Adjusting Equipment Size to Fit Modern Needs

Equipment used to transfer heat between fluids

A heat exchanger is a system used to transfer heat between a source and a working fluid. Heat exchangers are used in both cooling and heating processes.^[1] The fluids may be separated by a solid wall to prevent mixing or they may be in direct contact.^[2] 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 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 a liquid coolant.^[3]

Flow arrangement

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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 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.

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  Fig. 1: Shell and tube heat exchanger, single pass (1–1 parallel flow)
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  Fig. 2: Shell and tube heat exchanger, 2-pass tube side (1–2 crossflow)
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  Fig. 3: Shell and tube heat exchanger, 2-pass shell side, 2-pass tube side (2-2 countercurrent)

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 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 the LMTD is not available and the NTU method is used.

Types

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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 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 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 the fluids, as it creates a larger temperature differential when used under otherwise similar conditions.^{[citation needed]}

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 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 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 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 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 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 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 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 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 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

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Main article: Shell and tube heat exchanger

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 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).^[4] This is because the shell and tube heat exchangers are robust due to their shape.
Several thermal design features must be considered when designing 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.

• Tube diameter: Using a small tube diameter makes the heat exchanger both economical and compact. However, it is more likely for the heat exchanger to foul up faster and the small size makes mechanical cleaning of the fouling difficult. To prevail over the fouling and cleaning problems, larger tube diameters can be used. Thus to determine the tube diameter, the available space, cost and fouling nature of the fluids must be considered.
• Tube thickness: The thickness of the wall of the tubes is usually determined to ensure:
  • There is enough room for corrosion
  • That flow-induced vibration has resistance
  • Axial strength
  • Availability of spare parts
  • Hoop strength (to withstand internal tube pressure)
  • Buckling strength (to withstand overpressure in the shell)
• Tube length: heat exchangers are usually cheaper when they have a smaller shell diameter and a long tube length. Thus, typically there is an aim to make the heat exchanger as long as physically possible whilst not exceeding production capabilities. However, there are many limitations for this, including space available at the installation site and the need to ensure tubes are available in lengths that are twice the required length (so they can be withdrawn and replaced). Also, long, thin tubes are difficult to take out and replace.
• Tube pitch: when designing the tubes, it is practical to ensure that the tube pitch (i.e., the centre-centre distance of adjoining tubes) is not less than 1.25 times the tubes' outside diameter. A larger tube pitch leads to a larger overall shell diameter, which leads to a more expensive heat exchanger.
• Tube corrugation: this type of tubes, mainly used for the inner tubes, increases the turbulence of the fluids and the effect is very important in the heat transfer giving a better performance.
• Tube Layout: refers to how tubes are positioned within the shell. There are four main types of tube layout, which are, triangular (30°), rotated triangular (60°), square (90°) and rotated square (45°). The triangular patterns are employed to give greater heat transfer as they force the fluid to flow in a more turbulent fashion around the piping. Square patterns are employed where high fouling is experienced and cleaning is more regular.
• Baffle Design: baffles are used in shell and tube heat exchangers to direct fluid across the tube bundle. They run perpendicularly to the shell and hold the bundle, preventing the tubes from sagging over a long length. They can also prevent the tubes from vibrating. The most common type of baffle is the segmental baffle. The semicircular segmental baffles are oriented at 180 degrees to the adjacent baffles forcing the fluid to flow upward and downwards between the tube bundle. Baffle spacing is of large thermodynamic concern when designing shell and tube heat exchangers. Baffles must be spaced with consideration for the conversion of pressure drop and heat transfer. For thermo economic optimization it is suggested that the baffles be spaced no closer than 20% of the shell's inner diameter. Having baffles spaced too closely causes a greater pressure drop because of flow redirection. Consequently, having the baffles spaced too far apart means that there may be cooler spots in the corners between baffles. It is also important to ensure the baffles are spaced close enough that the tubes do not sag. The other main type of baffle is the disc and doughnut baffle, which consists of two concentric baffles. An outer, wider baffle looks like a doughnut, whilst the inner baffle is shaped like a disk. This type of baffle forces the fluid to pass around each side of the disk then through the doughnut baffle generating a different type of fluid flow.
• Tubes & fins Design: in application to cool air with shell-and-tube technology (such as intercooler / charge air cooler for combustion engines), the difference in heat transfer between air and cold fluid can be such that there is a need to increase heat transfer area on air side. For this function fins can be added on the tubes to increase heat transfer area on air side and create a tubes & fins configuration.

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.^{[citation needed]} (See: Copper in heat exchangers).

Plate

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Another type of heat exchanger 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 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, 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 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 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 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 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:

• High heat transfer efficiency especially in gas treatment
• Larger heat transfer area
• Approximately 5 times lighter in weight than that of shell and tube heat exchanger. ^{[citation needed]}
• Able to withstand high pressure

Disadvantages of plate and fin heat exchangers:

• Might cause clogging as the pathways are very narrow
• Difficult to clean the pathways
• Aluminium alloys are susceptible to Mercury Liquid Embrittlement Failure

The usage of fins in 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 the tube along the length of the fins, which are usually very thin.

The main construction types of finned tube exchangers are:

• A stack of evenly-spaced metal plates act as the fins and the tubes are pressed through pre-cut holes in the fins, good thermal contact usually being achieved by deformation of the fins around the tube. This is typical construction for HVAC air coils and large refrigeration condensers.
• Fins are spiral-wound onto individual tubes as a continuous strip, the tubes can then be assembled in banks, bent in a serpentine pattern, or wound into large spirals.
• Zig-zag metal strips are sandwiched between flat rectangular tubes, often being soldered or brazed together for good thermal and mechanical strength. This is common in low-pressure heat exchangers such as water-cooling radiators. Regular flat tubes will expand and deform if exposed to high pressures but flat microchannel tubes allow this construction to be used for high pressures.^[5]

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 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 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 a characteristic appearance of a swelled pillow formed out of metal.

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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 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 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 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 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.^[6][7]

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 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.^[8][9]

To conserve energy and cooling capacity in chemical and other plants, regenerative heat exchangers can transfer heat from 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 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 a separating wall.^[10] Thus such heat exchangers can be classified as:

• Gas – liquid
• Immiscible liquid – liquid
• Solid-liquid or solid – gas

Most direct contact heat exchangers fall under the Gas – Liquid category, where heat is transferred between a gas and liquid in the form of drops, films or sprays.^[4]

Such types of heat exchangers are used predominantly in air conditioning, humidification, industrial hot water heating, water cooling and condensing plants.^[11]

Microchannel heat exchangers are multi-pass parallel flow heat exchangers consisting of three main elements: manifolds (inlet and outlet), multi-port tubes with the hydraulic diameters smaller than 1mm, and fins. All the elements usually brazed together using controllable atmosphere brazing process. Microchannel heat exchangers are characterized by high heat transfer ratio, low refrigerant charges, compact size, and lower airside pressure drops compared to finned tube heat exchangers.^{[citation needed]} Microchannel heat exchangers are widely used in automotive industry as the car radiators, and as condenser, evaporator, and cooling/heating coils in HVAC industry.

