt.
3 1
1 1
Int.
suppt.
1 2
2 2

w 1 w 1
w 1 w w 1

w 2 w 2

w 2 w 2 w

w w 3 w w

Int.
suppt.
 Shell & Tube Heat Exchanger
Flow Distribution with Segmental Baffles

LBH

LBC

LBH LBH LBH

LBC LBC LBC
Shell & Tube Heat Exchanger
Dead Zones with Segmental Baffles
 Shell & Tube Heat Exchanger
Shortcomings with Segmental Baffles

Low Thermal Effectiveness

Inefficient Conversion of Shellside Pressure Drop to
Heat Transfer

Encourages Dead Spots or Recirculation zones,
where fouling can build up

Conflicting Performance and Reliability Goals
HELIXCHANGER

 HELIXCHANGER

Baffle Options

Single Helix Double Helix

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Single Helix Tube-Bundle in Fabrication
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Single Helix Tube-Bundle in Fabrication
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Shell-Side Heat Transfer vs Pressure Drop

TEMA type AES, Water-Water

9000
8000
Heat Transfer Coefficient

7000 S Segment
6000 Helix 17 deg.
Helix 40 deg.
5000
[W/m2.K]

Helix 44 deg.
4000
Helix 35 deg.
3000
Helix 24 deg.
2000
1000
0
0 5 10 15 20 25

Pressure Drop [kPa]

 HELIXCHANGER
Performance Characteristics

Higher heat transfer rate to
pressure drop ratio

Near plug-flow conditions

Little back-mixing,and
Uniform flow velocities

Lower unsupported tube-
spans and uniform flow
velocities

Lower Capital & Operating
Costs

Improved effective MTD,
Reduced surface

Reduced fouling tendency,
Longer run-lengths

Effective protection against
flow-induced vibrations,
Increased reliability
 HELIXCHANGER

Advantages

Reduced purchase price (CAPEX1)

Reduced install & replacement cost (CAPEX2)

Reduced operating cost (OPEX)

Reduced maintenance cost (MAINTEX)

Reduced disposal cost (DISPEX)

Lower Total Life Cycle Costs.. (TOTEX)

TOTAL LIFE CYCLE COSTS (1)
Helixchanger vs Conventional

Total Life Cycle Cost

New Heat Exchangers

dispex
maintex
opex
capex 2
capex 1

Helixchanger Conventional
TOTAL LIFE CYCLE COSTS (2)
Helixchanger vs Conventional

Total Life Cycle Cost

Bundle replacement

dispex
maintex
opex
capex 2
capex 1

Helixchanger Conventional
 HELIXCHANGER

Run Length Improvement

RUN LENGTH PERFORMANCE

Helixchanger vs. Conventional Heat Exchanger

Start of Run

Helixchanger

Conventional

Scheduled Maintenance
End of Run

TIME

FIGURE -1
 HELIXCHANGER

APPLICATION

Shell side heat transfer controlled.

Shell side pressure drop controlled.
High shell side Fouling.
Potential tube Vibration.
High thermal leakage.
 HELIXCHANGER

MECHANICAL GUIDELINES

Conventional design is NTIW.

Conventional design is Rod Type Baffle.
Conventional design has large
(>400 mm) segmental baffle spacing.
Conventional design has multi-segmental
baffles.
Low-fin tubes.
Tube inserts.
TEMA Type is E or J shell.
 HELIXCHANGER

THERMAL GUIDELINES(1)

Shell side thermal resistance > 40% of U fouled.

Shell side fouling resistance > 30% of U fouled.

Thermal leakage stream (E-stream) is > 15%.

 HELIXCHANGER

THERMAL GUIDELINES(2)

When Conventional design operates in turbulent

flow (Re > 10000), high Helix-angle (>25 degr.) can
be applied. CAPEX saving substantial by making
use of the shell-side enhancement factor (Y10).

Good anti-fouling characteristics for all Helix-

angles (5 - 40 degrees).

