Brazed heat exchangers are compact and highly efficient equipment that have become increasingly preferred in industrial heat transfer technologies in recent years. This technology is created by stacking thin stainless steel plates in a specific geometry and arrangement. Channels are designed between the plates for fluids to pass through, and these plates are fused together using copper or nickel-based brazing materials in a high-temperature furnace environment. This method results in a heat exchanger that is both resistant to high pressures and compact in structure.
Each plate has specially designed embossed surfaces. These embossments increase the contact of the fluid with the plate surface while also creating a highly turbulent flow. Turbulence increases the heat transfer coefficient (U value) between fluids and eliminates the heat transfer losses caused by laminar flow. Thus, brazed exchangers offer much higher performance in a much smaller volume compared to similar capacity tubular or shell-and-tube exchangers.
In its working principle, it is essential to direct two different fluids in a counter-flow or cross-flow arrangement between the plates. Counter-flow design provides superior energy efficiency, especially in applications requiring a high temperature difference. Cross-flow configuration is preferred to offer more compact solutions. In both cases, the brazed structure prevents the mixing of fluids while providing effective heat transfer.
The copper or nickel-based brazing material used in brazed exchangers not only connects the plates but also strengthens the integrity of the structure and provides resistance to high pressures and temperatures. Copper brazed models are generally preferred in cooling and heating applications, while nickel brazed exchangers offer suitable solutions for more corrosive fluids or aggressive process conditions.
Thanks to these principles, brazed exchangers:
• Allow for minimal space usage with compact design.
• Reduce energy consumption with a high heat transfer coefficient and provide savings in operating costs.
• Offer rapid heating-cooling cycles due to low fluid volume, facilitating process control.
• Provide long-lasting use in the challenging conditions of industrial facilities with a structure resistant to pressure and temperature.
• Can be customized according to different flow and temperature needs with flexible design options.
The basic principle of brazed exchangers relies on the optimization of fluid dynamics in plate design, the robust structure obtained through brazing technique, and the superior heat transfer performance created by high turbulent flow. This structure makes them an indispensable solution in both industrial processes and energy efficiency-focused projects.
Brazed exchangers are one of the most efficient solutions of modern industrial heat transfer technology. These exchangers are formed by stacking thin stainless steel plates in a specific arrangement. The junctions of the plates are usually joined using copper or nickel-based brazing materials in a vacuum furnace environment. This production method guarantees the compact structure and high durability of the device.
Each plate has special channels that allow for controlled and efficient fluid direction. These channels create turbulence during flow, maximizing the heat transfer surface area. Turbulent flow provides a much higher heat transfer coefficient (U value) compared to laminar flow. As a result, high heat transfer is possible with much less surface area.
Compared to traditional tubular or shell-and-tube exchangers, brazed exchangers offer the same or even higher heat transfer performance in much smaller volumes. This compact design provides space savings and allows for more flexible system design. Additionally, the low fluid volume allows for faster adaptation to temperature changes, simplifying process control.
The brazing material used in brazed exchangers is also critical in terms of performance. Copper brazed models are widely preferred in cooling and air conditioning systems, while nickel brazed models offer safe use in industrial applications where corrosive fluids or higher temperatures are present.
The design of plates to optimize fluid dynamics, ensuring maximum heat transfer with high turbulent flow, and obtaining a compact, durable structure through vacuum furnace brazing method are the foundations. This makes it a strategic heat transfer solution that offers both energy efficiency and long-lasting use advantages for industrial enterprises.
Industrial Application Areas
Brazed exchangers undertake critical roles in many areas of the industry due to their compact structures, high heat transfer efficiencies, and durability. In different sectors, they directly contribute to the sustainability goals of businesses by providing both energy savings and operational reliability.
• Chiller Manufacturers
Chiller systems are one of the most commonly used solutions for meeting cooling needs in large-scale industrial facilities. Brazed exchangers add compactness and efficiency to chiller designs by providing the same capacity in smaller sizes thanks to their high heat transfer coefficients. Additionally, the low refrigerant volume reduces both environmental impact and operating costs.
• Cooling Machines
In industrial cooling machines, energy efficiency is of great importance for the sustainability of the system. Brazed exchangers provide energy savings by reducing the load on the compressor thanks to high-performance heat transfer. At the same time, their durable structures offer reliability with long-lasting use and low maintenance needs.