Micro heat exchangers, Micro-scale heat exchangers, or microstructured heat exchangers are heat exchangers in which (at least one) fluid flows in lateral confinements with typical dimensions below 1 mm. The most typical such confinement are microchannels, which are channels with a hydraulic diameter below 1 mm. Microchannel heat exchangers can be made from metal or ceramics.^[13] Microchannel heat exchangers can be used for many applications including:

• high-performance aircraft gas turbine engines^[14]
• heat pumps^[15]
• Microprocessor and microchip cooling^[16]
• air conditioning^[17]

One of the widest uses of heat exchangers is for refrigeration and air conditioning. This class of heat exchangers is commonly called air coils, or just coils due to their often-serpentine internal tubing, or condensers in the case of refrigeration, and are typically of the finned tube type. Liquid-to-air, or air-to-liquid HVAC coils are typically of modified crossflow arrangement. In vehicles, heat coils are often called heater cores.

On the liquid side of these heat exchangers, the common fluids are water, a water-glycol solution, steam, or a refrigerant. For heating coils, hot water and steam are the most common, and this heated fluid is supplied by boilers, for example. For cooling coils, chilled water and refrigerant are most common. Chilled water is supplied from a chiller that is potentially located very far away, but refrigerant must come from a nearby condensing unit. When a refrigerant is used, the cooling coil is the evaporator, and the heating coil is the condenser in the vapor-compression refrigeration cycle. HVAC coils that use this direct-expansion of refrigerants are commonly called DX coils. Some DX coils are "microchannel" type.^[5]

On the air side of HVAC coils a significant difference exists between those used for heating, and those for cooling. Due to psychrometrics, air that is cooled often has moisture condensing out of it, except with extremely dry air flows. Heating some air increases that airflow's capacity to hold water. So heating coils need not consider moisture condensation on their air-side, but cooling coils must be adequately designed and selected to handle their particular latent (moisture) as well as the sensible (cooling) loads. The water that is removed is called condensate.

For many climates, water or steam HVAC coils can be exposed to freezing conditions. Because water expands upon freezing, these somewhat expensive and difficult to replace thin-walled heat exchangers can easily be damaged or destroyed by just one freeze. As such, freeze protection of coils is a major concern of HVAC designers, installers, and operators.

The introduction of indentations placed within the heat exchange fins controlled condensation, allowing water molecules to remain in the cooled air.^[18]

The heat exchangers in direct-combustion furnaces, typical in many residences, are not 'coils'. They are, instead, gas-to-air heat exchangers that are typically made of stamped steel sheet metal. The combustion products pass on one side of these heat exchangers, and air to heat on the other. A cracked heat exchanger is therefore a dangerous situation that requires immediate attention because combustion products may enter living space.

Although double-pipe heat exchangers are the simplest to design, the better choice in the following cases would be the helical-coil heat exchanger (HCHE):

• The main advantage of the HCHE, like that for the Spiral heat exchanger (SHE), is its highly efficient use of space, especially when it's limited and not enough straight pipe can be laid.^[19]
• Under conditions of low flowrates (or laminar flow), such that the typical shell-and-tube exchangers have low heat-transfer coefficients and becoming uneconomical.^[19]
• When there is low pressure in one of the fluids, usually from accumulated pressure drops in other process equipment.^[19]
• When one of the fluids has components in multiple phases (solids, liquids, and gases), which tends to create mechanical problems during operations, such as plugging of small-diameter tubes.^[20] Cleaning of helical coils for these multiple-phase fluids can prove to be more difficult than its shell and tube counterpart; however the helical coil unit would require cleaning less often.

These have been used in the nuclear industry as a method for exchanging heat in a sodium system for large liquid metal fast breeder reactors since the early 1970s, using an HCHE device invented by Charles E. Boardman and John H. Germer.^[21] There are several simple methods for designing HCHE for all types of manufacturing industries, such as using the Ramachandra K. Patil (et al.) method from India and the Scott S. Haraburda method from the United States.^[19][20]

However, these are based upon assumptions of estimating inside heat transfer coefficient, predicting flow around the outside of the coil, and upon constant heat flux.^[22]

A modification to the perpendicular flow of the typical HCHE involves the replacement of shell with another coiled tube, allowing the two fluids to flow parallel to one another, and which requires the use of different design calculations.^[23] These are the Spiral Heat Exchangers (SHE), which may refer to a helical (coiled) tube configuration, more generally, the term refers to a pair of flat surfaces that are coiled to form the two channels in a counter-flow arrangement. Each of the two channels has one long curved path. A pair of fluid ports are connected tangentially to the outer arms of the spiral, and axial ports are common, but optional.^[24]

The main advantage of the SHE is its highly efficient use of space. This attribute is often leveraged and partially reallocated to gain other improvements in performance, according to well known tradeoffs in heat exchanger design. (A notable tradeoff is capital cost vs operating cost.) A compact SHE may be used to have a smaller footprint and thus lower all-around capital costs, or an oversized SHE may be used to have less pressure drop, less pumping energy, higher thermal efficiency, and lower energy costs.

The distance between the sheets in the spiral channels is maintained by using spacer studs that were welded prior to rolling. Once the main spiral pack has been rolled, alternate top and bottom edges are welded and each end closed by a gasketed flat or conical cover bolted to the body. This ensures no mixing of the two fluids occurs. Any leakage is from the periphery cover to the atmosphere, or to a passage that contains the same fluid.^[25]

Spiral heat exchangers are often used in the heating of fluids that contain solids and thus tend to foul the inside of the heat exchanger. The low pressure drop lets the SHE handle fouling more easily. The SHE uses a “self cleaning” mechanism, whereby fouled surfaces cause a localized increase in fluid velocity, thus increasing the drag (or fluid friction) on the fouled surface, thus helping to dislodge the blockage and keep the heat exchanger clean. "The internal walls that make up the heat transfer surface are often rather thick, which makes the SHE very robust, and able to last a long time in demanding environments."^{[citation needed]} They are also easily cleaned, opening out like an oven where any buildup of foulant can be removed by pressure washing.

Self-cleaning water filters are used to keep the system clean and running without the need to shut down or replace cartridges and bags.

There are three main types of flows in a spiral heat exchanger:

• Counter-current Flow: Fluids flow in opposite directions. These are used for liquid-liquid, condensing and gas cooling applications. Units are usually mounted vertically when condensing vapour and mounted horizontally when handling high concentrations of solids.
• Spiral Flow/Cross Flow: One fluid is in spiral flow and the other in a cross flow. Spiral flow passages are welded at each side for this type of spiral heat exchanger. This type of flow is suitable for handling low density gas, which passes through the cross flow, avoiding pressure loss. It can be used for liquid-liquid applications if one liquid has a considerably greater flow rate than the other.
• Distributed Vapour/Spiral flow: This design is that of a condenser, and is usually mounted vertically. It is designed to cater for the sub-cooling of both condensate and non-condensables. The coolant moves in a spiral and leaves via the top. Hot gases that enter leave as condensate via the bottom outlet.

The Spiral heat exchanger is good for applications such as pasteurization, digester heating, heat recovery, pre-heating (see: recuperator), and effluent cooling. For sludge treatment, SHEs are generally smaller than other types of heat exchangers.^{[citation needed]} These are used to transfer the heat.

