Advancements in heat exchangers for enhanced efficiency and sustainability

Heat exchangers play a pivotal role in optimising energy usage and improving performance in various industries. According to Yash Sharma, Assistant Manager, Sales cum Development, Spirotech Heat Exchangers, recent innovations in compact designs, nanotechnology, and sustainable materials are shaping the future of heat exchange technology. These advancements are set to drive energy efficiency and sustainability across various applications.

Please discuss the role of heat exchangers in different sectors, such as HVAC, automotive, and manufacturing, in effectively transferring thermal energy.
Heat exchangers play a crucial role in various industries by efficiently transferring thermal energy between different mediums. Some sectors where heat exchangers play a vital role in various industries are mentioned herein.

HVAC&R industry, including the transport segment: Heat exchangers help cool the air by transferring heat from indoors to a refrigerant. This heat is then transferred outside with the help of a Compressor. In heating systems, the process is the complete opposite. Heat exchangers switch gears and move heat from a hot fluid, such as hot water, steam, or refrigerant, to the air, which, in turn, warms up the indoor space. In ventilation systems, heat exchangers capture heat from the air. They even help save energy by recycling heat from outgoing air to warm up the incoming fresh air in ventilation systems.

Automotive Industry: Your car would be in trouble without heat exchangers, especially under the hood. Heat exchangers – often in the form of radiators – transfer heat away from the engine coolant, preventing the engine from overheating. Automotive air conditioning systems use heat exchangers to cool and dehumidify the air inside the vehicle, ensuring passenger comfort.

Manufacturing Industry: In manufacturing, heat exchangers are like the conductors of a temperature. They facilitate precise temperature control in various manufacturing processes, such as metal forming, plastic moulding, and chemical/process industries. In various industries, heat exchangers have a nifty role. They help recover and recycle the heat that usually goes to waste during production. This reduces energy wastage and also enhances overall energy efficiency.

In all these applications, the effectiveness of heat exchangers is crucial. They are built to make the most of the surface area available for transferring heat, ensuring that thermal energy is exchanged efficiently between fluids or between a fluid and a solid surface. This aids industries in conserving energy and cutting expenses, helps maintain ideal working conditions and improves human comfort.

What new heat exchanger design and materials enhance energy efficiency and sustainability across different applications?
Recently, we have witnessed significant advancements in the design and materials used in heat exchangers, contributing to enhanced energy efficiency and sustainability across various applications. Here, I delve into some advancements in compact and microgroove heat exchangers, nanotechnology, and sustainable materials.

Compact and microgroove heat exchangers have intricate geometries and small diameter tubes. This unique design accelerates heat transfer and reduces the amount of refrigerant needed. These innovations result in many benefits, including minimising the required materials, shrinking the overall size, increasing efficiency, and improving performance. Additionally, less refrigerant usage directly contributes to environmental protection, addressing climate change and promoting sustainability.

These advanced heat exchangers find applications in various fields, such as cooling electronics, enhancing the performance of household appliances, and supporting technology-driven areas.

Nanotechnology is revolutionising the heat exchanger game. It is all about the materials, like nanoparticles and nanofluids, that bring some heat-conducting severe power to the table. These materials enhance the heat transfer rates. But that is not all. Heat exchangers are also getting a makeover with nanostructured surfaces and coatings. These high-tech additions work like magic, making heat exchangers more efficient by improving the flow of fluids and preventing fouling.

Nanotechnology-enhanced heat exchangers involve HVAC systems, electronics cooling to prevent overheating, and the world of renewable energy technologies. It is all about taking heat transfer to the next level.

To lessen the environmental footprint, heat exchangers are now being built using sustainable and eco-friendly materials like bio-based polymers and recyclable alloys. Their design prioritizes recyclability and easy disassembly, reducing waste and improving end-of-life handling. Across different industries, adopting sustainable heat exchangers aligns with their environmental objectives and regulatory requirements.

What challenges do engineers and designers face while selecting the appropriate type of heat exchanger?
Engineers and designers face several hurdles when choosing the right heat exchanger for specific tasks. These challenges encompass understanding the project’s needs, selecting the appropriate refrigerant, accommodating spatial limitations, ensuring sustainability, and adhering to regulatory requirements. Precisely determining the system’s temperature and pressure criteria is paramount, as different heat exchangers are suitable for distinct temperature and pressure ranges. 

Additionally, calculating the necessary heat transfer rate aids in selecting a heat exchanger with the right surface area and fluid flow rate.

In light of the growing need to reduce reliance on factors contributing to global warming, selecting a refrigerant that complies with environmental laws and mitigates the impact of climate change is increasingly important.

What growth do you envisage for a Microchannel heat exchanger?
Microchannel heat exchangers have gained attention due to their compact dimensions, impressive efficiency, and lightweight construction. This technology brings numerous benefits across various applications, such as automotive, aerospace, electronics cooling, and HVAC systems. However, despite these advantages, microchannels have struggled to impact the domestic market significantly. This is primarily due to challenges like corrosion protection, refrigerant selection, and limitations in field service capabilities.

Please share the latest developments taking place at your facility.
Spirotech has consistently been at the forefront of introducing cutting-edge technologies to the heat exchangers market. In 1996, we pioneered using compact, high-efficiency coils with 7 mm tubes in India. Our commitment to innovation continued with the introducing of Aluminum tube – Aluminum fin coils in 2012, a first in India, followed by 5 mm copper coils in 2013, also a pioneering move in the Indian market. Adopting 5 mm tube Heat Exchangers has set a standard for improved efficiency and reduced refrigerant consumption. Continuing this tradition, we are currently focused on developing Heat Exchangers with Inner Grooved Tubes (IGT), a technology expected to play a significant role in the global transport refrigeration market.