Thermal Engineering

Heat Transfer Calculations

Calculate heat transfer by conduction, convection, and radiation. Design heat exchangers using LMTD and effectiveness-NTU methods. Size insulation and estimate heat losses for thermal systems.

Conduction

Fourier's law

Q = -k A (dT/dx); heat transfer through solids (pipe walls, insulation).

Convection

Newton's law of cooling

Q = h A ΔT; fluid-to-surface heat transfer (film coefficients).

Overall U

30-300 Btu/hr·ft²·°F

Typical range for process heat exchangers (depends on fluids, fouling).

Use this guide when you need to:

  • Design and size heat exchangers.
  • Calculate heat loss from pipelines and vessels.
  • Determine insulation thickness requirements.

1. Overview & Modes of Heat Transfer

Heat transfer is the movement of thermal energy from high-temperature regions to low-temperature regions. In midstream operations, heat transfer governs process heating/cooling, heat loss prevention, and equipment sizing.

Conduction

Solid materials

Heat transfer through pipe walls, vessel shells, and insulation materials.

Convection

Fluid motion

Heat transfer between fluid and solid surface (forced or natural convection).

Radiation

Electromagnetic waves

Heat transfer via infrared radiation (significant at high temperatures).

Combined modes

Simultaneous transfer

Most real systems involve multiple modes (overall heat transfer coefficient).

Fundamental Heat Transfer Equation

Three panels showing heat transfer modes: conduction through solid with temperature gradient, convection from surface to fluid with boundary layer, and radiation between surfaces with wavy arrows and equations
Three heat transfer modes: Conduction through solids (Q=-kA·dT/dx), convection to fluids (Q=hA·ΔT), radiation between surfaces (Q=εσA·ΔT⁴).
First Law of Thermodynamics (Energy Balance): Q = ṁ × Cp × ΔT Where: Q = Heat transfer rate (Btu/hr or W) ṁ = Mass flow rate (lb/hr or kg/s) Cp = Specific heat capacity (Btu/lb·°F or J/kg·K) ΔT = Temperature change (°F or K) For constant pressure process: Q = ṁ × Cp × (T_out - T_in) Example: Heat natural gas from 60°F to 120°F at 1000 lb/hr: Cp ≈ 0.5 Btu/lb·°F (at avg conditions) Q = 1000 × 0.5 × (120 - 60) = 30,000 Btu/hr

Applications in Midstream Operations

Application Heat Transfer Type Typical Duty
Gas-gas heat exchanger (feed preheating) Convection (both sides) 0.5-5 MMBtu/hr
Gas-liquid heat exchanger (reboiler) Convection + boiling 1-20 MMBtu/hr
Pipeline heat loss (buried) Conduction to soil 10-50 Btu/hr·ft
Insulated vessel heat loss Conduction + convection + radiation 100-1000 Btu/hr
Fired heater (process heating) Radiation + convection 10-100 MMBtu/hr
Overall heat transfer coefficient (U): In most equipment, heat must pass through multiple resistances (inside fluid film, pipe wall, outside fluid film, fouling layers). The overall coefficient U combines all resistances into a single value for design calculations. Typical U values: gas-gas 5-50, liquid-liquid 50-300, condensing vapor 100-500 Btu/hr·ft²·°F.

2. Heat Transfer Mechanisms

Conduction (Fourier's Law)

One-Dimensional Steady-State Conduction: Q = -k × A × (dT/dx) For constant area and thermal conductivity: Q = k × A × (T₁ - T₂) / L Where: Q = Heat transfer rate (Btu/hr or W) k = Thermal conductivity (Btu/hr·ft·°F or W/m·K) A = Cross-sectional area perpendicular to heat flow (ft² or m²) T₁, T₂ = Temperatures at locations 1 and 2 (°F or K) L = Distance between locations (ft or m) Thermal resistance: R_cond = L / (k × A) (°F·hr/Btu or K/W) Example - Pipe wall conduction: For cylindrical coordinates (radial conduction through pipe wall): Q = 2π × k × L × (T_i - T_o) / ln(r_o / r_i) Where: L = Pipe length (ft) r_i, r_o = Inner and outer radii (ft) T_i, T_o = Inner and outer surface temperatures (°F)