Due to the many variables involved, selecting optimal heat exchangers is challenging. Hand calculations are possible, but many iterations are typically needed. As such, heat exchangers are most often selected via computer programs, either by system designers, who are typically engineers, or by equipment vendors.

To select an appropriate heat exchanger, the system designers (or equipment vendors) would firstly consider the design limitations for each heat exchanger type. Though cost is often the primary criterion, several other selection criteria are important:

• High/low pressure limits
• Thermal performance
• Temperature ranges
• Product mix (liquid/liquid, particulates or high-solids liquid)
• Pressure drops across the exchanger
• Fluid flow capacity
• Cleanability, maintenance and repair
• Materials required for construction
• Ability and ease of future expansion
• Material selection, such as copper, aluminium, carbon steel, stainless steel, nickel alloys, ceramic, polymer, and titanium.^[26][27]

Small-diameter coil technologies are becoming more popular in modern air conditioning and refrigeration systems because they have better rates of heat transfer than conventional sized condenser and evaporator coils with round copper tubes and aluminum or copper fin that have been the standard in the HVAC industry. Small diameter coils can withstand the higher pressures required by the new generation of environmentally friendlier refrigerants. Two small diameter coil technologies are currently available for air conditioning and refrigeration products: copper microgroove^[28] and brazed aluminum microchannel.^{[citation needed]}

Choosing the right heat exchanger (HX) requires some knowledge of the different heat exchanger types, as well as the environment where the unit must operate. Typically in the manufacturing industry, several differing types of heat exchangers are used for just one process or system to derive the final product. For example, a kettle HX for pre-heating, a double pipe HX for the 'carrier' fluid and a plate and frame HX for final cooling. With sufficient knowledge of heat exchanger types and operating requirements, an appropriate selection can be made to optimise the process.^[29]

Online monitoring of commercial heat exchangers is done by tracking the overall heat transfer coefficient. The overall heat transfer coefficient tends to decline over time due to fouling.

By periodically calculating the overall heat transfer coefficient from exchanger flow rates and temperatures, the owner of the heat exchanger can estimate when cleaning the heat exchanger is economically attractive.

Integrity inspection of plate and tubular heat exchanger can be tested in situ by the conductivity or helium gas methods. These methods confirm the integrity of the plates or tubes to prevent any cross contamination and the condition of the gaskets.

Mechanical integrity monitoring of heat exchanger tubes may be conducted through Nondestructive methods such as eddy current testing.

Fouling occurs when impurities deposit on the heat exchange surface. Deposition of these impurities can decrease heat transfer effectiveness significantly over time and are caused by:

• Low wall shear stress
• Low fluid velocities
• High fluid velocities
• Reaction product solid precipitation
• Precipitation of dissolved impurities due to elevated wall temperatures

The rate of heat exchanger fouling is determined by the rate of particle deposition less re-entrainment/suppression. This model was originally proposed in 1959 by Kern and Seaton.

Crude Oil Exchanger Fouling. In commercial crude oil refining, crude oil is heated from 21 °C (70 °F) to 343 °C (649 °F) prior to entering the distillation column. A series of shell and tube heat exchangers typically exchange heat between crude oil and other oil streams to heat the crude to 260 °C (500 °F) prior to heating in a furnace. Fouling occurs on the crude side of these exchangers due to asphaltene insolubility. The nature of asphaltene solubility in crude oil was successfully modeled by Wiehe and Kennedy.^[30] The precipitation of insoluble asphaltenes in crude preheat trains has been successfully modeled as a first order reaction by Ebert and Panchal^[31] who expanded on the work of Kern and Seaton.

Cooling Water Fouling. Cooling water systems are susceptible to fouling. Cooling water typically has a high total dissolved solids content and suspended colloidal solids. Localized precipitation of dissolved solids occurs at the heat exchange surface due to wall temperatures higher than bulk fluid temperature. Low fluid velocities (less than 3 ft/s) allow suspended solids to settle on the heat exchange surface. Cooling water is typically on the tube side of a shell and tube exchanger because it's easy to clean. To prevent fouling, designers typically ensure that cooling water velocity is greater than 0.9 m/s and bulk fluid temperature is maintained less than 60 °C (140 °F). Other approaches to control fouling control combine the "blind" application of biocides and anti-scale chemicals with periodic lab testing.

Plate and frame heat exchangers can be disassembled and cleaned periodically. Tubular heat exchangers can be cleaned by such methods as acid cleaning, sandblasting, high-pressure water jet, bullet cleaning, or drill rods.

In large-scale cooling water systems for heat exchangers, water treatment such as purification, addition of chemicals, and testing, is used to minimize fouling of the heat exchange equipment. Other water treatment is also used in steam systems for power plants, etc. to minimize fouling and corrosion of the heat exchange and other equipment.

A variety of companies have started using water borne oscillations technology to prevent biofouling. Without the use of chemicals, this type of technology has helped in providing a low-pressure drop in heat exchangers.

The design and manufacturing of heat exchangers has numerous regulations, which vary according to the region in which they will be used.

Design and manufacturing codes include: ASME Boiler and Pressure Vessel Code (US); PD 5500 (UK); BS 1566 (UK);^[32] EN 13445 (EU); CODAP (French); Pressure Equipment Safety Regulations 2016 (PER) (UK); Pressure Equipment Directive (EU); NORSOK (Norwegian); TEMA;^[33] API 12; and API 560.^{[citation needed]}

The human nasal passages serve as a heat exchanger, with cool air being inhaled and warm air being exhaled. Its effectiveness can be demonstrated by putting the hand in front of the face and exhaling, first through the nose and then through the mouth. Air exhaled through the nose is substantially cooler.^[34][35] This effect can be enhanced with clothing, by, for example, wearing a scarf over the face while breathing in cold weather.

In species that have external testes (such as human), the artery to the testis is surrounded by a mesh of veins called the pampiniform plexus. This cools the blood heading to the testes, while reheating the returning blood.

"Countercurrent" heat exchangers occur naturally in the circulatory systems of fish, whales and other marine mammals. Arteries to the skin carrying warm blood are intertwined with veins from the skin carrying cold blood, causing the warm arterial blood to exchange heat with the cold venous blood. This reduces the overall heat loss in cold water. Heat exchangers are also present in the tongues of baleen whales as large volumes of water flow through their mouths.^[36][37] Wading birds use a similar system to limit heat losses from their body through their legs into the water.

Carotid rete is a counter-current heat exchanging organ in some ungulates. The blood ascending the carotid arteries on its way to the brain, flows via a network of vessels where heat is discharged to the veins of cooler blood descending from the nasal passages. The carotid rete allows Thomson's gazelle to maintain its brain almost 3 °C (5.4 °F) cooler than the rest of the body, and therefore aids in tolerating bursts in metabolic heat production such as associated with outrunning cheetahs (during which the body temperature exceeds the maximum temperature at which the brain could function).^[38] Humans with other primates lack a carotid rete.^[39]

Heat exchangers are widely used in industry both for cooling and heating large scale industrial processes. The type and size of heat exchanger used can be tailored to suit a process depending on the type of fluid, its phase, temperature, density, viscosity, pressures, chemical composition and various other thermodynamic properties.

