What is a shell and tube heat exchanger and how does it work?

A shell and tube heat exchanger transfers heat between two fluids by passing one fluid through a bundle of tubes and the other around the outside within a sealed shell. Heat transfers across the tube walls without mixing the fluids. The design allows for high pressure and temperature resistance, making it suitable for heavy-duty industrial use.

Where are shell and tube heat exchangers commonly used?

Shell and tube heat exchangers are widely used in industries such as oil and gas, chemical processing, power generation, HVAC, mining, and food and beverage production. Their versatility and durability make them ideal for both clean and contaminated process fluids across a broad range of temperatures and pressures.

What are the benefits of using a shell and tube heat exchanger?

Shell and tube heat exchangers provide excellent thermal performance, robust mechanical strength, and flexibility in handling high-pressure or corrosive applications. They can also be configured for easy maintenance and long service life, supporting reliable operation in demanding industrial environments.

How do I choose the right type of shell and tube heat exchanger?

Selection depends on your process conditions, including fluid type, temperature and pressure range, fouling tendency, and space limitations. InKorr offers standard, engineered, and corrugated tube and shell exchangers to suit different operational needs and performance targets.

What’s the difference between standard, engineered, and corrugated shell and tube heat exchangers?

Standard exchangers are designed for general-purpose use with common fluids and moderate conditions. Engineered units are customised for specialised or extreme environments. Corrugated designs enhance turbulence, improving efficiency and reducing fouling in more demanding or efficiency-focused applications.

How often should a shell and tube heat exchanger be serviced?

Service intervals vary by application and fluid type. Systems using clean water may only require inspection every few years, while those exposed to fouling or corrosive media should be checked annually or more frequently. Regular cleaning and inspection prevent efficiency loss and costly downtime.

What are common signs a shell and tube heat exchanger needs maintenance?

Watch for reduced heat transfer, increased pressure drop, unusual temperature readings, or visible leaks. These symptoms may indicate fouling, tube blockage, or material wear. Early maintenance can help avoid significant process disruption or equipment damage.

How much does a shell and tube heat exchanger cost?

The cost of a shell and tube heat exchanger varies depending on size, material, and complexity. While the initial price tag is usually higher than compact alternatives like plate heat exchangers, shell and tube units are often preferred when handling high pressures, high temperatures, larger heat duties, or applications requiring a close approach temperature. This makes them a smart long-term investment for demanding industrial environments.

What causes fouling in shell and tube heat exchangers?

Fouling is typically caused by scale, biological growth, or particulates in the process fluid. Proper material selection, flow management, and cleaning schedules help reduce fouling and extend system life.

Can I clean a shell and tube heat exchanger myself?

Cleaning difficulty depends on the design. Floating head exchangers are generally the easiest to clean, followed by U-tube models, while fixed-tube designs are the most challenging. Although some cleaning can be done in-house, the most effective and safest option is to have a professional service the unit regularly. InKorr offers full cleaning and servicing support if required.

Do shell and tube heat exchangers work with aggressive or corrosive fluids?

Yes, provided the correct materials are selected. For aggressive media, corrosion-resistant alloys can be used to prevent corrosion and extend unit life.

What is a plate heat exchanger and how does it work?

A plate heat exchanger transfers heat between two fluids using a series of thin, corrugated metal plates. Each fluid flows through alternating channels, allowing heat to transfer efficiently without the fluids mixing. The corrugated design enhances turbulence, which increases heat transfer rates and reduces fouling.

Where are plate heat exchangers commonly used?

Plate heat exchangers are widely used in HVAC, food and beverage processing, chemical manufacturing, power generation, and renewable energy systems. Their high efficiency and compact design make them ideal for both clean and challenging process fluids.

What are the benefits of using a plate heat exchanger?

They offer high thermal efficiency, compact footprint, easy maintenance (especially gasketed models), and the ability to handle close temperature approaches. They also support heat recovery, helping to reduce energy consumption and operational costs.

How do I choose the right type of plate heat exchanger?

Selection depends on your process conditions, including fluid type, temperature and pressure, fouling risk, space constraints, and maintenance expectations. InKorr offers brazed, gasketed, semi-welded, welded, and shell and plate models tailored to these factors.

What’s the difference between brazed and gasketed plate heat exchangers?

Brazed plate heat exchangers are compact, sealed units ideal for high-pressure, low-maintenance systems. Gasketed exchangers are larger but can be easily opened for cleaning or reconfiguration, making them better suited for fluids that foul or require frequent servicing.

How often should a plate heat exchanger be serviced?

Service frequency varies by application. Clean fluids in HVAC systems may only require servicing every 2–3 years, while fouling-prone processes may need inspection or cleaning annually or more often. Regular maintenance prevents efficiency loss and equipment failure.

