An intercooler is a heat exchanger used to cool a gas after compression. Often found in turbocharged engines, intercoolers are also used in air compressors , air conditioners , refrigeration and gas turbines .
50-419: FMIC may refer to: Front mounted intercooler, a type of intercooler Fender Musical Instruments Corporation French Medical Institute for Children , Kabul, Afghanistan Topics referred to by the same term [REDACTED] This disambiguation page lists articles associated with the title FMIC . If an internal link led you here, you may wish to change
100-488: A characteristic appearance of a swelled pillow formed out of metal. A waste heat recovery unit (WHRU) is a heat exchanger that recovers heat from a hot gas stream while transferring it to a working medium, typically water or oils. The hot gas stream can be the exhaust gas from a gas turbine or a diesel engine or a waste gas from industry or refinery. Large systems with high volume and temperature gas streams, typical in industry, can benefit from steam Rankine cycle (SRC) in
150-523: A combination of both. In automotive engines where multiple stages of forced-induction are used (e.g. a sequential twin-turbo or twin-charged engine), the intercooling usually takes place after the last turbocharger/supercharger. However it is also possible to use separate intercoolers for each stage of the turbocharging/supercharging, such as in the JCB Dieselmax land speed record racing car. Some aircraft engines also use an intercooler for each stage of
200-450: A constant temperature but still allows for the heat exchanger to accept additional heat. One example where this has been investigated is for use in high power aircraft electronics. Heat exchangers functioning in multiphase flow regimes may be subject to the Ledinegg instability . Direct contact heat exchangers involve heat transfer between hot and cold streams of two phases in the absence of
250-455: A good flow of cooling air for an air-to-air unit would be difficult. Marine intercoolers take the form of a tubular heat exchanger with the air passing around a series of tubes within the cooler casing, and sea water circulating inside the tubes. The main materials used for this kind of application are meant to resist sea water corrosion: Copper-Nickel for the tubes and bronze for the sea water covers. An alternative to using intercoolers - which
300-438: A greater transfer of heat and a decrease in pressure. 4. Condensers and Boilers Heat exchangers using a two-phase heat transfer system are condensers, boilers and evaporators. Condensers are instruments that take and cool hot gas or vapor to the point of condensation and transform the gas into a liquid form. The point at which liquid transforms to gas is called vaporization and vice versa is called condensation. Surface condenser
350-408: A heat exchanger is found in an internal combustion engine in which a circulating fluid known as engine coolant flows through radiator coils and air flows past the coils, which cools the coolant and heats the incoming air . Another example is the heat sink , which is a passive heat exchanger that transfers the heat generated by an electronic or a mechanical device to a fluid medium, often air or
400-420: A liquid coolant. There are three primary classifications of heat exchangers according to their flow arrangement. In parallel-flow heat exchangers, the two fluids enter the exchanger at the same end, and travel in parallel to one another to the other side. In counter-flow heat exchangers the fluids enter the exchanger from opposite ends. The counter current design is the most efficient, in that it can transfer
450-418: A second flowpath ( the 'Shell side'). Plate and shell technology offers high heat transfer, high pressure, high operating temperature , compact size, low fouling and close approach temperature. In particular, it does completely without gaskets, which provides security against leakage at high pressures and temperatures. A fourth type of heat exchanger uses an intermediate fluid or solid store to hold heat, which
500-627: A single phase , heat exchangers can be used either to heat a liquid to evaporate (or boil) it or used as condensers to cool a vapor and condense it to a liquid. In chemical plants and refineries , reboilers used to heat incoming feed for distillation towers are often heat exchangers. Distillation set-ups typically use condensers to condense distillate vapors back into liquid. Power plants that use steam -driven turbines commonly use heat exchangers to boil water into steam . Heat exchangers or similar units for producing steam from water are often called boilers or steam generators. In
550-414: A stream that must be cooled to another stream that must be heated, such as distillate cooling and reboiler feed pre-heating. This term can also refer to heat exchangers that contain a material within their structure that has a change of phase. This is usually a solid to liquid phase due to the small volume difference between these states. This change of phase effectively acts as a buffer because it occurs at
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#1732856190186600-405: A thin sheet of metal welded to the thicker surface of a tank or vessel, or two thin sheets welded together. The surface of the plate is welded with a regular pattern of dots or a serpentine pattern of weld lines. After welding the enclosed space is pressurised with sufficient force to cause the thin metal to bulge out around the welds, providing a space for heat exchanger liquids to flow, and creating
650-494: A tube-based heat exchanger is common when one of the working fluids is a low-pressure gas, and is typical for heat exchangers that operate using ambient air, such as automotive radiators and HVAC air condensers . Fins dramatically increase the surface area with which heat can be exchanged, which improves the efficiency of conducting heat to a fluid with very low thermal conductivity , such as air. The fins are typically made from aluminium or copper since they must conduct heat from