Thermal Conductivity Values

Material k (Btu/hr·ft·°F) k (W/m·K) Application
Carbon steel (pipe) 25-30 43-52 Pipeline, pressure vessels
Stainless steel 316 8-10 14-17 Process piping, heat exchanger tubes
Fiberglass insulation 0.02-0.025 0.035-0.043 Pipe/vessel insulation
Mineral wool 0.022-0.028 0.038-0.048 High-temperature insulation
Polyurethane foam 0.012-0.016 0.021-0.028 Cryogenic insulation (LNG)
Concrete (buried pipe) 0.4-0.8 0.7-1.4 Pipe coatings, foundations
Soil (moist) 0.5-1.5 0.9-2.6 Buried pipeline heat transfer

Convection (Newton's Law of Cooling)

Convective Heat Transfer: Q = h × A × (T_s - T_∞) Where: Q = Heat transfer rate (Btu/hr or W) h = Convective heat transfer coefficient (Btu/hr·ft²·°F or W/m²·K) A = Surface area (ft² or m²) T_s = Surface temperature (°F or K) T_∞ = Bulk fluid temperature (°F or K) Thermal resistance: R_conv = 1 / (h × A) (°F·hr/Btu or K/W) Convection types: 1. Forced convection: External force (pump, fan) drives fluid motion 2. Natural convection: Buoyancy-driven flow from density gradients 3. Boiling/condensation: Phase change enhances heat transfer

Convection Coefficient Correlations

Convection coefficients depend on fluid properties, flow regime, and geometry. Common correlations:

Dittus-Boelter Equation (Turbulent Flow in Pipes): Nu = 0.023 × Re^0.8 × Pr^n Where: Nu = Nusselt number = h × D / k Re = Reynolds number = ρ × V × D / μ Pr = Prandtl number = Cp × μ / k n = 0.4 for heating, 0.3 for cooling Valid for: - Re > 10,000 (turbulent) - 0.7 < Pr < 160 - L/D > 10 (fully developed) Example: Natural gas in 4" pipe, Re = 50,000, Pr = 0.75: Nu = 0.023 × 50,000^0.8 × 0.75^0.4 = 128 If k = 0.02 Btu/hr·ft·°F, D = 0.333 ft: h = Nu × k / D = 128 × 0.02 / 0.333 = 7.7 Btu/hr·ft²·°F

Typical Convection Coefficients

Fluid/Condition h (Btu/hr·ft²·°F) h (W/m²·K)
Natural gas (forced convection) 5-25 28-142
Water (forced convection) 300-3,000 1,700-17,000
Oil/liquid hydrocarbons 50-500 284-2,840
Condensing steam 1,000-5,000 5,680-28,400
Boiling water 500-5,000 2,840-28,400
Air (natural convection) 1-5 6-28
Air (forced, 10 mph wind) 5-10 28-57

Radiation (Stefan-Boltzmann Law)

Thermal Radiation: Q = ε × σ × A × (T₁⁴ - T₂⁴) Where: Q = Radiant heat transfer rate (Btu/hr or W) ε = Emissivity (0-1, dimensionless) σ = Stefan-Boltzmann constant = 0.1714×10⁻⁸ Btu/hr·ft²·°R⁴ = 5.67×10⁻⁸ W/m²·K⁴ A = Surface area (ft² or m²) T₁, T₂ = Absolute temperatures (°R = °F+459.67, or K) For small temperature differences, linearized form: Q ≈ h_r × A × (T₁ - T₂) Where h_r = ε × σ × (T₁² + T₂²) × (T₁ + T₂) Radiation typically important when: - High temperatures (> 500°F) - Low convection coefficients (gas/air) - View factor close to 1 (large surfaces facing each other)

Emissivity Values

Surface Emissivity (ε) Notes
Polished aluminum 0.05-0.10 Reflective, low radiation
Oxidized steel 0.80-0.90 Typical piping/vessels
Painted surface (any color) 0.85-0.95 Paint increases emissivity
Black body (theoretical) 1.00 Perfect emitter/absorber
Insulation jacket (aluminum) 0.10-0.20 Reduces radiant heat loss
Combined heat transfer: In most practical cases, all three modes occur simultaneously. For example, heat loss from an insulated pipe involves: conduction through pipe wall and insulation, convection to ambient air, and radiation to surroundings. Use overall heat transfer coefficient U to combine all resistances in series.

3. LMTD Method (Log Mean Temperature Difference)

The LMTD method is the standard approach for rating (checking performance of) existing heat exchangers or designing new ones when inlet/outlet temperatures are known.