In many industrial processes there is waste of energy or a heat stream that is being exhausted, heat exchangers can be used to recover this heat and put it to use by heating a different stream in the process. This practice saves a lot of money in industry, as the heat supplied to other streams from the heat exchangers would otherwise come from an external source that is more expensive and more harmful to the environment.

Heat exchangers are used in many industries, including:

• Waste water treatment
• Refrigeration
• Wine and beer making
• Petroleum refining
• Nuclear power

In waste water treatment, heat exchangers play a vital role in maintaining optimal temperatures within anaerobic digesters to promote the growth of microbes that remove pollutants. Common types of heat exchangers used in this application are the double pipe heat exchanger as well as the plate and frame heat exchanger.

In commercial aircraft heat exchangers are used to take heat from the engine's oil system to heat cold fuel.^[40] This improves fuel efficiency, as well as reduces the possibility of water entrapped in the fuel freezing in components.^[41]

Estimated at US$17.5 billion in 2021, the global demand of heat exchangers is expected to experience robust growth of about 5% annually over the next years. The market value is expected to reach US$27 billion by 2030. With an expanding desire for environmentally friendly options and increased development of offices, retail sectors, and public buildings, market expansion is due to grow.^[42]

A simple heat exchange ^[43][44] might be thought of as two straight pipes with fluid flow, which are thermally connected. Let the pipes be of equal length L, carrying fluids with heat capacity $\displaystyle C_i$ (energy per unit mass per unit change in temperature) and let the mass flow rate of the fluids through the pipes, both in the same direction, be $\displaystyle j_i$ (mass per unit time), where the subscript i applies to pipe 1 or pipe 2.

Temperature profiles for the pipes are $\displaystyle T_1(x)$ and $\displaystyle T_2(x)$ where x is the distance along the pipe. Assume a steady state, so that the temperature profiles are not functions of time. Assume also that the only transfer of heat from a small volume of fluid in one pipe is to the fluid element in the other pipe at the same position, i.e., there is no transfer of heat along a pipe due to temperature differences in that pipe. By Newton's law of cooling the rate of change in energy of a small volume of fluid is proportional to the difference in temperatures between it and the corresponding element in the other pipe:

$\displaystyle \frac du_1dt=\gamma (T_2-T_1)$

$\displaystyle \frac du_2dt=\gamma (T_1-T_2)$

( this is for parallel flow in the same direction and opposite temperature gradients, but for counter-flow heat exchange countercurrent exchange the sign is opposite in the second equation in front of $\displaystyle \gamma (T_1-T_2)$ ), where $\displaystyle u_i(x)$ is the thermal energy per unit length and γ is the thermal connection constant per unit length between the two pipes. This change in internal energy results in a change in the temperature of the fluid element. The time rate of change for the fluid element being carried along by the flow is:

$\displaystyle \frac du_1dt=J_1\frac dT_1dx$

$\displaystyle \frac du_2dt=J_2\frac dT_2dx$

where $\displaystyle J_i=C_ij_i$ is the "thermal mass flow rate". The differential equations governing the heat exchanger may now be written as:

$\displaystyle J_1\frac \partial T_1\partial x=\gamma (T_2-T_1)$

$\displaystyle J_2\frac \partial T_2\partial x=\gamma (T_1-T_2).$

Since the system is in a steady state, there are no partial derivatives of temperature with respect to time, and since there is no heat transfer along the pipe, there are no second derivatives in x as is found in the heat equation. These two coupled first-order differential equations may be solved to yield:

$\displaystyle T_1=A-\frac Bk_1k\,e^-kx$

$\displaystyle T_2=A+\frac Bk_2k\,e^-kx$

where $\displaystyle k_1=\gamma /J_1$, $\displaystyle k_2=\gamma /J_2$,

$\displaystyle k=k_1+k_2$

(this is for parallel-flow, but for counter-flow the sign in front of $\displaystyle k_2$ is negative, so that if $\displaystyle k_2=k_1$, for the same "thermal mass flow rate" in both opposite directions, the gradient of temperature is constant and the temperatures linear in position x with a constant difference $\displaystyle (T_2-T_1)$ along the exchanger, explaining why the counter current design countercurrent exchange is the most efficient )

and A and B are two as yet undetermined constants of integration. Let $\displaystyle T_10$ and $\displaystyle T_20$ be the temperatures at x=0 and let $\displaystyle T_1L$ and $\displaystyle T_2L$ be the temperatures at the end of the pipe at x=L. Define the average temperatures in each pipe as:

$\displaystyle \overline T_1=\frac 1L\int _0^LT_1(x)dx$

$\displaystyle \overline T_2=\frac 1L\int _0^LT_2(x)dx.$

Using the solutions above, these temperatures are:

$\displaystyle T_10=A-\frac Bk_1k$	$\displaystyle T_20=A+\frac Bk_2k$
$\displaystyle T_1L=A-\frac Bk_1ke^-kL$	$\displaystyle T_2L=A+\frac Bk_2ke^-kL$
$\displaystyle \overline T_1=A-\frac Bk_1k^2L(1-e^-kL)$	$\displaystyle \overline T_2=A+\frac Bk_2k^2L(1-e^-kL).$

Choosing any two of the temperatures above eliminates the constants of integration, letting us find the other four temperatures. We find the total energy transferred by integrating the expressions for the time rate of change of internal energy per unit length:

$\displaystyle \frac dU_1dt=\int _0^L\frac du_1dt\,dx=J_1(T_1L-T_10)=\gamma L(\overline T_2-\overline T_1)$

$\displaystyle \frac dU_2dt=\int _0^L\frac du_2dt\,dx=J_2(T_2L-T_20)=\gamma L(\overline T_1-\overline T_2).$

By the conservation of energy, the sum of the two energies is zero. The quantity $\displaystyle \overline T_2-\overline T_1$ is known as the Log mean temperature difference, and is a measure of the effectiveness of the heat exchanger in transferring heat energy.

• Coulson, J. and Richardson, J (1999). Chemical Engineering- Fluid Flow. Heat Transfer and Mass Transfer- Volume 1; Reed Educational & Professional Publishing LTD
• Dogan Eryener (2005), 'Thermoeconomic optimization of baffle spacing for shell and tube heat exchangers', Energy Conservation and Management, Volume 47, Issue 11–12, Pages 1478–1489.
• G.F.Hewitt, G.L.Shires, T.R.Bott (1994) Process Heat Transfer, CRC Press, Inc, United States Of America.

Wikimedia Commons has media related to Heat exchangers.

• Shell and Tube Heat Exchanger Design Software for Educational Applications (PDF)
• EU Pressure Equipment Guideline
• A Thermal Management Concept For More Electric Aircraft Power System Application (PDF)

 

System that transfers heat from one space to another

This article is about devices used to heat and potentially also cool a building (or water) using the refrigeration cycle. For more about the theory, see Heat pump and refrigeration cycle. For details of the most common type, see air source heat pump. For a similar device for cooling only, see air conditioner. For heat pumps used to keep food cool, see refrigerator. For other uses, see Heat pump (disambiguation).

