External Herms Heat Exchanger Design

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egolds77

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hi

I'm building a external-HERMS and eas wanting to hear from people about their external heat exchanger design specifications. I've read the about the ideal design guides but would like to hear from you guys about yours. i.e. vessel size (L), coil size - length and diameter, and performance from them (are you getting 1C/min)?

Cheers
:icon_chickcheers:
 
I had a 10L plastic bucket with a 2000w element and 3m of 1/2 inch copper tube - heavily insulated

Temp measured at wort return to mash tun - was getting around about 1/min out of it when my flow rates were where I wanted them - PID controller through a mechanical relay.

I found I was getting a bit of overshoot and lag with the HERMS and have changed to a RIMS instead ... still deciding whether I like it better or not. But I do get faster response and less overshoot. Marginally better rate of change, still around 1/min though.

If I changed back to HERMS I would try to cram roughly the same length coil into a smaller heat-ex container. 5L or less if I could manage it, so that the system's response time was a bit snappier. I might even try to get a coil professionally wound and cram it all into a couple of litres.

I will eventually get around to building a pretty control box - when I do the mechanical relays will be getting the flick and SSR control will be in
 
I have an old cooking pot that I butchered. With the coil installed, it holds 6l of water. I have a 1500W element in it. The coil is 25' (approx 8m) of 3/8" ID (approx 9.5mm) copper tubing. When the system is ramping to a new temperature, the max difference between the temperature of the water in the HE and the temperature of the mash itself is 3C. When ramping I get about 1C every 3-4 minutes, but I'm doing double batches (approx 42l finished volume) and only with a 1500W element. I was limited to ordinary 120V household voltage - hooking up a 240V system would have been too big of a pain to do. Everything is insulated - even the lines.
 
I use a 15L pot from Kmart (about $20) and made Bucket'o'death style setup with the element out of a Sollys/Sams kettle in the base of the pot. The coil is about 4.0m long 1/2" Copper tube. The HE is contolled with a Tempmate and the probe is in a thermowell at the entry side to the heat exchange. I havent timed the ramp up as yet but I havent overshot either. Although from memory it was about 10 min for a single batch.

One trick I found worked well (thanks to AHB) when making the coil fill the tube with sand before bending, stops it from kinking. Another is don't insulate the HE. A few sites I looked at had isssues with overshooting temp with an insulated HE and after removing it didn't have any problems. I'm not speaking for anyone elses system though, some have insulated HE and never have any issues.

Cheers

Sully
 
Sully: What temp do you keep the water in the HE at and do you pump the wort through until you reach the desired temp in the MT. My thoughts were to hold the water temp in the HE at just under boiling IE: 95C and keep circulating to raise temps in MT until I hit the desired temp not withstanding overshoot of course which would need to be ironed out during setting up.

Cheers
 
You will get a better result if you design your HERMS to be as efficient as possible in every aspect. What ever vessel you use go for an insulation type surrounding on the outside. Photo is mine but I have no electrical expertise so I just cut the top off a SS HE and dangle a Hand Held Element into it.

28122008_002_.jpg
 
Sully: What temp do you keep the water in the HE at and do you pump the wort through until you reach the desired temp in the MT. My thoughts were to hold the water temp in the HE at just under boiling IE: 95C and keep circulating to raise temps in MT until I hit the desired temp not withstanding overshoot of course which would need to be ironed out during setting up.

Cheers

Regarding HE water temp. My HE temp adjusts to whatever the temp needs to be to have the wort exiting the coil at my exact desired temperature. I actually measure and control my temp from just above my sparge arm as it enters back into the mash tun which isn't very far from the HE coil exit anyway). Frankly I dont care, nor need to know what the HE water temp is as long as my wort coming out of that coil is exactly where I want it to be, which is my set point. If that means my HE is boiling well that's fine because my wort temp is still only at 65C or whatever the temp is set at. The reality is that my HE temp is usually at my set point temp, maybe a degree above. if I want to raise temp I change the set point value on the controller and a minute or two later the temp exiting the HE is at the new temp (assuming the jump isn't too high). I have a very small volume of water in my HE (4L) and use a 1200W element with stirring and it works fine and responds very quickly because it's such a small volume (300W/L). Sounds small but that 300W/L is actually better than a 2400W element in 10L (240W/L), well the results seem to follow that logic anyway :unsure: . But I do also only use my HE to maintain temp and mash out, I dont bother to step mash and if I did I'd probably employ the additional help of my hand held element to make things fast and easy. Having said that it will raise the temp just fine as I use it to mash out.

