Heat exchangers are among the most critical process equipment items in any chemical plant, refinery, power station, pharmaceutical manufacturing unit or HVAC system. They transfer thermal energy between two fluid streams — without mixing them — to heat, cool, condense or evaporate process fluids in a controlled and efficient manner. The design of a heat exchanger profoundly affects plant energy consumption, reliability and maintenance cost.
We design and manufacture heat exchangers to TEMA (Tubular Exchanger Manufacturers Association) B, C and R standards, ASME Section VIII Division 1, IS 4503 and PD 5500, with design pressures up to 350 bar and temperatures from cryogenic (-200°C) to high-temperature service (+650°C). All pressure vessels undergo radiographic examination, PWHT and hydrotest before dispatch.
Air-cooled heat exchangers (fin-fan coolers) use ambient air as the cooling medium — eliminating cooling water consumption and the associated problems of scale, fouling and biological treatment. They are preferred for remote locations, water-scarce sites and high-inlet-temperature process streams. Forced-draft and induced-draft fan configurations are available with variable-speed drives for efficient part-load operation.
Our in-house thermal design capability uses HTRI Xchanger Suite® and ASPEN HYSYS process simulation for rigorous rating and optimisation of heat transfer area, pressure drop and fouling margin. We also undertake re-rating and performance enhancement of existing exchangers — identifying and correcting fouling issues, vibration damage and design deficiencies.
The most common industrial heat exchanger — a bundle of tubes enclosed in a cylindrical shell. One fluid flows through the tubes (tube-side) and the other through the shell (shell-side), with baffles directing shell-side flow across the tube bundle for maximum heat transfer. TEMA B (general chemical), C (commercial) and R (severe oil refinery service) construction grades are available. AES, BEM, BEU, AEW, BKU and other head/shell/rear-end type combinations are engineered for specific process requirements including thermal expansion, cleaning access and high-pressure service.
Corrugated metal plates create multiple thin flow channels alternating between hot and cold fluids. The high turbulence in the chevron-pattern corrugations achieves heat transfer coefficients 3–5× higher than shell & tube exchangers, in a fraction of the footprint. Gasketed PHEs are cleanable by plate removal — ideal for fouling fluids. Brazed and fully welded PHEs handle high pressure and aggressive chemicals. Available in SS 304, SS 316L, titanium, hastelloy and SMO 254.
Hot process fluid flows through finned tube bundles cooled by ambient air driven by axial fans. Extended fin surface (10:1 fin-to-tube area ratio) compensates for air's low heat transfer coefficient. Aluminium fins are helical or knurled onto carbon steel, stainless steel or carbon steel tube cores by high-tension winding for intimate thermal contact. Suitable for: gas coolers, condensers, trim coolers and air blast oil coolers. Fan blade pitch adjustment provides capacity control in varying ambient temperatures.
The simplest multi-tube exchanger — an inner tube inside an outer pipe, with one fluid in the inner tube (tube-side) and another in the annular space (shell-side). True countercurrent flow achieves the maximum LMTD (log mean temperature difference) for any given duty, making it ideal for temperature crosses and close temperature approaches. Multiple hairpin sections are connected in series for larger duties. Easy to clean, inspect and maintain.
Two long metal strips wound into concentric spiral channels create two fluid paths in pure countercurrent flow. The self-cleaning channel geometry handles slurries, fibrous materials and heavily fouling fluids that block conventional tube bundles. A single unit of 400 m² can replace multiple shell & tube exchangers. Used in sludge-to-sludge heat recovery in STPs, pulp washers and chemical slurry heating.
Material selection is critical for long service life: Carbon steel (SA-516 Gr 70) for non-corrosive, moderate-temperature service; SS 304/316L for general corrosive chemical and food-grade service; Duplex 2205/2507 for seawater and chloride service; Titanium Grade 2 for concentrated acid, seawater and aggressive chemical duties; Hastelloy C-276 for HCl, FeCl₃ and oxidising acids; Aluminium for cryogenic and gas processing applications. All welding by ASME Sec IX qualified welders.
| Types | Shell & Tube / Plate / Fin-Fan / Double Pipe / Spiral |
| Design Standard | TEMA B/C/R, ASME Sec VIII Div 1, IS 4503 |
| Heat Transfer Area | 0.1 m² to 500 m² |
| Design Pressure | Full vacuum to 350 bar |
| Design Temperature | −200°C to +650°C |
| Shell Diameter | 100 mm to 2,500 mm |
| Tube Dia & Length | 19–38 mm OD, up to 9 m long |
| Materials | CS / SS 304 / SS 316L / Duplex / Ti / Hastelloy |
| Thermal Design | HTRI Xchanger Suite® / ASPEN |
| Inspection | UT / RT / PWHT / Hydrotest / PMI |
Provide your process duty — fluid names, temperatures, pressures and flow rates — and we will return a preliminary design with thermal area, dimensions and price within 3 working days.