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A heat pump is a device that consumes energy (usually electricity) to transfer heat from a cold heat sink to a hot heat sink. Specifically, the heat pump transfers thermal energy using a refrigeration cycle, cooling the cool space and warming the warm space.^[1] In cold weather, a heat pump can move heat from the cool outdoors to warm a house (e.g. winter); the pump may also be designed to move heat from the house to the warmer outdoors in warm weather (e.g. summer). As they transfer heat rather than generating heat, they are more energy-efficient than other ways of heating or cooling a home.^[2]

A gaseous refrigerant is compressed so its pressure and temperature rise. When operating as a heater in cold weather, the warmed gas flows to a heat exchanger in the indoor space where some of its thermal energy is transferred to that indoor space, causing the gas to condense to its liquid state. The liquified refrigerant flows to a heat exchanger in the outdoor space where the pressure falls, the liquid evaporates and the temperature of the gas falls. It is now colder than the temperature of the outdoor space being used as a heat source. It can again take up energy from the heat source, be compressed and repeat the cycle.

Air source heat pumps are the most common models, while other types include ground source heat pumps, water source heat pumps and exhaust air heat pumps.^[3] Large-scale heat pumps are also used in district heating systems.^[4]

The efficiency of a heat pump is expressed as a coefficient of performance (COP), or seasonal coefficient of performance (SCOP). The higher the number, the more efficient a heat pump is. For example, an air-to-water heat pump that produces 6kW at a SCOP of 4.62 will give over 4kW of energy into a heating system for every kilowatt of energy that the heat pump uses itself to operate. When used for space heating, heat pumps are typically more energy-efficient than electric resistance and other heaters.

Because of their high efficiency and the increasing share of fossil-free sources in electrical grids, heat pumps are playing a role in climate change mitigation.^[5][6] Consuming 1 kWh of electricity, they can transfer 1^[7] to 4.5 kWh of thermal energy into a building. The carbon footprint of heat pumps depends on how electricity is generated, but they usually reduce emissions.^[8] Heat pumps could satisfy over 80% of global space and water heating needs with a lower carbon footprint than gas-fired condensing boilers: however, in 2021 they only met 10%.^[4]

Principle of operation

[edit]

Heat flows spontaneously from a region of higher temperature to a region of lower temperature. Heat does not flow spontaneously from lower temperature to higher, but it can be made to flow in this direction if work is performed. The work required to transfer a given amount of heat is usually much less than the amount of heat; this is the motivation for using heat pumps in applications such as the heating of water and the interior of buildings.^[9]

The amount of work required to drive an amount of heat Q from a lower-temperature reservoir such as ambient air to a higher-temperature reservoir such as the interior of a building is: $$\displaystyle W=\frac Q\mathrm COP$$ where

• $\displaystyle W$ is the work performed on the working fluid by the heat pump's compressor.
• $\displaystyle Q$ is the heat transferred from the lower-temperature reservoir to the higher-temperature reservoir.
• $\displaystyle \mathrm COP$ is the instantaneous coefficient of performance for the heat pump at the temperatures prevailing in the reservoirs at one instant.

The coefficient of performance of a heat pump is greater than one so the work required is less than the heat transferred, making a heat pump a more efficient form of heating than electrical resistance heating. As the temperature of the higher-temperature reservoir increases in response to the heat flowing into it, the coefficient of performance decreases, causing an increasing amount of work to be required for each unit of heat being transferred.^[9]

The coefficient of performance, and the work required by a heat pump can be calculated easily by considering an ideal heat pump operating on the reversed Carnot cycle:

• If the low-temperature reservoir is at a temperature of 270 K (−3 °C) and the interior of the building is at 280 K (7 °C) the relevant coefficient of performance is 27. This means only 1 joule of work is required to transfer 27 joules of heat from a reservoir at 270 K to another at 280 K. The one joule of work ultimately ends up as thermal energy in the interior of the building so for each 27 joules of heat that are removed from the low-temperature reservoir, 28 joules of heat are added to the building interior, making the heat pump even more attractive from an efficiency perspective.^{[note 1]}
• As the temperature of the interior of the building rises progressively to 300 K (27 °C) the coefficient of performance falls progressively to 9. This means each joule of work is responsible for transferring 9 joules of heat out of the low-temperature reservoir and into the building. Again, the 1 joule of work ultimately ends up as thermal energy in the interior of the building so 10 joules of heat are added to the building interior.^{[note 2]}

This is the theoretical amount of heat pumped but in practice it will be less for various reasons, for example if the outside unit has been installed where there is not enough airflow. More data sharing with owners and academics—perhaps from heat meters—could improve efficiency in the long run.^[11]

Milestones:

1748

William Cullen demonstrates artificial refrigeration.^[12]

1834

Jacob Perkins patents a design for a practical refrigerator using dimethyl ether.^[13]

1852

Lord Kelvin describes the theory underlying heat pumps.^[14]

1855–1857

Peter von Rittinger develops and builds the first heat pump.^[15]

1877

In the period before 1875, heat pumps were for the time being pursued for vapour compression evaporation (open heat pump process) in salt works with their obvious advantages for saving wood and coal. In 1857, Peter von Rittinger was the first to try to implement the idea of vapor compression in a small pilot plant. Presumably inspired by Rittinger's experiments in Ebensee, Antoine-Paul Piccard from the University of Lausanne and the engineer J. H. Weibel from the Weibel–Briquet company in Geneva built the world's first really functioning vapor compression system with a two-stage piston compressor. In 1877 this first heat pump in Switzerland was installed in the Bex salt works.^[14][16]

1928

Aurel Stodola constructs a closed-loop heat pump (water source from Lake Geneva) which provides heating for the Geneva city hall to this day.^[17]

1937–1945

During the First World War, fuel prices were very high in Switzerland but it had plenty of hydropower.^{[14]: 18â€ÅÂÂÂÂÂÂÂÂÂ}  In the period before and especially during the Second World War, when neutral Switzerland was completely surrounded by fascist-ruled countries, the coal shortage became alarming again. Thanks to their leading position in energy technology, the Swiss companies Sulzer, Escher Wyss and Brown Boveri built and put in operation around 35 heat pumps between 1937 and 1945. The main heat sources were lake water, river water, groundwater, and waste heat. Particularly noteworthy are the six historic heat pumps from the city of Zurich with heat outputs from 100 kW to 6 MW. An international milestone is the heat pump built by Escher Wyss in 1937/38 to replace the wood stoves in the City Hall of Zurich. To avoid noise and vibrations, a recently developed rotary piston compressor was used. This historic heat pump heated the town hall for 63 years until 2001. Only then was it replaced by a new, more efficient heat pump.^[14]

1945

John Sumner, City Electrical Engineer for Norwich, installs an experimental water-source heat pump fed central heating system, using a nearby river to heat new Council administrative buildings. It had a seasonal efficiency ratio of 3.42, average thermal delivery of 147 kW, and peak output of 234 kW.^[18]

1948

Robert C. Webber is credited as developing and building the first ground-source heat pump.^[19]

1951

First large scale installation—the Royal Festival Hall in London is opened with a town gas-powered reversible water-source heat pump, fed by the Thames, for both winter heating and summer cooling needs.^[18]

2019

The Kigali Amendment to phase out harmful refrigerants takes effect.