• Apartment Entry Stations
In buildings where central systems are commonly used, apartment entry stations play a critical role in transferring hot water and heat energy to the user. Brazed exchangers offer ease of installation with their compact structures in these systems and provide low-cost and efficient heat transfer. Additionally, high pressure and temperature resistance is an added advantage in terms of building safety.
• General Machinery Manufacturing
In the machinery manufacturing sector, process reliability is vital for the continuity of the production line. Brazed exchangers minimize overheating risks by meeting the cooling and heating needs of various production machines. This extends the machine's life and increases production efficiency by reducing downtime.
• Food Machinery and Processes
In the food sector, hygiene, reliability, and energy efficiency are the most basic requirements. Brazed exchangers are effectively used in pasteurization processes of milk, fruit juice, beer, and other beverages. Thanks to stainless steel plates and nickel brazing options, they offer solutions suitable for contact with food. Additionally, rapid heat transfer shortens process times, increasing the efficiency of the production line.
• Cold Cabinet Manufacturers
In the production of cold cabinets and commercial refrigerators, compactness, energy efficiency, and long life are critical criteria. Brazed exchangers provide high-performance heat transfer in these systems, allowing products to operate with lower energy consumption. Additionally, the low maintenance requirement provides a cost advantage to manufacturers and end-users.
Technical Advantages
Brazed exchangers have strong technical advantages that underlie their preference in industrial facilities. These advantages offer significant contributions not only in terms of initial investment costs but also in terms of operational efficiency, ease of maintenance, and long-term sustainability.
• Compact Design
The most distinctive feature of brazed exchangers is their extremely compact structures. Compared to traditional tubular exchangers, they can provide the same capacity in a much smaller volume. This provides space savings in facilities, increases installation flexibility, and allows easy integration into existing systems. This advantage creates critical value, especially in production facilities with limited space.
• High Heat Transfer Coefficient
Thanks to the special geometry of the plates, fluids enter a highly turbulent flow regime. This situation allows the heat transfer coefficient to be maximized. Therefore, higher heat transfer performance is achieved in a smaller surface area. This feature shortens process times and provides a direct cost advantage by reducing energy consumption.
• Durability and Reliability
Brazed exchangers are produced with copper or nickel brazing techniques. This production method provides superior durability against high pressures and temperatures. Additionally, material options developed against corrosion (e.g., stainless steel - nickel brazing combinations) allow for long-lasting and reliable use even in industrial environments with aggressive fluids.
• Low Maintenance Cost
Thanks to its design without moving parts, the failure rate is quite low. This reduces the frequency of planned maintenance and prevents unexpected downtimes. Additionally, it can be easily cleaned with CIP (Clean-in-Place) cleaning systems, which shortens maintenance times and reduces the workload for maintenance personnel.
• Low Total Cost of Ownership
In addition to the initial investment cost, the low maintenance requirement, long service life, and energy savings of brazed exchangers significantly reduce the total cost of ownership. In most scenarios, the return on investment (ROI) is completed within a few years. This provides not only a technical but also a strategic advantage for businesses.
Application Scenarios
Brazed exchangers can be integrated into a wide variety of applications in different sectors due to their compact structure, high efficiency, and reliability. This technology, which supports the energy savings, operational continuity, and low-cost goals needed by industrial facilities, stands out in the following scenarios:
• Process Cooling Systems
The efficient removal of excess heat generated in production lines is a critical factor in terms of both product quality and process reliability. Brazed exchangers increase energy efficiency by providing high heat transfer performance in process cooling systems. Especially in the plastics, chemical, and metal processing sectors, they increase productivity by shortening cooling times.
• Waste Heat Recovery
The waste heat released during processes in industrial facilities often goes unused. Brazed exchangers make it possible to recover this waste heat. The recovered energy can be used in other processes or integrated into the facility's energy needs. This approach provides significant energy savings to businesses and contributes to sustainability goals.
• Energy Systems (Cogeneration, Geothermal, and Solar Energy)
Brazed exchangers also play a critical role in energy systems. They work as a reliable intermediary in cogeneration facilities for the combined production of electricity and heat energy, in geothermal-based heating systems, and in solar energy-based applications. Thanks to their resistance to high temperature and pressure in these systems, they offer a long-lasting and efficient solution.
• Food Production Lines (Pasteurization, Milk, Fruit Juice, Beer, etc.)
