Heat Exchanger Guide
In this heat exchanger guide, we’ll explore how heat exchangers work, their different types, industry applications, pros and cons, and emerging innovations in the industry. Our heat exchanger guide will provide you with the knowledge you need to be able to make an informed decision for what type of heat exchanger is right for you.
What Is the Purpose of a Heat Exchanger?
A heat exchanger transfers thermal energy from a hotter fluid or gas to a cooler one. This can be for heating or cooling processes. A barrier such as a solid wall separates the two fluids, allowing heat to flow while keeping them from coming into contact. This process boosts energy efficiency by recovering heat that would otherwise go to waste. Read below to see the different types of heat exchangers our heat exchanger guide covers.
Types of Heat Exchangers
There are several types of heat exchangers available, each designed for specific conditions and applications. At InKorr, we offer a comprehensive range including:
Plate Heat Exchangers: These consist of multiple thin, corrugated plates that create channels for fluid flow. They offer a high surface area for heat transfer, making them extremely efficient. They have a compact design, and are easy to expand or maintain.
Shell and Tube Heat Exchangers: Shell and tube units consist of a bundle of tubes enclosed within a cylindrical shell. One fluid flows through the tubes while the other flows over them within the shell. They are ideal for high-pressure and high-temperature applications and are easy to clean and service.
Graphite and Non-Metallic Heat Exchangers: These are specifically engineered for handling corrosive fluids. Graphite offers exceptional thermal conductivity, superior corrosion resistance, and a long service life.
Crossflow Welded Plate Heat Exchangers: Crossflow combines the benefits of plate technology with the strength of welded construction. They are designed for high-pressure duties where a fully gasket-free design is needed, enhancing durability and thermal performance.
Shell and Plate Heat Exchangers: A hybrid design that integrates plates within a shell. They combine the high efficiency of plate heat exchangers with the robust construction of shell-and-tube designs, making them suitable for demanding applications involving pressure or temperature variations.
Spiral Heat Exchangers: Built with two flat surfaces wound into a spiral, these units are compact, self-cleaning, and highly efficient. Their design resists clogging, makes maintenance easier, and is ideal for viscous fluids.
Applications Across Industries
Heat exchangers play a vital role in a wide array of industries. In power plants, they transfer heat from one process to another, often converting steam to mechanical energy. Chemical processors and oil refineries rely on heat exchangers to manage extreme temperatures and pressures during chemical reactions. In HVAC systems, they regulate indoor temperatures by transferring heat between air and fluid systems.
Food processing and dairy industries use heat exchangers to pasteurise, cook, or cool ingredients efficiently. The pharmaceutical sector employs them for maintaining precise temperature control during production. Laboratories, mining operations, and the automotive industry (especially in radiators) all benefit from specialised heat exchanger designs to optimise their operations.
Heat Exchanger Guide: How Design Affects Efficiency and Performance
The efficiency of a heat exchanger depends heavily on its design, flow characteristics, and how well it matches the demands of the application. Plate heat exchangers typically deliver the highest thermal efficiency. Their corrugated plates create highly turbulent flow even at low fluid velocities, which maximises heat transfer between fluids. The compact design and large surface area also contribute to quick temperature changes and minimal heat loss.
Shell and tube heat exchangers provide moderate to high efficiency. They are well-suited for high-pressure and high-temperature applications where other types may struggle. Their durability and ability to handle large heat duties make them a reliable choice in demanding industrial settings.
Spiral heat exchangers also perform at a high level due to their single-channel flow path. This unique design promotes consistent turbulence, which improves heat transfer while helping to minimise fouling. Their self-cleaning nature makes them particularly efficient in systems where scaling or contamination might otherwise reduce performance.
Selecting the right type of heat exchanger ensures optimal energy use, lower operational costs, and more reliable process control. Matching the efficiency characteristics of the design to the specific application is key to achieving long-term performance benefits.
Can Heat Exchangers Be Repaired?
Technicians can repair many heat exchangers, and doing so is often more economical than a full replacement. The repairability depends largely on the exchanger’s design and the extent of the damage. For shell and tube heat exchangers, repairs can include plugging leaking tubes to isolate them from the system, replacing damaged tubes, or welding cracks or wear spots in the shell. Technicians can remove and replace tube bundles when necessary, making these exchangers highly serviceable.
In plate heat exchangers, technicians can disassemble the unit to replace individual plates and gaskets that have become worn, cracked, or corroded. Technicians can thoroughly clean and refurbish the frame to restore performance and extend operational life. Re-gasketing, reassembly, and pressure testing are standard steps in this process.
Timely repairs not only prevent larger failures but also reduce downtime and cut costs associated with emergency shutdowns. With proper maintenance and repair, many heat exchangers can remain in service for decades.
What Affects the Lifespan of a Heat Exchanger?
The lifespan of a heat exchanger is influenced by multiple interrelated factors. One of the most significant is the nature of the fluids running through it. Corrosive chemicals, high-salinity water, or fluids with suspended solids can cause internal erosion, corrosion, and fouling, all of which degrade performance and shorten service life.
Water quality is especially critical, as minerals can accumulate on internal surfaces, forming scale that restricts flow and reduces thermal efficiency. Similarly, dirty or particle-laden fluids can clog passageways and create uneven flow patterns, putting additional strain on components.
Thermal and pressure conditions also play a major role. Repeated exposure to high temperatures can cause gaskets, seals, and certain materials to degrade, especially if they are not rated for those conditions. High operating pressure can stress welds and joints, increasing the risk of mechanical failure.
Beyond the working environment, maintenance practices significantly affect longevity. Routine inspections, cleaning, and diagnostic testing help catch early warning signs like pressure drops, leaks, or unusual temperature differences. Scheduled servicing ensures the exchanger continues to operate efficiently and safely.
Lastly, the initial build quality, including materials used and adherence to industry standards, determines how well a heat exchanger will handle operational stresses over time. Units built with premium materials and proper design tolerances tend to last longer, especially in demanding industrial applications.
Are Heat Exchangers Expensive?
The cost of a heat exchanger depends on several factors, including its size, material, pressure rating, and construction complexity.
Simple designs like brazed plate exchangers can be very cost-effective, especially for smaller systems, while complex custom-built shell and tube units used in large industrial processes can be quite expensive.
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