An air source heat pump (ASHP) is a heat pump that can absorb heat from air outside a building and release it inside; it uses the same vapor-compression refrigeration process and much the same equipment as an air conditioner, but in the opposite direction. ASHPs are the most common type of heat pump and, usually being smaller, tend to be used to heat individual houses or flats rather than blocks, districts or industrial processes.^[20][21]

Air-to-air heat pumps provide hot or cold air directly to rooms, but do not usually provide hot water. Air-to-water heat pumps use radiators or underfloor heating to heat a whole house and are often also used to provide domestic hot water.

An ASHP can typically gain 4 kWh thermal energy from 1 kWh electric energy. They are optimized for flow temperatures between 30 and 40 °C (86 and 104 °F), suitable for buildings with heat emitters sized for low flow temperatures. With losses in efficiency, an ASHP can even provide full central heating with a flow temperature up to 80 °C (176 °F).^[22]

As of 2023^[update] about 10% of building heating worldwide is from ASHPs. They are the main way to phase out gas boilers (also known as "furnaces") from houses, to avoid their greenhouse gas emissions.^[23]

Air-source heat pumps are used to move heat between two heat exchangers, one outside the building which is fitted with fins through which air is forced using a fan and the other which either directly heats the air inside the building or heats water which is then circulated around the building through radiators or underfloor heating which releases the heat to the building. These devices can also operate in a cooling mode where they extract heat via the internal heat exchanger and eject it into the ambient air using the external heat exchanger. Some can be used to heat water for washing which is stored in a domestic hot water tank.^[24]

Air-source heat pumps are relatively easy and inexpensive to install, so are the most widely used type. In mild weather, coefficient of performance (COP) may be between 2 and 5, while at temperatures below around −8 °C (18 °F) an air-source heat pump may still achieve a COP of 1 to 4.^[25]

While older air-source heat pumps performed relatively poorly at low temperatures and were better suited for warm climates, newer models with variable-speed compressors remain highly efficient in freezing conditions allowing for wide adoption and cost savings in places like Minnesota and Maine in the United States.^[26]

A ground source heat pump (also geothermal heat pump) is a heating/cooling system for buildings that use a type of heat pump to transfer heat to or from the ground, taking advantage of the relative constancy of temperatures of the earth through the seasons. Ground-source heat pumps (GSHPs) – or geothermal heat pumps (GHP), as they are commonly termed in North America – are among the most energy-efficient technologies for providing HVAC and water heating, using far less energy than can be achieved by burning a fuel in a boiler/furnace or by use of resistive electric heaters.

Efficiency is given as a coefficient of performance (CoP) which is typically in the range 3 – 6, meaning that the devices provide 3 – 6 units of heat for each unit of electricity used. Setup costs are higher than for other heating systems, due to the requirement to install ground loops over large areas or to drill bore holes, and for this reason, ground source is often suitable when new blocks of flats are built.^[27] Otherwise air-source heat pumps are often used instead.

Exhaust air heat pumps extract heat from the exhaust air of a building and require mechanical ventilation. Two classes exist:

• Exhaust air-air heat pumps transfer heat to intake air.
• Exhaust air-water heat pumps transfer heat to a heating circuit that includes a tank of domestic hot water.

A solar-assisted heat pump (SAHP) is a machine that combines a heat pump and thermal solar panels and/or PV solar panels in a single integrated system.^[28] Typically these two technologies are used separately (or only placing them in parallel) to produce hot water.^[29] In this system the solar thermal panel performs the function of the low temperature heat source and the heat produced is used to feed the heat pump's evaporator.^[30] The goal of this system is to get high coefficient of performance (COP) and then produce energy in a more efficient and less expensive way.

It is possible to use any type of solar thermal panel (sheet and tubes, roll-bond, heat pipe, thermal plates) or hybrid (mono/polycrystalline, thin film) in combination with the heat pump. The use of a hybrid panel is preferable because it allows covering a part of the electricity demand of the heat pump and reduce the power consumption and consequently the variable costs of the system.

A water-source heat pump works in a similar manner to a ground-source heat pump, except that it takes heat from a body of water rather than the ground. The body of water does, however, need to be large enough to be able to withstand the cooling effect of the unit without freezing or creating an adverse effect for wildlife.^[31] The largest water-source heat pump was installed in the Danish town of Esbjerg in 2023.^[32][33]

A thermoacoustic heat pump operates as a thermoacoustic heat engine without refrigerant but instead uses a standing wave in a sealed chamber driven by a loudspeaker to achieve a temperature difference across the chamber.^[34]

Electrocaloric heat pumps are solid state.^[35]

The International Energy Agency estimated that, as of 2021, heat pumps installed in buildings have a combined capacity of more than 1000 GW.^[4] They are used for heating, ventilation, and air conditioning (HVAC) and may also provide domestic hot water and tumble clothes drying.^[36] The purchase costs are supported in various countries by consumer rebates.^[37]

In HVAC applications, a heat pump is typically a vapor-compression refrigeration device that includes a reversing valve and optimized heat exchangers so that the direction of heat flow (thermal energy movement) may be reversed. The reversing valve switches the direction of refrigerant through the cycle and therefore the heat pump may deliver either heating or cooling to a building.

Because the two heat exchangers, the condenser and evaporator, must swap functions, they are optimized to perform adequately in both modes. Therefore, the Seasonal Energy Efficiency Rating (SEER in the US) or European seasonal energy efficiency ratio of a reversible heat pump is typically slightly less than those of two separately optimized machines. For equipment to receive the US Energy Star rating, it must have a rating of at least 14 SEER. Pumps with ratings of 18 SEER or above are considered highly efficient. The highest efficiency heat pumps manufactured are up to 24 SEER.^[38]

Heating seasonal performance factor (in the US) or Seasonal Performance Factor (in Europe) are ratings of heating performance. The SPF is Total heat output per annum / Total electricity consumed per annum in other words the average heating COP over the year.^[39]

Window mounted heat pumps run on standard 120v AC outlets and provide heating, cooling, and humidity control. They are more efficient with lower noise levels, condensation management, and a smaller footprint than window mounted air conditioners that just do cooling.^[40]

In water heating applications, heat pumps may be used to heat or preheat water for swimming pools, homes or industry. Usually heat is extracted from outdoor air and transferred to an indoor water tank.^[41][42]

Large (megawatt-scale) heat pumps are used for district heating.^[43] However as of 2022^[update] about 90% of district heat is from fossil fuels.^[44] In Europe, heat pumps account for a mere 1% of heat supply in district heating networks but several countries have targets to decarbonise their networks between 2030 and 2040.^[4] Possible sources of heat for such applications are sewage water, ambient water (e.g. sea, lake and river water), industrial waste heat, geothermal energy, flue gas, waste heat from district cooling and heat from solar seasonal thermal energy storage.^[45] Large-scale heat pumps for district heating combined with thermal energy storage offer high flexibility for the integration of variable renewable energy. Therefore, they are regarded as a key technology for limiting climate change by phasing out fossil fuels.^[45][46] They are also a crucial element of systems which can both heat and cool districts.^[47]

There is great potential to reduce the energy consumption and related greenhouse gas emissions in industry by application of industrial heat pumps, for example for process heat.^[48][49] Short payback periods of less than 2 years are possible, while achieving a high reduction of CO₂ emissions (in some cases more than 50%).^[50][51] Industrial heat pumps can heat up to 200 °C, and can meet the heating demands of many light industries.^[52][53] In Europe alone, 15 GW of heat pumps could be installed in 3,000 facilities in the paper, food and chemicals industries.^[4]

The performance of a heat pump is determined by the ability of the pump to extract heat from a low temperature environment (the source) and deliver it to a higher temperature environment (the sink).^[54] Performance varies, depending on installation details, temperature differences, site elevation, location on site, pipe runs, flow rates, and maintenance.