Overall Heat Transfer Equation

Basic Heat Exchanger Equation: Q = U × A × LMTD × F_t Where: Q = Heat duty (Btu/hr or W) U = Overall heat transfer coefficient (Btu/hr·ft²·°F or W/m²·K) A = Heat transfer area (ft² or m²) LMTD = Log mean temperature difference (°F or K) F_t = Temperature correction factor for exchanger configuration This equation applies to all heat exchanger types (shell-and-tube, plate, air-cooled, etc.).

LMTD Calculation

Side-by-side temperature profiles for counterflow and parallel flow heat exchangers showing hot and cold fluid lines with ΔT₁ and ΔT₂ labeled and LMTD formula
Temperature profiles: Counterflow maintains higher average ΔT for better effectiveness; parallel flow has converging outlet temperatures.
For Counterflow (True Countercurrent): LMTD = (ΔT₁ - ΔT₂) / ln(ΔT₁ / ΔT₂) Where: ΔT₁ = T_h,in - T_c,out (hot inlet - cold outlet) ΔT₂ = T_h,out - T_c,in (hot outlet - cold inlet) For Parallel Flow (Cocurrent): ΔT₁ = T_h,in - T_c,in (hot inlet - cold inlet) ΔT₂ = T_h,out - T_c,out (hot outlet - cold outlet) LMTD_parallel = (ΔT₁ - ΔT₂) / ln(ΔT₁ / ΔT₂) Note: Counterflow gives larger LMTD → smaller exchanger for same duty. Special case - equal temperature differences: If ΔT₁ = ΔT₂ = ΔT: LMTD = ΔT (arithmetic mean)

LMTD Example Calculation

Problem: Heat natural gas from 60°F to 100°F using hot oil cooling from 200°F to 150°F in a countercurrent heat exchanger. Gas flow: 10,000 lb/hr (Cp = 0.52 Btu/lb·°F) Calculate LMTD and required area if U = 15 Btu/hr·ft²·°F. Solution: Step 1: Calculate duty from gas side Q = ṁ × Cp × ΔT Q = 10,000 × 0.52 × (100 - 60) = 208,000 Btu/hr Step 2: Verify from oil side (energy balance) Q = ṁ_oil × Cp_oil × (200 - 150) 208,000 = ṁ_oil × 0.5 × 50 ṁ_oil = 8,320 lb/hr ✓ Step 3: Calculate LMTD (counterflow) ΔT₁ = T_h,in - T_c,out = 200 - 100 = 100°F ΔT₂ = T_h,out - T_c,in = 150 - 60 = 90°F LMTD = (100 - 90) / ln(100/90) LMTD = 10 / ln(1.111) LMTD = 10 / 0.1054 = 94.9°F Step 4: Calculate required area (assume F_t = 1.0 for true counterflow) Q = U × A × LMTD × F_t 208,000 = 15 × A × 94.9 × 1.0 A = 208,000 / (15 × 94.9) = 146 ft² Result: Require ~150 ft² heat transfer area. For shell-and-tube with 3/4" OD tubes, 10 ft long: Area per tube = π × (0.75/12) × 10 = 1.96 ft² Number of tubes = 150 / 1.96 = 77 tubes

Overall Heat Transfer Coefficient (U)

Tube cross-section showing thermal resistance layers from hot fluid through convection, fouling, wall, fouling, to cold fluid, with electrical circuit analogy showing resistors in series
Thermal resistance network: Heat passes through five resistances in series; overall U determined by sum of individual resistances.
Resistance Network (Series Resistances): 1/U = 1/h_i + (r_o ln(r_o/r_i))/k_w + R_f,i × (A_o/A_i) + R_f,o + 1/h_o Where: h_i = Inside fluid film coefficient (Btu/hr·ft²·°F) h_o = Outside fluid film coefficient k_w = Tube wall thermal conductivity r_i, r_o = Inner and outer tube radii R_f,i, R_f,o = Fouling resistances (inside and outside) A_i, A_o = Inside and outside tube areas For thin-walled tubes, wall resistance negligible: 1/U ≈ 1/h_i + R_f,i + R_f,o + 1/h_o Note: U based on outside area A_o is common convention. Fouling factors (from TEMA standards): - Clean gas: R_f = 0.001 hr·ft²·°F/Btu - Clean water: R_f = 0.001 - Treated cooling water: R_f = 0.002 - River water: R_f = 0.003-0.005 - Light hydrocarbons: R_f = 0.001-0.002 - Heavy oils: R_f = 0.003-0.005