In the food sector, hygienic standards and product safety are of great importance. Brazed exchangers are an ideal solution in food processes thanks to their smooth surface structure and CIP compatibility. In processes such as pasteurization, milk processing, fruit juice production, and beer fermentation, they maintain product quality while minimizing energy consumption.
• Data Center Cooling
With digitalization, uninterrupted cooling has become a critical requirement in data centers. Brazed exchangers are preferred in data center cooling solutions due to their high reliability and low maintenance needs. They reduce operating costs thanks to energy efficiency while ensuring system continuity.
• Automotive Production Processes
In the automotive industry, precise temperature control and durability are of great importance. Brazed exchangers are used in many stages, from paint lines to the production of engine parts. They shorten process times thanks to high heat transfer performance and offer long-term reliability thanks to their durability.
Material Selection and Reliability
The material selection used in brazed exchangers is one of the most critical factors in terms of the device's performance, durability, and long-term operating costs. Incorrectly selected material reduces energy efficiency and leads to early failures, imposing additional costs on the business.
• Plate Material: Stainless Steel
Mostly AISI 316L stainless steel plates are preferred. The 316L alloy stands out with its high corrosion resistance and more reliable performance, especially in chlorinated environments. Stainless steel plates provide safe operation under high pressure and variable temperatures thanks to their high mechanical strength. Additionally, their surface smoothness reduces the risk of contamination, offering an advantage in hygienic applications.
• Brazing Material: Copper and Nickel Alloys
• Copper Brazing: It is the most commonly used material in general industrial applications. Copper provides maximum efficiency in heat transfer thanks to its high thermal conductivity. It stands out as an economical choice in chiller systems, HVAC applications, and general process cooling.
• Nickel Brazing: It is preferred in more corrosive environments, where aggressive chemicals or high temperatures are present. It is also widely used in the food industry, especially in pasteurization and beverage production processes where hygienic requirements are at the forefront. Nickel alloys provide significant advantages in terms of long-term durability and food safety.
• Reliability and Long Life
Appropriate material selection directly extends the life of the device. Stainless steel and nickel alloy combinations provide protection against chemical corrosion and increase resistance to thermal fatigue. Thus, the exchanger can be operated reliably for many years with minimal maintenance requirements.
• Differences in Sectoral Application
• In HVAC and cooling systems, copper brazed stainless steel plates offer economical and efficient solutions.
• In the chemical, petrochemical, and food sectors, nickel brazed options are preferred for both safety and hygiene standards.
• In geothermal and energy recovery applications, material selection plays a decisive role in long-term performance and investment return (ROI).
Maintenance, Cleaning, and CIP Applications
Brazed exchangers stand out with their low maintenance requirements due to their compact structure without moving parts. However, regular maintenance and cleaning applications are of critical importance to maintain long-term performance and prevent a decrease in heat transfer efficiency. Especially in industrial processes, depending on the structure of the fluid, scaling, sediment accumulation, oil residues, or chemical precipitates may occur. Such accumulations increase the pressure drop of the exchanger and reduce energy efficiency.
• Periodic Control and Maintenance
• Depending on operating conditions, a performance test of the exchanger should be conducted at least once a year.
• By monitoring pressure drop, temperature difference, and flow measurements, signs of clogging or contamination can be detected early.
• Gaskets and connection points should be regularly visually inspected to prevent potential leakage risks.
• CIP (Cleaning in Place) Applications
The most common method for cleaning brazed exchangers is CIP (cleaning in place) systems. This method is based on passing special chemical solutions through the exchanger circuit without the need to disassemble the device.
• Acidic solutions (phosphoric, citric acid, etc.) are used to dissolve lime and minerals.
• Alkaline solutions are effective in cleaning oil and organic dirt.
• CIP application ensures maximum cleanliness on the plate surfaces of the exchanger while minimizing production downtime.
• Advantages of the CIP System
• Time Savings: There is no need to disassemble and reassemble the exchanger.
• Cost Advantage: Reduces labor and downtime costs.
• Efficiency: Quickly restores heat transfer performance to its previous level.
• Safety: Closed-loop cleaning eliminates the risk of operators coming into direct contact with chemicals.
• Additional Applications
• After CIP, the exchanger should be rinsed with clean water and cleared of chemical residues.
• In processes with heavy contamination, pre-treatment of the fluid entering the exchanger should be done with filtration systems.