700-404: A tubes & fins configuration. 3. Plate Heat Exchanger A plate heat exchanger contains an amount of thin shaped heat transfer plates bundled together. The gasket arrangement of each pair of plates provides two separate channel system. Each pair of plates form a channel where the fluid can flow through. The pairs are attached by welding and bolting methods. The following shows the components in
750-468: A waste heat recovery unit, but these cycles are too expensive for small systems. The recovery of heat from low temperature systems requires different working fluids than steam. An organic Rankine cycle (ORC) waste heat recovery unit can be more efficient at low temperature range using refrigerants that boil at lower temperatures than water. Typical organic refrigerants are ammonia , pentafluoropropane (R-245fa and R-245ca), and toluene . The refrigerant
800-415: Is a plate and shell heat exchanger, which combines plate heat exchanger with shell and tube heat exchanger technologies. The heart of the heat exchanger contains a fully welded circular plate pack made by pressing and cutting round plates and welding them together. Nozzles carry flow in and out of the platepack (the 'Plate side' flowpath). The fully welded platepack is assembled into an outer shell that creates
850-471: Is a system used to transfer heat between a source and a working fluid . Heat exchangers are used in both cooling and heating processes. The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact. They are widely used in space heating , refrigeration , air conditioning , power stations , chemical plants , petrochemical plants , petroleum refineries , natural-gas processing , and sewage treatment . The classic example of
900-446: Is boiled by the heat source in the evaporator to produce super-heated vapor. This fluid is expanded in the turbine to convert thermal energy to kinetic energy, that is converted to electricity in the electrical generator. This energy transfer process decreases the temperature of the refrigerant that, in turn, condenses. The cycle is closed and completed using a pump to send the fluid back to the evaporator. Another type of heat exchanger
950-433: Is called " (dynamic) scraped surface heat exchanger ". This is mainly used for heating or cooling with high- viscosity products, crystallization processes, evaporation and high- fouling applications. Long running times are achieved due to the continuous scraping of the surface, thus avoiding fouling and achieving a sustainable heat transfer rate during the process. In addition to heating up or cooling down fluids in just
1000-512: Is commonly used in the dairy industry for cooling milk in large direct-expansion stainless steel bulk tanks . Nearly the entire surface area of a tank can be integrated with this heat exchanger, without gaps that would occur between pipes welded to the exterior of the tank. Pillow plates can also be constructed as flat plates that are stacked inside a tank. The relatively flat surface of the plates allows easy cleaning, especially in sterile applications. The pillow plate can be constructed using either
1050-443: Is produced. Plates are produced in different depths, sizes and corrugated shapes. There are different types of plates available including plate and frame, plate and shell and spiral plate heat exchangers. The distribution area guarantees the flow of fluid to the whole heat transfer surface. This helps to prevent stagnant area that can cause accumulation of unwanted material on solid surfaces. High flow turbulence between plates results in
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#17328561901861100-476: Is rarely used these days - was to inject excess fuel into the combustion chamber, so that the vaporization process would cool the cylinders in order to prevent knocking. However the downsides to this method were increased fuel consumption and exhaust gas emissions . Intercoolers are used to remove the waste heat from the first stage of two-stage air compressors. Two-stage air compressors are manufactured because of their inherent efficiency. The cooling action of
1150-447: Is the plate heat exchanger . These exchangers are composed of many thin, slightly separated plates that have very large surface areas and small fluid flow passages for heat transfer. Advances in gasket and brazing technology have made the plate-type heat exchanger increasingly practical. In HVAC applications, large heat exchangers of this type are called plate-and-frame ; when used in open loops, these heat exchangers are normally of
1200-402: Is the most common type of condenser where it includes a water supply device. Figure 5 below displays a two-pass surface condenser. The pressure of steam at the turbine outlet is low where the steam density is very low where the flow rate is very high. To prevent a decrease in pressure in the movement of steam from the turbine to condenser, the condenser unit is placed underneath and connected to
1250-617: Is then moved to the other side of the heat exchanger to be released. Two examples of this are adiabatic wheels, which consist of a large wheel with fine threads rotating through the hot and cold fluids, and fluid heat exchangers. This type of heat exchanger uses "sandwiched" passages containing fins to increase the effectiveness of the unit. The designs include crossflow and counterflow coupled with various fin configurations such as straight fins, offset fins and wavy fins. Plate and fin heat exchangers are usually made of aluminum alloys, which provide high heat transfer efficiency. The material enables