Typical Overall U Values

Fluid Combination U (Btu/hr·ft²·°F) U (W/m²·K) Controlling Resistance
Gas to gas 5-50 28-284 Both film coefficients low
Gas to liquid 10-80 57-454 Gas-side film coefficient
Liquid to liquid (light oils) 50-200 284-1,135 Fouling and film coefficients
Liquid to liquid (water/water) 200-500 1,135-2,840 Mainly fouling
Condensing vapor to liquid 100-500 568-2,840 Liquid-side film + fouling
Boiling liquid (reboiler) 100-300 568-1,703 Heating medium-side film

Temperature Correction Factor (F_t)

For shell-and-tube exchangers with multiple tube passes, flow is not true counterflow. Correction factor F_t accounts for this:

F_t Calculation: F_t depends on two dimensionless parameters: P = (t₂ - t₁) / (T₁ - t₁) (temperature effectiveness) R = (T₁ - T₂) / (t₂ - t₁) (capacity ratio) Where: T₁, T₂ = Shell-side inlet and outlet temperatures t₁, t₂ = Tube-side inlet and outlet temperatures F_t is read from charts (TEMA, Kern) based on P, R, and number of shell/tube passes. Typical values: - True counterflow (1 shell pass, many tube passes): F_t = 1.0 - 1 shell pass, 2 tube passes: F_t = 0.85-0.95 - 1 shell pass, 4+ tube passes: F_t = 0.75-0.90 - 2 shell passes: F_t = 0.90-0.98 Design guideline: F_t should be > 0.75 for economical design. If F_t < 0.75, consider adding shell passes or switching to true counterflow.

4. Effectiveness-NTU Method

The effectiveness-NTU (Number of Transfer Units) method is preferred when outlet temperatures are unknown, common in preliminary design and performance rating with unknown fouling.

Heat Exchanger Effectiveness

Effectiveness-NTU chart for counterflow heat exchangers showing curves for capacity ratios C_r from 0 to 1.0, with diminishing returns noted above NTU of 3
ε-NTU chart: C_r=0 (phase change) reaches ε→1; C_r=1 (balanced) limited to ε=NTU/(1+NTU); diminishing returns above NTU≈3.
Effectiveness Definition: ε = Q_actual / Q_max Where: Q_actual = Actual heat transfer rate Q_max = Maximum possible heat transfer rate Maximum heat transfer occurs when the fluid with minimum heat capacity rate experiences the largest possible temperature change: Q_max = C_min × (T_h,in - T_c,in) Where: C_min = min(C_h, C_c) C_h = ṁ_h × Cp_h (hot fluid heat capacity rate, Btu/hr·°F) C_c = ṁ_c × Cp_c (cold fluid heat capacity rate) Heat capacity ratio: C_r = C_min / C_max Note: 0 ≤ C_r ≤ 1

Number of Transfer Units (NTU)

NTU Definition: NTU = U × A / C_min Where: U = Overall heat transfer coefficient (Btu/hr·ft²·°F) A = Heat transfer area (ft²) C_min = Minimum heat capacity rate (Btu/hr·°F) Physical meaning: NTU represents the "thermal size" of the exchanger. - Large NTU (> 5): Approaches temperature equilibrium - Small NTU (< 1): Limited heat transfer Relationship to effectiveness: ε = f(NTU, C_r, flow configuration) The function f depends on exchanger type (counterflow, parallel flow, cross-flow, shell-and-tube, etc.).

Effectiveness Relations for Common Configurations

Counterflow: For C_r < 1: ε = [1 - exp(-NTU × (1 - C_r))] / [1 - C_r × exp(-NTU × (1 - C_r))] For C_r = 1 (balanced flow): ε = NTU / (1 + NTU) Parallel Flow (Cocurrent): ε = [1 - exp(-NTU × (1 + C_r))] / (1 + C_r) Condenser or Evaporator (C_r = 0, one fluid phase change): ε = 1 - exp(-NTU) Note: This applies when one fluid's temperature is constant (condensing steam, boiling liquid in pool). NTU = UA / C_min where C_min is the single-phase fluid. Cross-Flow (both fluids unmixed): ε = 1 - exp[(NTU^0.22 / C_r) × (exp(-C_r × NTU^0.78) - 1)] Note: More complex; use charts or approximations for practical calculations.