When Conventional design operates in laminair

flow (Re < 5000) low Helix-angle (5 < H-angle < 20)
can be applied. Good anti fouling and moderate
shell-side heat transfer improvement.
 HELIXCHANGER

Thermal Guidelines to recognize possibilities for Helixchanger

SK Corporation
This sheet can be used when possibly a HELIXchanger can be applied: Process Engineering Team
Kug-Kyong Song
Total 49.1% Tel : 052-270-1201
Fouling Shell Side 25.7% >30% ? NO
Fouling Tube Side 23.5% HELIXchanger should be applied.
NO
Overall heat transfer coefficient U[W/m2C] 733.67
Heat transfer coefficient outside tube ho[W/m2C] 2500 29.3% >40% ? NO
Heat transfer coefficient inside tube hi [W/m2C] 6000
Fouling factor outside ro[m2C/W] 0.00035
Fouling factor inside ri [m2C/W] 0.00025

Outer tube diameter Do [mm] 25.4

Wallthickness tube t [mm] 2.77
Thermal conductivity of tube wall material k [W/mC] 39
Inner tube diameter Di [mm] 19.86

Helichanger possible when: Shell side film heat transfer coefficient is >40% Note: These numbers are for guiding only!
Shell side fouling resistance is >30% In case of smaller numbers and in doubt,
Thermal leakage stream (E-stream) is > 15% Please contact K. K. Song.
 HELIXCHANGER

Thermal Guidelines to recognize possibilities for Helixchanger

SK Corporation
This sheet can be used when possibly a HELIXchanger can be applied: Process Engineering Team
Kug-Kyong Song
Total 53.9% Tel : 052-270-1201
Fouling Shell Side 40.9% >30% ? YES
Fouling Tube Side 13.1% HELIXchanger should be applied.
YES
Overall heat transfer coefficient U[W/m2C] 408.77
Heat transfer coefficient outside tube ho[W/m2C] 1200 34.1% >40% ? NO
Heat transfer coefficient inside tube hi [W/m2C] 6000
Fouling factor outside ro[m2C/W] 0.001
Fouling factor inside ri [m2C/W] 0.00025

Outer tube diameter Do [mm] 25.4

Wallthickness tube t [mm] 2.77
Thermal conductivity of tube wall material k [W/mC] 39
Inner tube diameter Di [mm] 19.86

Helichanger possible when: Shell side film heat transfer coefficient is >40% Note: These numbers are for guiding only!
Shell side fouling resistance is >30% In case of smaller numbers and in doubt,
Thermal leakage stream (E-stream) is > 15% Please contact K. K. Song.
 HELIXCHANGER

Thermal Guidelines to recognize possibilities for Helixchanger

SK Corporation
This sheet can be used when possibly a HELIXchanger can be applied: Process Engineering Team
Kug-Kyong Song
Total 30.3% Tel : 052-270-1201
Fouling Shell Side 15.8% >30% ? NO
Fouling Tube Side 14.4% HELIXchanger should be applied.
YES, a
Overall heat transfer coefficient U[W/m2C] 451.87
Heat transfer coefficient outside tube ho[W/m2C] 800 56.5% >40% ? YES
Heat transfer coefficient inside tube hi [W/m2C] 6000
Fouling factor outside ro[m2C/W] 0.00035
Fouling factor inside ri [m2C/W] 0.00025

Outer tube diameter Do [mm] 25.4

Wallthickness tube t [mm] 2.77
Thermal conductivity of tube wall material k [W/mC] 39
Inner tube diameter Di [mm] 19.86

Helichanger possible when: Shell side film heat transfer coefficient is >40% Note: These numbers are for guiding only!
Shell side fouling resistance is >30% In case of smaller numbers and in doubt,
Thermal leakage stream (E-stream) is > 15% Please contact K. K. Song.
 HELIXCHANGER

