Shell and tube heat exchanger
A shell and tube heat exchanger is a device that transfers heat from one fluid to another without mixing them. One fluid flows through a series of tubes, and the second fluid flows around those tubes inside a larger shell. As the fluids pass by each other, heat is exchanged efficiently through the tube walls.
At United Cooling Systems Pvt. Ltd., Our specialty is manufacturing reliable and long-lasting shell and tube heat exchangers. Made with high-grade materials and expert engineering, our exchangers are suitable for a wide range of industrial applications and perform consistently even under tough operating conditions. They are energy-efficient, easy to maintain, and custom-designed to meet specific project requirements.
What Is a Shell and Tube Heat Exchanger?
A shell and tube heat exchanger is a device that facilitates heat transfer between two fluids by passing them through separate paths within a cylindrical shell containing a bundle of tubes. The hot fluid flows through a bundle of tubes, while the cold fluid circulates around those tubes within a larger outer shell.These exchangers are simple, efficient, and very reliable, making them suitable for power plants, oil refineries, chemical factories, and HVAC systems. At United Cooling Systems Pvt. Ltd., we offer custom-engineered solutions that meet global standards and deliver high performance in every environment.
How Does a Shell and Tube Heat Exchanger Work?
The working of this exchanger is based on thermal conduction and flow dynamics. Here’s how:- Tube-side fluid: This fluid moves inside the tubes.
- Shell-side fluid: Through the tubes within the shell, this fluid flows.
- Heat transfer: The heat moves from the hot fluid to the cold fluid via the tube walls.
Advantages of Shell and Tube Heat Exchangers
Our units provide several benefits:- High thermal performance
- Handles high-pressure and high-temperature conditions
- Flexible and customizable design
- Easy to clean and maintain
- Suitable for multiple fluids (oil, gas, water, steam)
- Long service life
Types of Shell and Tube Heat Exchangers
We manufacture the following types:Fixed Tube Sheet Design
- Simple structure
- Easy to clean the shell side
- Best for non-corrosive fluids
U-Tube Design
- Allows thermal expansion
- Cost-effective and compact
- Easy to inspect tube interiors
Floating Head Design
- Ideal for high-fouling applications
- Both sides can be cleaned
- Offers long-term operational flexibility
Materials Used in Construction
Depending on your process and fluid type, we use:- Carbon Steel – Durable and cost-effective
- Stainless Steel (SS304, SS316) – Corrosion resistant
- Copper Alloys – High thermal conductivity
- Titanium – Best for aggressive or corrosive fluids
Shell and Tube Heat Exchanger Design Details
| Parameter | Specification |
|---|---|
| Tube Diameter | ¼” to 2” |
| Shell Size | Customised per requirement |
| Pressure Rating | Up to 100 bar |
| Temperature Range | -50°C to +400°C |
| Baffle Spacing | Engineered for optimal flow |
| Standards Followed | ASME, TEMA, ISO Certifications |
Common Applications in Industries
United Cooling’s exchangers are widely used in:- Power Generation
- Oil and Gas Refineries
- Chemical and Petrochemical Plants
- Food and Beverage Industries
- HVAC and Refrigeration Systems
- Marine and Offshore Engineering
Why Choose United Cooling Systems Pvt. Ltd.?
- Over 20 Years of Experience
- Certified Manufacturing (ISO 9001:2015)
- Advanced Testing and Fabrication Facility
- Custom-Built Heat Transfer Solutions
- Worldwide Delivery & After-Sales Support
Maintenance Tips and Best Practices
To ensure optimal performance:- Periodically inspect for fouling or clogging
- Use appropriate cleaning methods (chemical or hydro jetting)
- Monitor for pressure changes
- Replace gaskets and seals on time
- Schedule yearly maintenance checks
Other Products by United Cooling Systems Pvt. Ltd.
- Air-Cooled Heat Exchangers (ACHEs): An efficient, fan-driven system that cools fluids using ambient air—ideal for locations where water is scarce or expensive.
- Fin Tube Heat Exchanger:Compact and high-performance, these are designed with extended surface area (fins) to boost thermal transfer in compact spaces.
- Double Pipe Heat Exchanger:Suitable for smaller capacity applications, especially where precise temperature control is needed.
- Pressure Vessels:Designed for safe storage of gases or liquids under pressure, built to ASME or IS codes with high durability.
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If you’re looking for a durable, efficient, and custom-designed shell and tube heat exchanger, United Cooling Systems Pvt. Ltd. is your trusted partner. With years of experience and a strong focus on quality, we provide thermal solutions that work reliably across all industries.FAQs – Shell and Tube Heat Exchangers
1. What is the definition of a shell and tube heat exchanger?A shell and tube heat exchanger is a mechanical device used to transfer heat between two fluids without allowing them to mix. It consists of a large outer shell that holds a bundle of tubes. One fluid flows inside the tubes, while the other fluid flows around the tubes within the shell. Effective heat transmission through the tube walls is guaranteed by this configuration.
2. What is the working principle of a shell and tube heat exchanger?
The exchanger works on the principle of indirect heat exchange, where heat is transferred through the walls of the tubes from the hot fluid to the cold one. The mechanism relies on conduction through the tube material and convection within the fluids, making it both reliable and efficient.
3. What is the general principle behind heat exchangers?
All heat exchangers work on the fundamental concept of thermal energy transfer between two fluids. This transfer can occur either through direct contact or via a separating wall, as in shell and tube designs. The main aim is to achieve heating or cooling of a process stream efficiently.
4. What does "approach" mean in a shell and tube heat exchanger?
In heat exchanger terminology, "approach" refers to the temperature difference between the cold fluid outlet and the hot fluid outlet. A smaller approach value means better efficiency, but it may require a larger heat transfer area. It is an important factor during the design stage.
5. What is the difference between shell side and tube side?
- Tube side: The fluid flows inside the tubes. It is generally suitable for clean fluids and higher pressure applications.
- Shell side: The fluid circulates outside the tubes, inside the shell. This side is better for fluids with higher viscosity or a tendency to foul.
6. Why is viscous fluid usually routed through the shell side?
Viscous fluids are routed through the shell side because the shell offers more flow area and better flexibility in design. Baffles can be used to increase turbulence, which improves heat transfer and reduces the chance of clogging or pressure drop—especially important when handling thick fluids like oils or syrups.
7. What are the major types of shell and tube heat exchangers?
- Fixed Tube Sheet: Simple in construction and economical; suitable when frequent cleaning is not required.
- U-Tube Design: Allows for thermal expansion; ideal when space is limited.
- Floating Head Type: Provides easy access for cleaning both shell and tube sides; ideal for processes with fouling or high contamination.
Industry prefers shell and tube heat exchangers because they are:
- Durable and long-lasting
- Suitable for high-pressure and high-temperature operations
- Customizable based on application
- Scalable and easy to install
- Relatively easy to maintain with proper design
9. How are shell and tube heat exchangers maintained?
To ensure smooth operation and long life, the following maintenance practices are recommended:
- Regular cleaning of the tubes (chemical or mechanical)
- Checking for pressure drops and unusual temperature readings
- Inspecting for scaling or fouling inside the tubes or shell
- Replacing worn-out gaskets, seals, or damaged tubes
- Periodic testing for leaks and corrosion
10. What is the typical life span of a shell and tube heat exchanger?
With proper material selection, correct design, and regular maintenance, shell and tube heat exchangers can serve reliably for 15 to 25 years or even more. Lifespan also depends on the operating environment and the type of fluids being used.
