What are the main causes of reduced heat exchanger performance?

When a heat exchanger is not performing as well as it should, the cause is often contamination, limescale build-up, damaged gaskets or changes in process conditions. In practice, we regularly see that a heat exchanger has operated without any problems for years, whilst the process has changed over time. A higher flow rate, a different process temperature or a new product can mean that the original heat exchanger no longer performs optimally. In such cases, a new thermal calculation is often the first step.

When a heat exchanger is not performing as well as it should, the cause often lies with one or more of the following factors:

• Fouling;
• Limescale or product deposits;
• Damaged or worn gaskets;
• Insufficient flow rate;
• Changed process conditions;
• Air or gas entrapment;
• Corrosion or erosion.

These factors reduce heat transfer and often increase the pressure drop. Regular inspection and maintenance prevent unnecessary energy loss and extend the service life of the heat exchanger.