Thermal Guidelines to recognize possibilities for Helixchanger

SK Corporation
This sheet can be used when possibly a HELIXchanger can be applied: Process Engineering Team
Kug-Kyong Song
Total 40.4% Tel : 052-270-1201
Fouling Shell Side 36.4% >30% ? YES
Fouling Tube Side 4.0% HELIXchanger should be applied.
YES, a perfect
Overall heat transfer coefficient U[W/m2C] 182.23
Heat transfer coefficient outside tube ho[W/m2C] 330 55.2% >40% ? YES
Heat transfer coefficient inside tube hi [W/m2C] 8000
Fouling factor outside ro[m2C/W] 0.002
Fouling factor inside ri [m2C/W] 0.00017

Outer tube diameter Do [mm] 25.4

Wallthickness tube t [mm] 2.77
Thermal conductivity of tube wall material k [W/mC] 39
Inner tube diameter Di [mm] 19.86

Helichanger possible when: Shell side film heat transfer coefficient is >40% Note: These numbers are for guiding only!
Shell side fouling resistance is >30% In case of smaller numbers and in doubt,
Thermal leakage stream (E-stream) is > 15% Please contact K. K. Song.
 HELIXCHANGER

Typical Industry Applications

Refinery & Petrochemical Industry

- Crude/Vacuum Distillation Units
- Thermal Conversion and Hydro-treating/cracking Units
- Hydrogen Manufacturing/Purification Units
- Ethylene Plants

Chemical Process Industry

- Temperature Sensitive Processes
- Feed/Effluent Heat Recovery

Power Industry
- Conventional and Nuclear Power Plants

Pulp & Paper Industry

Offshore Heat Recovery Units
 HELIXCHANGER

Typical Services

Crude Preheat Train

Feed/Effluent Heat Exchangers

Heat Recovery Exchangers

Secondary Quench Exchangers

Compressor Aftercoolers/Intercoolers

Gas-Gas Heat Exchangers

Utility Cooling System Exchangers
Fractionator Bottoms/VGO Feed Exchanger

1.1 1.2
(Ao)/(Ao)s,p
dPss,calc./dPss,allow.
1 1.1

0.9 1
Ao = Outside Bare Surface Area

,allow.
ss,allow.
0.8 0.9
)s,p
Ao)s,p

dP ss
./dP
)/(Ao

,calc./
0.7 0.8

ss,calc
Ao)/(
Area Ratio, ((Ao

dP ss
Ratio,dP
0.6 0.7

Pressure Drop Ratio,

0.5 0.6

0.4 0.5

0.3 0.4

0.2 0.3

0.1 0.2
S,P H,P

S,P = Segmental Baffles, Plain Tubes

H,P = Helical Baffles, Plain Tubes
Alkylation Unit Condenser (Capacity Upgrade)

1.8 2.8
Q/Qs,p
dPss,calc./dPss,allow.
1.6 2.4

,allow.
ss,allow.
Heat Duty Ratio, Q/Qs,p

dP ss
1.4 2

ss,calc
dP ss
Ratio,dP ./dP
,calc./
1.2 1.6

Pressure Drop Ratio,

1 1.2

0.8 0.8

0.6 0.4

0.4 0
S,P S,F H,F

S,P = Segmental Baffles, Plain Tubes

S,F = Segmental Baffles, Low-
Low-Finned Tubes
H,F = Helical Baffles, Low-
Low-Finned Tubes
HELIXCHANGER

Power Plant
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Texaco Reboiler
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DuPont Gas Cooler
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Gasoil Cooler for Wintershall, Germany
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Gas Cooler for SK, Korea
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VDU Preheat Train (1)
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VDU Preheat Train (2)
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VDU Preheat Train (3)
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VDU Preheat Train (4)
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VDU Preheat Train (5)
Conventional Segmental Exchanger

Notice fouling accumulation in the stagnant areas

 SK Helixchanger

052-270-2451 011-9509-7369

Basic Design 052-270-1201 011-9393-9733