1300-404: Is used to counteract the heat of compression and heat soak in the pressurised intake air. By reducing the temperature of the intake air, the air becomes denser (allowing more fuel to be injected, resulting in increased power) and less likely to suffer from pre-ignition or knocking . Additional cooling can be provided by externally spraying a fine mist onto the intercooler surface, or even into
1350-469: The intake air itself , to further reduce intake charge temperature through evaporative cooling . Intercoolers can vary dramatically in size, shape and design, depending on the performance and space requirements of the system. Many passenger cars use either front-mounted intercoolers located in the front bumper or grill opening, or top-mounted intercoolers located above the engine. An intercooling system can use an air-to-air design, an air-to-liquid design, or
1400-661: The LMTD is not available and the NTU method is used. Double pipe heat exchangers are the simplest exchangers used in industries. On one hand, these heat exchangers are cheap for both design and maintenance, making them a good choice for small industries. On the other hand, their low efficiency coupled with the high space occupied in large scales, has led modern industries to use more efficient heat exchangers like shell and tube or plate. However, since double pipe heat exchangers are simple, they are used to teach heat exchanger design basics to students as
1450-405: The dimensions and configurations the boilers are manufactured. Several boilers are only able to produce hot fluid while on the other hand the others are manufactured for steam production. Shell and tube heat exchangers consist of a series of tubes which contain fluid that must be either heated or cooled. A second fluid runs over the tubes that are being heated or cooled so that it can either provide
1500-500: The engine's cooling system is also used for the intercooling system. Air-to-liquid intercoolers are usually heavier than their air-to-air counterparts, due to additional components making up the system (e.g. water circulation pump, radiator, fluid, and plumbing). The majority of marine engines use air-to-liquid intercoolers, since the water of the lake, river or sea can easily be accessed for cooling purposes. In addition, most marine engines are located in closed compartments where obtaining
1550-449: The exchanger. The exchanger's performance can also be affected by the addition of fins or corrugations in one or both directions, which increase surface area and may channel fluid flow or induce turbulence. The driving temperature across the heat transfer surface varies with position, but an appropriate mean temperature can be defined. In most simple systems this is the " log mean temperature difference " (LMTD). Sometimes direct knowledge of
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1600-405: The flow-induced vibrations. There are several variations of shell-and-tube exchangers available; the differences lie in the arrangement of flow configurations and details of construction. In application to cool air with shell-and-tube technology (such as intercooler / charge air cooler for combustion engines ), fins can be added on the tubes to increase heat transfer area on air side and create
1650-400: The fluids, as it creates a larger temperature differential when used under otherwise similar conditions. The figure above illustrates the parallel and counter-flow flow directions of the fluid exchanger. 2. Shell-and-tube heat exchanger In a shell-and-tube heat exchanger, two fluids at different temperatures flow through the heat exchanger. One of the fluids flows through the tube side and
1700-458: The forced induction. In engines with two-stage turbocharging, the term intercooler can specifically refer to the cooler between the two turbochargers and the term aftercooler is used for the cooler located between the second-stage turbo and the engine. However, the terms intercooler and charge-air cooler are also often used regardless of the location in the intake system. Air-to-air intercoolers are heat exchangers that transfer heat from
1750-418: The fundamental rules for all heat exchangers are the same. 1. Double-pipe heat exchanger When one fluid flows through the smaller pipe, the other flows through the annular gap between the two pipes. These flows may be parallel or counter-flows in a double pipe heat exchanger. (a) Parallel flow, where both hot and cold liquids enter the heat exchanger from the same side, flow in the same direction and exit at
1800-568: The gasket type to allow periodic disassembly, cleaning, and inspection. There are many types of permanently bonded plate heat exchangers, such as dip-brazed, vacuum-brazed, and welded plate varieties, and they are often specified for closed-loop applications such as refrigeration . Plate heat exchangers also differ in the types of plates that are used, and in the configurations of those plates. Some plates may be stamped with "chevron", dimpled, or other patterns, where others may have machined fins and/or grooves. When compared to shell and tube exchangers,
1850-446: The heat exchanger. In single channels the configuration of the gaskets enables flow through. Thus, this allows the main and secondary media in counter-current flow. A gasket plate heat exchanger has a heat region from corrugated plates. The gasket function as seal between plates and they are located between frame and pressure plates. Fluid flows in a counter current direction throughout the heat exchanger. An efficient thermal performance
1900-471: The heat or absorb the heat required. A set of tubes is called the tube bundle and can be made up of several types of tubes: plain, longitudinally finned, etc. Shell and tube heat exchangers are typically used for high-pressure applications (with pressures greater than 30 bar and temperatures greater than 260 °C). This is because the shell and tube heat exchangers are robust due to their shape. Several thermal design features must be considered when designing