NTU Method Example

Problem: A counterflow heat exchanger with U = 20 Btu/hr·ft²·°F and A = 200 ft² heats natural gas from 60°F using hot oil. Gas: 10,000 lb/hr, Cp = 0.52 Btu/lb·°F Oil: 8,000 lb/hr, Cp = 0.50 Btu/lb·°F, inlet at 180°F Find: Gas outlet temperature and heat duty. Solution: Step 1: Calculate heat capacity rates C_gas = 10,000 × 0.52 = 5,200 Btu/hr·°F C_oil = 8,000 × 0.50 = 4,000 Btu/hr·°F C_min = 4,000 Btu/hr·°F (oil side) C_max = 5,200 Btu/hr·°F (gas side) C_r = 4,000 / 5,200 = 0.769 Step 2: Calculate NTU NTU = U × A / C_min = 20 × 200 / 4,000 = 1.0 Step 3: Calculate effectiveness (counterflow, C_r = 0.769) ε = [1 - exp(-1.0 × (1 - 0.769))] / [1 - 0.769 × exp(-1.0 × (1 - 0.769))] ε = [1 - exp(-0.231)] / [1 - 0.769 × exp(-0.231)] ε = [1 - 0.794] / [1 - 0.769 × 0.794] ε = 0.206 / (1 - 0.611) ε = 0.206 / 0.389 = 0.530 Step 4: Calculate actual heat transfer Q_max = C_min × (T_h,in - T_c,in) = 4,000 × (180 - 60) = 480,000 Btu/hr Q_actual = ε × Q_max = 0.530 × 480,000 = 254,400 Btu/hr Step 5: Find outlet temperatures From gas side: Q = C_gas × (T_gas,out - T_gas,in) 254,400 = 5,200 × (T_gas,out - 60) T_gas,out = 60 + 254,400/5,200 = 109°F From oil side: Q = C_oil × (T_oil,in - T_oil,out) 254,400 = 4,000 × (180 - T_oil,out) T_oil,out = 180 - 254,400/4,000 = 116°F Results: Gas outlet: 109°F Oil outlet: 116°F Heat duty: 254,400 Btu/hr

NTU vs. LMTD Method Comparison

Aspect LMTD Method NTU Method
Best use case Outlet temperatures known (rating) Outlet temperatures unknown (sizing)
Typical application Performance check, confirm design Preliminary design, optimization
Calculation Direct (if T known) Requires charts or equations
Iteration required Sometimes (if T unknown) No (effectiveness explicit)
Industry preference Shell-and-tube design (TEMA) Compact exchangers, academic
Method selection: Use LMTD when all four temperatures are known or specified (rating existing exchangers, verifying vendor proposals). Use NTU when designing new exchangers with unknown outlet temperatures (sizing calculations, sensitivity studies). Both methods give identical results when applied correctly.

5. Applications & Design Considerations

Pipeline Heat Loss Calculation

Cross-section of insulated pipeline showing concentric layers from fluid core through pipe wall and insulation to ambient, with temperature profile showing largest drop through low-k insulation
Insulated pipe heat loss: Low thermal conductivity of insulation creates largest temperature drop, minimizing heat loss to surroundings.
Insulated Pipe Heat Loss: Q/L = 2π × (T_fluid - T_amb) / [1/(h_i × r_i) + ln(r_p/r_i)/k_pipe + ln(r_ins/r_p)/k_ins + 1/(h_o × r_ins)] Where: Q/L = Heat loss per unit length (Btu/hr·ft) T_fluid = Fluid temperature (°F) T_amb = Ambient temperature (°F) r_i = Inner pipe radius (ft) r_p = Outer pipe radius (ft) r_ins = Outer insulation radius (ft) h_i = Inside convection coefficient (Btu/hr·ft²·°F) h_o = Outside convection coefficient (includes wind, radiation) k_pipe = Pipe thermal conductivity k_ins = Insulation thermal conductivity Simplified (negligible pipe wall resistance, h_i very large): Q/L ≈ 2π × (T_fluid - T_amb) / [ln(r_ins/r_p)/k_ins + 1/(h_o × r_ins)] Example: 6" NPS pipe (OD = 6.625"), 3" insulation, 200°F gas, 50°F ambient r_p = 6.625/(2×12) = 0.276 ft r_ins = (6.625 + 2×3)/(2×12) = 0.526 ft k_ins = 0.025 Btu/hr·ft·°F h_o = 3 Btu/hr·ft²·°F (still air + radiation) Q/L = 2π × (200-50) / [ln(0.526/0.276)/0.025 + 1/(3×0.526)] Q/L = 942 / [25.6 + 0.634] = 942 / 26.2 = 36 Btu/hr·ft For 1 mile (5280 ft): Q = 36 × 5280 = 190,000 Btu/hr