In general, heat pumps work most efficiently (that is, the heat output produced for a given energy input) when the difference between the heat source and the heat sink is small. When using a heat pump for space or water heating, therefore, the heat pump will be most efficient in mild conditions, and decline in efficiency on very cold days. Performance metrics supplied to consumers attempt to take this variation into account.

Common performance metrics are the SEER (in cooling mode) and seasonal coefficient of performance (SCOP) (commonly used just for heating), although SCOP can be used for both modes of operation.^[54] Larger values of either metric indicate better performance.^[54] When comparing the performance of heat pumps, the term performance is preferred to efficiency, with coefficient of performance (COP) being used to describe the ratio of useful heat movement per work input.^[54] An electrical resistance heater has a COP of 1.0, which is considerably lower than a well-designed heat pump which will typically have a COP of 3 to 5 with an external temperature of 10 °C and an internal temperature of 20 °C. Because the ground is a constant temperature source, a ground-source heat pump is not subjected to large temperature fluctuations, and therefore is the most energy-efficient type of heat pump.^[54]

The "seasonal coefficient of performance" (SCOP) is a measure of the aggregate energy efficiency measure over a period of one year which is dependent on regional climate.^[54] One framework for this calculation is given by the Commission Regulation (EU) No. 813/2013.^[55]

A heat pump's operating performance in cooling mode is characterized in the US by either its energy efficiency ratio (EER) or seasonal energy efficiency ratio (SEER), both of which have units of BTU/(h·W) (note that 1 BTU/(h·W) = 0.293 W/W) and larger values indicate better performance.

The carbon footprint of heat pumps depends on their individual efficiency and how electricity is produced. An increasing share of low-carbon energy sources such as wind and solar will lower the impact on the climate.

In most settings, heat pumps will reduce CO₂ emissions compared to heating systems powered by fossil fuels.^[62] In regions accounting for 70% of world energy consumption, the emissions savings of heat pumps compared with a high-efficiency gas boiler are on average above 45% and reach 80% in countries with cleaner electricity mixes.^[4] These values can be improved by 10 percentage points, respectively, with alternative refrigerants. In the United States, 70% of houses could reduce emissions by installing a heat pump.^[63][4] The rising share of renewable electricity generation in many countries is set to increase the emissions savings from heat pumps over time.^[4]

Heating systems powered by green hydrogen are also low-carbon and may become competitors, but are much less efficient due to the energy loss associated with hydrogen conversion, transport and use. In addition, not enough green hydrogen is expected to be available before the 2030s or 2040s.^[64][65]

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Large heat pump setup for a commercial building

Wiring and connections to a central air unit inside

Vapor-compression uses a circulating refrigerant as the medium which absorbs heat from one space, compresses it thereby increasing its temperature before releasing it in another space. The system normally has eight main components: a compressor, a reservoir, a reversing valve which selects between heating and cooling mode, two thermal expansion valves (one used when in heating mode and the other when used in cooling mode) and two heat exchangers, one associated with the external heat source/sink and the other with the interior. In heating mode the external heat exchanger is the evaporator and the internal one being the condenser; in cooling mode the roles are reversed.

Circulating refrigerant enters the compressor in the thermodynamic state known as a saturated vapor^[66] and is compressed to a higher pressure, resulting in a higher temperature as well. The hot, compressed vapor is then in the thermodynamic state known as a superheated vapor and it is at a temperature and pressure at which it can be condensed with either cooling water or cooling air flowing across the coil or tubes. In heating mode this heat is used to heat the building using the internal heat exchanger, and in cooling mode this heat is rejected via the external heat exchanger.

The condensed, liquid refrigerant, in the thermodynamic state known as a saturated liquid, is next routed through an expansion valve where it undergoes an abrupt reduction in pressure. That pressure reduction results in the adiabatic flash evaporation of a part of the liquid refrigerant. The auto-refrigeration effect of the adiabatic flash evaporation lowers the temperature of the liquid and-vapor refrigerant mixture to where it is colder than the temperature of the enclosed space to be refrigerated.

The cold mixture is then routed through the coil or tubes in the evaporator. A fan circulates the warm air in the enclosed space across the coil or tubes carrying the cold refrigerant liquid and vapor mixture. That warm air evaporates the liquid part of the cold refrigerant mixture. At the same time, the circulating air is cooled and thus lowers the temperature of the enclosed space to the desired temperature. The evaporator is where the circulating refrigerant absorbs and removes heat which is subsequently rejected in the condenser and transferred elsewhere by the water or air used in the condenser.

To complete the refrigeration cycle, the refrigerant vapor from the evaporator is again a saturated vapor and is routed back into the compressor.

Over time, the evaporator may collect ice or water from ambient humidity. The ice is melted through defrosting cycle. An internal heat exchanger is either used to heat/cool the interior air directly or to heat water that is then circulated through radiators or underfloor heating circuit to either heat or cool the buildings.

Heat input can be improved if the refrigerant enters the evaporator with a lower vapor content. This can be achieved by cooling the liquid refrigerant after condensation. The gaseous refrigerant condenses on the heat exchange surface of the condenser. To achieve a heat flow from the gaseous flow center to the wall of the condenser, the temperature of the liquid refrigerant must be lower than the condensation temperature.

Additional subcooling can be achieved by heat exchange between relatively warm liquid refrigerant leaving the condenser and the cooler refrigerant vapor emerging from the evaporator. The enthalpy difference required for the subcooling leads to the superheating of the vapor drawn into the compressor. When the increase in cooling achieved by subcooling is greater that the compressor drive input required to overcome the additional pressure losses, such a heat exchange improves the coefficient of performance.^[67]

One disadvantage of the subcooling of liquids is that the difference between the condensing temperature and the heat-sink temperature must be larger. This leads to a moderately high pressure difference between condensing and evaporating pressure, whereby the compressor energy increases.

