Process Optimization
Plate heat exchangers: 7 tips to balance efficiency & costs
You want your heat exchanger to run at optimal efficiency. You also want a low total cost of ownership. But, as you know, you can’ t have your cake and eat it too. Instead, you need to strike a balance between efficiency and costs that leads to less downtime, improved overall production, and a more dependable operation in the long term. These seven tips will help you find that balance.
Text & images by Tranter
1. Optimize your heat exchanger configuration Start by checking your heat exchanger’ s operating parameters. What fluids are flowing, and at what pressure, temperature and volume? Heat exchangers are often overdesigned, meaning engineers have added 10 % to all parameters, and intermediaries add even more on top to ensure it doesn’ t underperform. The result is an exchanger with either too many plates or one designed for something different than what it’ s being used for. So what can you do to fix this issue and make sure your heat exchanger is adapted to your particular needs? Contact a vendor that can run calculations to check your heat exchanger’ s current operating parameters against its design parameters and see if it’ s configured correctly. You can often make changes that result in better heat transfer efficiency and the appropriate pressure drop. A properly configured heat exchanger will remain clean during operations and provide optimal performance for your system. It can also improve the overall performance of the
system around it. For example, pumps don’ t have to work as hard if the pressure drop is correct.
2. Make sure your exchanger has the right number of plates Your heat exchanger can have high, low or medium heat transfer plates theta – or a mix of all three. This means you can reconfigure your exchanger by simply changing the number of plates and without touching the piping or its frame. You might think more plates is the way to go because a larger surface area equals better heat transfer – but that’ s not always the case. It all comes down to the purpose of your heat exchanger. Run calculations to determine how many plates your specific heat exchanger needs for optimal heat transfer efficiency and pressure drop and then add or remove plates accordingly.
3. Choose a vendor with a global supply chain When you opt for a local, small supplier, you take a significant risk. The vendor might not be around tomorrow, be too busy to help, or not have your exact plates and gaskets in stock. You’ ll be at their – and whoever they buy their parts from – mercy. Instead, choose an established vendor with a global supply chain and ample resources. This way, your vendor will have numerous sources to pull supplies from, ensuring you’ ll have the parts you need whenever you need them. A global actor will meet your needs and has the financial muscle and market presence to back it up.
48 Heat Exchanger World June 2025 www. heat-exchanger-world. com