What are the most common mistakes made when selecting a heat exchanger?

Selecting a heat exchanger based solely on the required capacity is a common mistake. Factors such as fouling, pressure drop, material compatibility, maintenance, future capacity expansion and Total Cost of Ownership also determine the final performance.

An incorrect choice can lead to higher energy consumption, more frequent maintenance or a shorter service life. It is therefore essential to carry out a thorough thermal and mechanical analysis before selecting a heat exchanger.

In practice, we regularly see heat exchangers being selected on the basis of a single design condition, whilst in reality the process varies across a wider operating range. Consider, for example, seasonal influences, fluctuating flow rates or changing product streams. As a result, a system may, in practice, operate outside its optimal operating range, leading to higher pressure drop, fouling or reduced efficiency. A correct selection therefore always takes into account the full operating range and not just the nominal design points.