Insulation Thickness Optimization

Economic insulation thickness balances insulation cost vs. energy savings:

Service Temperature (°F) Typical Insulation Thickness (in) Material
50-100 (cold service) 1-2 Polyurethane foam, cellular glass
100-200 (warm service) 2-3 Fiberglass, mineral wool
200-400 (hot service) 3-4 Mineral wool, calcium silicate
400-800 (high temp) 4-6 Calcium silicate, ceramic fiber
-260 (LNG, cryogenic) 6-12 Polyurethane foam, perlite

Heat Exchanger Sizing Procedure

Design Steps: 1. Define process requirements - Fluid flow rates (ṁ_h, ṁ_c) - Inlet temperatures (T_h,in, T_c,in) - Required outlet temperatures (T_h,out, T_c,out) or heat duty (Q) 2. Calculate heat duty (if not specified) Q = ṁ_h × Cp_h × (T_h,in - T_h,out) Verify: Q = ṁ_c × Cp_c × (T_c,out - T_c,in) 3. Estimate overall heat transfer coefficient (U) Use typical values or calculate from film coefficients + fouling 4. Calculate LMTD (or use NTU method) LMTD = (ΔT₁ - ΔT₂) / ln(ΔT₁/ΔT₂) 5. Apply correction factor F_t (for shell-and-tube) Ensure F_t > 0.75 for economical design 6. Calculate required area A = Q / (U × LMTD × F_t) 7. Mechanical design - Select tube size, length, number of tubes - Determine shell diameter, baffle spacing - Check for tube-side and shell-side pressure drop - Verify velocities (erosion, vibration limits) 8. Iterate if needed - Recalculate U with actual geometry and velocities - Adjust F_t if changing number of passes - Re-size if pressure drop excessive or U too low

Common Design Issues

Issue Cause Solution
Low overall U Fouling, low film coefficients, gas-gas service Increase velocity, clean regularly, use extended surfaces (fins)
F_t < 0.75 Temperature cross (T_c,out approaching T_h,in) Add shell pass, switch to true counterflow, split into 2 exchangers
Excessive pressure drop High velocity, small tubes, long flow path Increase tube diameter, reduce tube length, add tube passes
Tube vibration High velocity, long unsupported span Add support baffles, reduce shell-side velocity, thicker tubes
Fouling/plugging Dirty fluids, low velocity, dead zones Design for cleaning access, maintain velocity > 3 ft/s, install filters

Temperature Approach and Pinch Point

Minimum Temperature Approach: ΔT_min = Minimum temperature difference between hot and cold streams at any point in exchanger For counterflow: ΔT_min = min(T_h,out - T_c,in, T_h,in - T_c,out) Typical minimum approaches: - Gas-gas: 20-50°F (large ΔT needed due to low U) - Liquid-liquid: 10-20°F - Condensing/boiling: 10-30°F (depends on process) - Refrigeration: 5-10°F (tight approach for efficiency) Small ΔT_min → large exchanger (expensive) Large ΔT_min → small exchanger but less heat recovery Pinch point: Location of minimum ΔT in process heat exchanger network. Determines maximum heat recovery in multi-exchanger systems.

Heat Exchanger Selection Guide

Type Best Application Advantages Limitations
Shell & tube General purpose, high P/T Robust, repairable, TEMA standardized Large footprint, expensive
Plate & frame Liquid-liquid, moderate P/T Compact, high U, easy cleaning Gasket limited (< 400°F, < 300 psi)
Plate-fin (brazed) Gas service, cryogenic Very compact, high effectiveness Not repairable, fouling-sensitive
Air-cooled (fin-fan) Gas/liquid cooling, no water available No water consumption, low maintenance Large, ambient-dependent, high power (fans)
Double-pipe Small duty (< 1 MMBtu/hr) Simple, true counterflow, low cost Limited area, high pressure drop
Fouling factor importance: Fouling reduces U by 20-50% over operating life. Always include TEMA-recommended fouling factors in design calculations. Clean exchanger performance will exceed design, but fouled performance must still meet process requirements. Schedule cleaning when measured U drops below 80% of clean design value.