Tube Sheets / Headers

Tube sheets (also called tube plates) are thick, perforated plates that secure and seal the ends of heat exchanger tubes within a shell-and-tube configuration. Headers (or manifolds) are chambers attached to tube sheets that distribute incoming fluid to multiple tubes (inlet header) or collect fluid from tubes (outlet header). In tail gas heaters, these components create the primary heat transfer surface where combustion gases transfer thermal energy to process fluids through tube walls.

Tube sheets provide structural support and pressure boundary between shell-side and tube-side fluids. Headers ensure even fluid distribution across multiple parallel tubes to maximize heat transfer surface area utilization. The working principle involves: 1) Inlet header distributes cold process fluid evenly to all tubes, 2) Tubes conduct heat from hot tail gases to the fluid, 3) Outlet header collects heated fluid from all tubes, 4) Tube sheets maintain tube alignment and prevent fluid mixing between shell and tube sides.