1950-401: The intake air directly to the atmosphere. Alternatively, air-to-liquid intercoolers transfer the heat from the intake air to intermediate liquid (usually water), which in turn transfers the heat to the atmosphere. The heat exchanger that transfers the heat from the fluid to the atmosphere operates in a similar fashion to the main radiator in a water-cooled engine's cooling system, or in some cases
2000-437: The intercooler is principally responsible for this higher efficiency, bringing it closer to Carnot efficiency . Removing the heat-of-compression from the discharge of the first stage has the effect of densifying the air charge. This, in turn, allows the second stage to produce more work from its fixed compression ratio. Adding an intercooler to the setup requires additional investments. Heat exchanger A heat exchanger
2050-419: The link to point directly to the intended article. Retrieved from " https://en.wikipedia.org/w/index.php?title=FMIC&oldid=927347923 " Category : Disambiguation pages Hidden categories: Short description is different from Wikidata All article disambiguation pages All disambiguation pages Intercooler Most commonly used with turbocharged engines, an intercooler
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2100-455: The most heat from the heat (transfer) medium per unit mass due to the fact that the average temperature difference along any unit length is higher . See countercurrent exchange . In a cross-flow heat exchanger, the fluids travel roughly perpendicular to one another through the exchanger. For efficiency, heat exchangers are designed to maximize the surface area of the wall between the two fluids, while minimizing resistance to fluid flow through
2150-570: The nuclear power plants called pressurized water reactors , special large heat exchangers pass heat from the primary (reactor plant) system to the secondary (steam plant) system, producing steam from water in the process. These are called steam generators . All fossil-fueled and nuclear power plants using steam-driven turbines have surface condensers to convert the exhaust steam from the turbines into condensate (water) for re-use. To conserve energy and cooling capacity in chemical and other plants, regenerative heat exchangers can transfer heat from
2200-428: The other fluid flows outside the tubes, but inside the shell (shell side). Baffles are used to support the tubes, direct the fluid flow to the tubes in an approximately natural manner, and maximize the turbulence of the shell fluid. There are many various kinds of baffles, and the choice of baffle form, spacing, and geometry depends on the allowable flow rate of the drop in shell-side force, the need for tube support, and
2250-433: The same end. This configuration is preferable when the two fluids are intended to reach exactly the same temperature, as it reduces thermal stress and produces a more uniform rate of heat transfer. (b) Counter-flow, where hot and cold fluids enter opposite sides of the heat exchanger, flow in opposite directions, and exit at opposite ends. This configuration is preferable when the objective is to maximize heat transfer between
2300-493: The stacked-plate arrangement typically has lower volume and cost. Another difference between the two is that plate exchangers typically serve low to medium pressure fluids, compared to medium and high pressures of shell and tube. A third and important difference is that plate exchangers employ more countercurrent flow rather than cross current flow, which allows lower approach temperature differences, high temperature changes, and increased efficiencies. A third type of heat exchanger
2350-439: The system to operate at a lower temperature difference and reduce the weight of the equipment. Plate and fin heat exchangers are mostly used for low temperature services such as natural gas, helium and oxygen liquefaction plants, air separation plants and transport industries such as motor and aircraft engines . Advantages of plate and fin heat exchangers: Disadvantages of plate and fin heat exchangers: The usage of fins in
2400-444: The tube along the length of the fins, which are usually very thin. The main construction types of finned tube exchangers are: Stacked-fin or spiral-wound construction can be used for the tubes inside shell-and-tube heat exchangers when high efficiency thermal transfer to a gas is required. In electronics cooling, heat sinks , particularly those using heat pipes , can have a stacked-fin construction. A pillow plate heat exchanger
2450-568: The tubes in the shell and tube heat exchangers: There can be many variations on the shell and tube design. Typically, the ends of each tube are connected to plenums (sometimes called water boxes) through holes in tubesheets. The tubes may be straight or bent in the shape of a U, called U-tubes. Fixed tube liquid-cooled heat exchangers especially suitable for marine and harsh applications can be assembled with brass shells, copper tubes, brass baffles, and forged brass integral end hubs. (See: Copper in heat exchangers ). Another type of heat exchanger
2500-432: The turbine. Inside the tubes the cooling water runs in a parallel way, while steam moves in a vertical downward position from the wide opening at the top and travel through the tube. Furthermore, boilers are categorized as initial application of heat exchangers. The word steam generator was regularly used to describe a boiler unit where a hot liquid stream is the source of heat rather than the combustion products. Depending on
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