Pure refrigerants can be divided into organic substances (hydrocarbons (HCs), chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs), hydrofluorocarbons (HFCs), hydrofluoroolefins (HFOs), and HCFOs), and inorganic substances (ammonia (NH
₃), carbon dioxide (CO
₂), and water (H
₂O)^[68]).^[69] Their boiling points are usually below −25 °C.^[70]

In the past 200 years, the standards and requirements for new refrigerants have changed. Nowadays low global warming potential (GWP) is required, in addition to all the previous requirements for safety, practicality, material compatibility, appropriate atmospheric life,^{[clarification needed]} and compatibility with high-efficiency products. By 2022, devices using refrigerants with a very low GWP still have a small market share but are expected to play an increasing role due to enforced regulations,^[71] as most countries have now ratified the Kigali Amendment to ban HFCs.^[72] Isobutane (R600A) and propane (R290) are far less harmful to the environment than conventional hydrofluorocarbons (HFC) and are already being used in air-source heat pumps.^[73] Propane may be the most suitable for high temperature heat pumps.^[74] Ammonia (R717) and carbon dioxide (R-744) also have a low GWP. As of 2023^[update] smaller CO
₂ heat pumps are not widely available and research and development of them continues.^[75] A 2024 report said that refrigerants with GWP are vulnerable to further international restrictions.^[76]

Until the 1990s, heat pumps, along with fridges and other related products used chlorofluorocarbons (CFCs) as refrigerants, which caused major damage to the ozone layer when released into the atmosphere. Use of these chemicals was banned or severely restricted by the Montreal Protocol of August 1987.^[77]

Replacements, including R-134a and R-410A, are hydrofluorocarbons (HFC) with similar thermodynamic properties with insignificant ozone depletion potential (ODP) but had problematic GWP.^[78] HFCs are powerful greenhouse gases which contribute to climate change.^[79][80] Dimethyl ether (DME) also gained in popularity as a refrigerant in combination with R404a.^[81] More recent refrigerants include difluoromethane (R32) with a lower GWP, but still over 600.

Devices with R-290 refrigerant (propane) are expected to play a key role in the future.^[74][85] The 100-year GWP of propane, at 0.02, is extremely low and is approximately 7000 times less than R-32. However, the flammability of propane requires additional safety measures: the maximum safe charges have been set significantly lower than for lower flammability refrigerants (only allowing approximately 13.5 times less refrigerant in the system than R-32).^[86][87][88] This means that R-290 is not suitable for all situations or locations. Nonetheless, by 2022, an increasing number of devices with R-290 were offered for domestic use, especially in Europe.^{[citation needed]}

At the same time,^[when?] HFC refrigerants still dominate the market. Recent government mandates have seen the phase-out of R-22 refrigerant. Replacements such as R-32 and R-410A are being promoted as environmentally friendly but still have a high GWP.^[89] A heat pump typically uses 3 kg of refrigerant. With R-32 this amount still has a 20-year impact equivalent to 7 tons of CO₂, which corresponds to two years of natural gas heating in an average household. Refrigerants with a high ODP have already been phased out.^{[citation needed]}

Financial incentives aim to protect consumers from high fossil gas costs and to reduce greenhouse gas emissions,^[90] and are currently available in more than 30 countries around the world, covering more than 70% of global heating demand in 2021.^[4]

Food processors, brewers, petfood producers and other industrial energy users are exploring whether it is feasible to use renewable energy to produce industrial-grade heat. Process heating accounts for the largest share of onsite energy use in Australian manufacturing, with lower-temperature operations like food production particularly well-suited to transition to renewables.

To help producers understand how they could benefit from making the switch, the Australian Renewable Energy Agency (ARENA) provided funding to the Australian Alliance for Energy Productivity (A2EP) to undertake pre-feasibility studies at a range of sites around Australia, with the most promising locations advancing to full feasibility studies.^[91]

In an effort to incentivize energy efficiency and reduce environmental impact, the Australian states of Victoria, New South Wales, and Queensland have implemented rebate programs targeting the upgrade of existing hot water systems. These programs specifically encourage the transition from traditional gas or electric systems to heat pump based systems.^{[92][93][94][95][96]}

In 2022, the Canada Greener Homes Grant^[97] provides up to $5000 for upgrades (including certain heat pumps), and $600 for energy efficiency evaluations.

Purchase subsidies in rural areas in the 2010s reduced burning coal for heating, which had been causing ill health.^[98]

In the 2024 report by the International Energy Agency (IEA) titled "The Future of Heat Pumps in China," it is highlighted that China, as the world's largest market for heat pumps in buildings, plays a critical role in the global industry. The country accounts for over one-quarter of global sales, with a 12% increase in 2023 alone, despite a global sales dip of 3% the same year.^[99]

Heat pumps are now used in approximately 8% of all heating equipment sales for buildings in China as of 2022, and they are increasingly becoming the norm in central and southern regions for both heating and cooling. Despite their higher upfront costs and relatively low awareness, heat pumps are favored for their energy efficiency, consuming three to five times less energy than electric heaters or fossil fuel-based solutions. Currently, decentralized heat pumps installed in Chinese buildings represent a quarter of the global installed capacity, with a total capacity exceeding 250 GW, which covers around 4% of the heating needs in buildings.^[99]

Under the Announced Pledges Scenario (APS), which aligns with China's carbon neutrality goals, the capacity is expected to reach 1,400 GW by 2050, meeting 25% of heating needs. This scenario would require an installation of about 100 GW of heat pumps annually until 2050. Furthermore, the heat pump sector in China employs over 300,000 people, with employment numbers expected to double by 2050, underscoring the importance of vocational training for industry growth. This robust development in the heat pump market is set to play a significant role in reducing direct emissions in buildings by 30% and cutting PM2.5 emissions from residential heating by nearly 80% by 2030.^[99][100]

To speed up the deployment rate of heat pumps, the European Commission launched the Heat Pump Accelerator Platform in November 2024.^[101] It will encourage industry experts, policymakers, and stakeholders to collaborate, share best practices and ideas, and jointly discuss measures that promote sustainable heating solutions.^[102]

As of 2022: heat pumps have no Value Added Tax (VAT) although in Northern Ireland they are taxed at the reduced rate of 5% instead of the usual level of VAT of 20% for most other products.^[103] As of 2022^[update] the installation cost of a heat pump is more than a gas boiler, but with the "Boiler Upgrade Scheme"^[104] government grant and assuming electricity/gas costs remain similar their lifetime costs would be similar on average.^[105] However lifetime cost relative to a gas boiler varies considerably depending on several factors, such as the quality of the heat pump installation and the tariff used.^[106] In 2024 England was criticised for still allowing new homes to be built with gas boilers, unlike some other counties where this is banned.^[107]

The High-efficiency Electric Home Rebate Program was created in 2022 to award grants to State energy offices and Indian Tribes in order to establish state-wide high-efficiency electric-home rebates. Effective immediately, American households are eligible for a tax credit to cover the costs of buying and installing a heat pump, up to $2,000. Starting in 2023, low- and moderate-level income households will be eligible for a heat-pump rebate of up to $8,000.^[108]

In 2022, more heat pumps were sold in the United States than natural gas furnaces.^[109]

In November 2023 Biden's administration allocated 169 million dollars from the Inflation Reduction Act to speed up production of heat pumps. It used the Defense Production Act to do so, because according to the administration, energy that is better for the climate is also better for national security.^[110]

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• Media related to Heat pumps at Wikimedia Commons