• In critical applications (e.g., food processes, pharmaceutical industry), additional cleaning with disinfectant solutions suitable for hygiene standards is recommended.
• Tips for Long-Term Durability
• Operating pressure and temperature should not exceed the limits specified by the manufacturer.
• Sudden temperature changes should be avoided, and thermal shocks should be prevented.
• Regular maintenance records should be kept, and CIP frequency should be optimized according to the contamination tendency of the process.
Economic Analysis: Energy Savings and Return on Investment
Brazed exchangers are a strategic investment for industrial facilities not only in technical terms but also in terms of economic benefits. Thanks to their compact structure, high efficiency, and low maintenance requirements, they significantly reduce total operating costs (TCO - Total Cost of Ownership).
• Energy Savings
• The same performance is achieved with lower energy consumption thanks to the high heat transfer coefficient.
• Since heat losses are minimized, energy efficiency increases throughout the operation.
• Initial Investment Cost Advantage
• Brazed exchangers require lower material and installation costs as they are produced in much smaller sizes compared to traditional tubular exchangers.
• Occupying less space also reduces in-facility layout costs.
• Operating and Maintenance Costs
• Since it does not contain moving parts, the risk of failure is quite low.
• Maintenance time is shortened with the CIP (cleaning in place) method, and production downtimes are minimized.
• The limited need for spare parts keeps the maintenance budget lower in the long term.
• Return on Investment (ROI)
• In many industrial facilities, the return on investment period for brazed exchangers is between 1 - 3 years.
• In sectors where energy costs are high, this period can be even shorter.
• The return on investment should be measured not only through energy savings but also through low maintenance costs, fewer production downtimes, and increased process reliability.
• Strategic Added Value
• Profit margin increases thanks to energy savings and low maintenance costs.
• The use of environmentally friendly and sustainable technology contributes to the company's corporate reputation.
• Longer service life delays the need for renewal investment, providing an advantage in capital planning.
MIT Brazed Exchanger Solutions: Local and Global Perspective
MIT, as one of Turkey's leading exchanger manufacturers, holds a strong position both in the local market and globally. With its local production power, engineering capability, and production approach in accordance with international standards, MIT offers innovative and reliable solutions for industrial facilities.
• Local Power, Global Standards
MIT brazed exchangers are developed specifically for the needs of industrial organizations in Turkey, while also being produced in accordance with EN, ISO, and ASME standards. This ensures they are confidently preferred in both domestic and international projects.
• Energy Efficiency and Cost Advantage
• MIT solutions minimize energy consumption thanks to high heat transfer efficiency.
• With its compact design, it reduces both investment and operating costs.
• With low maintenance needs, it reduces the total cost of ownership (TCO).
• Industrial Application Areas
MIT brazed exchangers have a wide range of applications in chiller manufacturers, cooling machines, food processes, energy recovery systems, automotive, and machinery manufacturing sectors. This diversity is the most important indicator that the products can be safely used in different sectors.
• R&D and Innovative Approach
MIT continuously invests in R&D to develop performance-enhancing new designs and long-lasting material solutions in brazed exchangers. This approach is a strategic step towards meeting the future needs of both local industry and global customers.
Conclusion: Small Size, Big Power - A Strategic Investment for Sustainability in Industry
Brazed exchangers are among the critical equipment of modern industry with their compact designs, high heat transfer performances, and low operating costs. They offer both cost advantage and operational reliability by providing much higher efficiency in much smaller sizes compared to traditional systems.
• Energy and Efficiency Dimension
One of the most important priorities of industrial facilities is to increase energy efficiency. Brazed exchangers directly reduce the energy costs of businesses thanks to the high performance they provide in critical areas such as waste heat recovery, process cooling, food production, and data center cooling. This contributes to sustainable production goals.
• MIT's Contribution
MIT provides high efficiency, cost advantage, and long-term reliability to industrial facilities with its local production power and global competitive advantage. The solutions it offers in both Turkey and international markets not only meet today's efficiency needs of businesses but also draw a roadmap compatible with future sustainability strategies.
• Looking to the Future
Considering increasing energy costs, carbon emission reduction targets, and the need for uninterrupted efficiency in production processes, brazed exchangers will continue to be one of the key equipment of industrial transformation in the coming years. The solutions developed by MIT will not only meet today's demands but also ensure that industrial enterprises are ready for the future, sustainable, and competitive.