What are common signs a plate heat exchanger needs maintenance?

Watch for reduced heat transfer, increased pressure drop, unusual temperature readings, or visible leaks. These may signal fouling, worn gaskets, or flow blockages. Early intervention helps avoid downtime and costly repairs.

How much does a plate heat exchanger cost?

Costs vary depending on type, size, materials, and configuration. Small commercial units may start around $1,000, while larger or custom industrial units can exceed $100,000. We provide tailored quotes based on your requirements.

What causes fouling in plate heat exchangers?

Fouling is typically caused by scale, biological growth, or particulates in the process fluid. Selecting the right materials and maintaining proper cleaning schedules help reduce fouling and extend system life.

Can I clean a plate heat exchanger myself?

Gasketed models can be opened for manual or CIP (clean-in-place) cleaning. Always follow manufacturer or service provider guidelines to avoid damaging the plates or gaskets. InKorr offers full cleaning and servicing support if required.

Do plate heat exchangers work with aggressive or corrosive fluids?

Yes, provided the correct materials are selected. For aggressive media, semi-welded designs can be used to prevent corrosion and extend unit life.

Shell and Tube Heat Exchangers

At InKorr, we deliver shell and tube heat exchangers built for long-term reliability and high performance in industrial and commercial environments. Our systems are designed to meet the precise thermal requirements of heating, cooling, condensation, and evaporation processes across a wide range of industries. Each unit is carefully selected or custom-engineered based on fluid properties, pressure, temperature, and installation needs, ensuring maximum heat transfer efficiency and seamless system integration.

Our product range includes standard, engineered, and corrugated shell and tube designs. This diversity allows us to support everything from general-purpose heating and cooling systems to demanding, high-pressure industrial applications. Whether you’re upgrading existing equipment or commissioning a new project, our engineering team works closely with you to design and deliver robust, energy-efficient solutions that optimise uptime and reduce operating costs.

Explore our full range online or speak with our engineering team here to find the right solution for your needs.

Our Shell and Tube Heat Exchanger Types

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Standard Shell & Tube Heat Exchangers

Engineered Shell & Tube Heat Exchangers

Engineered Shell and Tube Heat Exchanger

Corrugated Tube Heat Exchangers

What is a Shell and Tube Heat Exchanger?

A shell and tube heat exchanger is a mechanical device that transfers heat between two fluids while keeping them completely separated. The exchanger consists of a cylindrical shell that houses a bundle of tubes. One fluid flows through the tubes (the tube side), while another fluid flows around them within the shell (the shell side). Heat is transferred through the tube walls, enabling effective temperature regulation without mixing the fluids.

This design is exceptionally versatile and well-suited to both heating and cooling duties. Shell and tube heat exchangers are widely used in industries such as chemical processing, oil and gas, power generation, HVAC, marine, and food production. Their ability to handle high pressures and temperatures, combined with durable construction and long service life, makes them a trusted solution for critical process applications.

Standard Shell and Tube Heat Exchangers

Standard models offer reliable, cost-effective thermal performance for general applications. They use straight or U-shaped tubes within a cylindrical shell, allowing efficient heat transfer between fluids. These exchangers are ideal for processes involving water, oil, steam, or other compatible fluids where maintenance and operating costs need to remain low.
Their simple, proven design makes them a go-to choice for industrial cooling, heating, and heat recovery systems that require consistent results with minimal complexity.

Engineered Shell and Tube Heat Exchangers

Engineered designs are custom-built for specific process requirements. Our engineers tailor each unit’s materials, geometry, and flow configuration to handle complex or extreme operating conditions. These units are ideal for high-pressure, high-temperature, or corrosive environments such as petrochemical plants, refineries, and power stations.
Engineered exchangers are designed to integrate seamlessly into unique plant layouts and process systems, ensuring optimal performance, energy efficiency, and long-term reliability even under the harshest conditions.

Corrugated Shell and Tube Heat Exchangers

Corrugated tube exchangers use internally corrugated tubes that enhance turbulence and increase heat transfer rates. This design reduces fouling, improves cleaning efficiency, and supports higher mechanical strength. They are often used in wastewater treatment, food processing, and energy recovery applications where both efficiency and low maintenance are priorities.
The corrugation pattern increases heat transfer surface area while reducing pressure drop, making these exchangers ideal for operations seeking improved performance in compact or demanding installations.

Industry Applications

InKorr’s shell and tube heat exchangers are used across Australia in industries that demand durability, precision, and efficient heat transfer under challenging conditions.

Oil and Gas:
Cooling lubricants, condensing vapours, and recovering waste heat in refineries and compressor systems. Shell and tube exchangers are also essential for offshore platforms and gas processing plants, where they handle high pressures and aggressive media with ease.