What I do in initial set up is get my HE going, mash water volume corrent and pumping around until I have everything sitting at my desired strike temp. Then I turn the pump off and HE element, set my PV (set controller to my desired temp) and then start doughing in. By the time I've doughed in, mixed it thoroughly, allowed a minute to settle, then I start opening the valve slowly to start drawing liquid through and set the bed for the mash my HE has usually dropped a degree or two and with the first running it pulls the HE water temp down to the desired temp. That sounds way more complicated than it is but it has worked great and because there is only 4L of water in there it doesn't take much for it to auto correct to the necessary temp.

RE setting the HE temp at 95C, not a real good idea IMHO. If you are holding your HE water at 95C that means if your heat exchanger is any good then the wort exiting the coil is going to be 95 also (if it can pick up temp that fast which it should get pretty close I'd say, but that is a big temp differential). In the meantime you will be creaming those enzymes going through the heat exchanger, and probably quite quickly too (the higher the temp the faster denaturing occurs). This is not really the idea of a herms if you ask me. It may work(?) but I wouldn't do it that way.

I'll also second Jimmyjacks comments, insulate your HE cause you might as well. In fact for the best results I'd insulate your hoses too if you can. Silly to pull hot liquid out, allow it to cool, heat it up again, let it cool and put it back from where it came at the same temp at what it would have been if you just left it there. Insulation on your HE will have nothing to do with temp overshoot unless you need to shed temp from you HE because you are already over temp, which indicates a problem in how you've set up your control system and running your system. I suspect that overshoot problem mentioned above was because the HE water temp was hotter than it needed to be before the wort was pumped through and hence it needed to loose heat to get back to the required temp. The lack of insulation would speed that up. That's why I pump everything round for a while until the system is in equilibrium and stable before I let grain hit the system. Given how quick conversion is done, if you are spending 15-20 mins fiddling trying to hit your temp then you blew it IMO and a heap of the conversion is already done. Dont belive me, do an iodine test at 15mins and see what it reveals. This depends on grain bill of course but if you dont have large amounts of adjuncts or highly kilned malts it will churn through that starch in no time.

Good luck with it. Ok, tired of rambling on and spewing my thoughts. Hope it might give some help.
Justin
 
At risk of sounding like a c*nt, there is a topic asking pretty much this exact question started every week or 2. Did you try the search function?
 
Justin pretty well summed up my thoughts -

BUT

Not that I disagree with insulating hoses, its more that I cannot see the point when the flow rate leaving the MT - entering the HE - leaving the HE - returning to the MT would be all of 5-15 seconds (if that) between vessels, temperature drop will be a poofteenth of a degree if any. I would be more concerned at that level only if you have extra long hoses or in freezing cold conditions. The only effect insulation will have on the heat exchange would be heating the water faster to increasing ramping times. It's something the boffins will probably be able to explain better.


Well thats my theory and works for me, but I'm more than likely wrong as I am far from being an expert on the matter. Just suck-it-n-see? What works for one may not work for another.

Cheers

Sully
 
Justin pretty well summed up my thoughts -

BUT

Not that I disagree with insulating hoses, its more that I cannot see the point when the flow rate leaving the MT - entering the HE - leaving the HE - returning to the MT would be all of 5-15 seconds (if that) between vessels, temperature drop will be a poofteenth of a degree if any. I would be more concerned at that level only if you have extra long hoses or in freezing cold conditions. The only effect insulation will have on the heat exchange would be heating the water faster to increasing ramping times. It's something the boffins will probably be able to explain better.


Well thats my theory and works for me, but I'm more than likely wrong as I am far from being an expert on the matter. Just suck-it-n-see? What works for one may not work for another.

Cheers

Sully

In my experience the heat loss is (somewhat) significant. I had a probe on the exit of my HE and at the end of the hose returning the wort to my mash. Over about 50cm of silicon hose I lost over a degree.

TBH I reckon HERMS is a crock, never experience any advantage from it, so I ditched it :p I guess it makes my opinions invalid lol
 
Thanks for the advice. I did do a search but couldn't find anything helpful. I find the search function is not very helpful at times, quite obscure with its findings and not necassarly totally relavent.
 
....... flow rate leaving the MT - entering the HE - leaving the HE - returning to the MT would be all of 5-15 seconds (if that) between vessels, temperature drop will be a poofteenth of a degree if any.
Sully

Valid. :icon_cheers:

I haven't insulated my lines, they are silicon and short so I figured the same. Some people do go copper though which should be worse, if it's worth considering is up to the individual. I have seen a few with crazy long lines too though. It can get a little bit nippley in Tassie :icon_chickcheers:
 
Yes Justin I have run into this problem and have had to adjust my suggested temps in beersmith 5-7C higher, but hey we get to lager brewing earlier.

Cheers :beer:
 

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