Chemical Processing:
Controlling reaction temperatures and managing corrosive or high-viscosity fluids. They are ideal for chemical plants requiring consistent temperature control in reactors, distillation units, and solvent recovery systems.

Power Generation:
Preheating boiler feedwater, cooling turbine oil, and condensing exhaust steam. These exchangers ensure reliable thermal performance in both conventional and renewable energy plants, supporting continuous, high-demand operations.

HVAC and Refrigeration:
Providing large-scale temperature control in industrial chillers, condensers, and heat recovery systems. Shell and tube units are commonly installed in central plants and large air conditioning systems due to their durability and high capacity.

Mining and Heavy Industry:
Handling abrasive or slurry-laden process fluids in high-pressure, high-load environments. They are frequently used for cooling hydraulic oils, treating process fluids, and recovering heat from smelting and mineral extraction operations.

Food and Beverage:
Supporting hygienic heating and cooling processes, including pasteurisation and CIP (clean-in-place) operations. Stainless steel designs ensure food-grade compliance while maintaining efficient heat transfer in dairy, brewing, and beverage applications.

Water and Wastewater Treatment:
Heating sludge, recovering thermal energy, and managing corrosive or fouling-prone flows. Shell and tube heat exchangers are particularly effective for anaerobic digestion and wastewater reuse systems due to their robust construction and easy maintenance.

Shell and Tube Heat Exchangers FAQ:

What is a shell and tube heat exchanger and how does it work?

A tube and shell heat exchanger transfers heat between two fluids by passing one fluid through a bundle of tubes and the other around the outside of those tubes within a sealed shell. Heat transfers across the tube walls without the fluids mixing. The design allows for high pressure and temperature resistance, making it suitable for heavy-duty industrial use.
Where are shell and tube heat exchangers commonly used?

They are widely used in industries such as oil and gas, chemical processing, power generation, HVAC, mining, and food and beverage production. Their versatility and durability make them ideal for both clean and contaminated process fluids across a broad range of temperatures and pressures.
What are the benefits of using a shell and tube heat exchanger?

They provide excellent thermal performance, robust mechanical strength, and flexibility in handling high-pressure or corrosive applications. They can also be configured for easy maintenance and long service life, supporting reliable operation in demanding industrial environments.
How do I choose the right type of shell and tube heat exchanger?

Selection depends on your process conditions, including fluid type, temperature and pressure range, fouling tendency, and space limitations. InKorr offers standard, engineered, and corrugated tube and shell exchangers to suit different operational needs and performance targets.
What’s the difference between standard, engineered, and corrugated shell and tube heat exchangers?

Standard exchangers are designed for general-purpose use with common fluids and moderate conditions. Engineered units are customised for specialised or extreme environments. Corrugated designs enhance turbulence, improving efficiency and reducing fouling in more demanding or efficiency-focused applications.
How often should a shell and tube heat exchanger be serviced?

Service intervals vary by application and fluid type. Systems using clean water may only require inspection every few years, while those exposed to fouling or corrosive media should be checked annually or more frequently. Regular cleaning and inspection prevent efficiency loss and costly downtime.
What are common signs a shell and tube heat exchanger needs maintenance?
How much does a shell and tube heat exchanger cost?

The cost of a shell and tube heat exchanger varies depending on size, material, and complexity. While the initial price tag is usually higher than compact alternatives like plate heat exchangers, shell and tube units are often preferred when handling high pressures, high temperatures, larger heat duties, or applications requiring a close approach temperature. This makes them a smart long-term investment for demanding industrial environments.
What causes fouling in shell and tube heat exchangers?
Can I clean a shell and tube heat exchanger myself?

Cleaning difficulty depends on the design. Floating head exchangers are generally the easiest to clean, followed by U-tube models, while fixed-tube designs are the most challenging. Although some cleaning can be done in-house, the most effective and safest option is to have a professional service the unit regularly. InKorr offers full cleaning and servicing support if required.
Do shell and tube heat exchangers work with aggressive or corrosive fluids?

Why Choose InKorr?

InKorr is your trusted partner for industrial heat transfer systems in Australia. Our deep expertise in shell and tube heat exchanger technology, combined with a responsive local support team, allows us to deliver engineered solutions that are practical, durable, and cost-effective.

What sets InKorr apart is our commitment to customer support and aftersales service. From commissioning and maintenance to repairs and performance optimisation, our technicians are with you every step of the way. We provide a rapid turnaround on servicing and product delivery across the country, minimising downtime and keeping your operations moving.

And with our enhanced diagnostic testing and automated transparent reporting system, you can be sure your equipment will be well maintained. We don’t just sell equipment, we provide solutions that enhance productivity, reduce energy consumption, and support growth.