Tube heat exchangers are one of the most reliable and widely used equipment to meet the heat transfer needs in industrial facilities. The basic principle in these systems is the heat exchange between two different fluids circulating through the tubes and the body without direct contact. Thus, a safe, controlled, and efficient energy transfer occurs between both liquids and gases.
Tubular exchangers stand out with their structures resistant to high temperature and pressure. These devices, usually consisting of a body, tube bundle, and headers, allow fluids to circulate in different directions or arrangements, adapting to different process needs. Counterflow, parallel flow, or crossflow designs can be chosen according to the need. This variety increases the flexible usage advantage of tubular exchangers.
One of the most important features of these exchangers is their long-lasting use. Thanks to their robust body structure and appropriate material selection, they can operate smoothly for years. Additionally, when periodic maintenance is done correctly, performance loss is minimized. In this respect, tubular exchangers stand out as an investment that reduces operating costs and provides a safe working environment.
Thanks to their compact designs, they save space and can be produced in different sizes, catering to a wide range of applications from small facilities to large industrial complexes. The ability to customize according to the special conditions required by the process is also one of the reasons these products are preferred. Every detail, from the arrangement of the tubes to the body structure, from the type of material to capacity, can be shaped according to the need.
The advantages provided by tubular exchangers are not limited to durability. With high heat transfer efficiency, they contribute to energy savings and offer an environmentally friendly solution. This feature holds strategic value for businesses in today's era where energy costs and sustainability concerns are increasing.
In short, tubular heat exchangers are indispensable as a reliable heat transfer solution in industrial facilities with their durability, flexible design options, high efficiency, and long-lasting structure. Their widespread use in different sectors such as food, energy, chemistry, metal, and maritime also shows how critical a role these equipment play.
Tubular heat exchangers have a simple but highly efficient structure. The body, tube bundle, headers, flanges, and gaskets form the main components of the exchanger. The tube bundle is the primary heat transfer surface through which the fluid passes. The body protects the tubes from external influences, while the headers direct the fluid's entry and exit. Flanges and gaskets ensure the system's sealing.
The working principle is quite clear: A fluid passing through the tubes and another fluid circulating on the body side transfer heat without direct contact. In this way, fluids with different temperature and pressure conditions transfer energy to each other safely and controlled.
The heat transfer arrangement can be designed in different ways according to the need:
• Counterflow systems provide the highest efficiency by using the temperature difference at the maximum level.
• Parallel flow systems are preferred in certain processes and offer balanced temperature distribution.
• Crossflow systems stand out in applications requiring compact solutions.
This flexible design approach makes tubular exchangers adaptable to different industrial applications. In terms of both energy efficiency and operational safety, tubular exchangers are among the indispensable equipment of modern facilities.
Custom Production Tubular Exchangers: Design Opportunity Suitable for the Process
In industrial processes, each application brings different needs. Therefore, tubular heat exchangers are often designed as custom production rather than standard solutions. The details of the process are analyzed by the engineering team, and the exchanger design is made considering the type of fluid, temperature values, pressure conditions, and capacity needs.
During the design phase, schematic drawings are prepared first, and dimensional suitability checks are carried out. Manufacturing drawings are created based on the approved drawings, and the production process is initiated. Thanks to this approach, each exchanger becomes a unique product optimized only for the process it is designed for.
After production, insulation is applied upon request to minimize heat losses. Additionally, exchangers can be grouped with series or parallel connections without capacity limitation, making it possible to reach the desired capacity for large-scale facilities.
These custom production exchangers, used in high-capacity areas such as petrochemical plants, power plants, and heavy industry applications, offer a long-lasting solution in terms of durability and performance. Ekin Industrial, with its engineering experience, develops solutions tailored to the needs of different sectors, providing reliable heat transfer.
Materials and Durability Used in Tubular Exchangers
The performance and lifespan of tubular heat exchangers are directly related to the quality of the materials used. Different processes, fluid properties, and operating conditions play a decisive role in material selection. Factors such as corrosion resistance, resistance to high temperature and pressure, and ease of cleaning are the most important criteria for correct material selection.
The materials commonly used in the manufacture of tubular exchangers are as follows:
• ST37 and ST35.8: Durable carbon steel materials are preferred in high-pressure applications.
• AISI 304 and AISI 316 stainless steel: Offer high corrosion resistance, hygienic, and long-lasting solutions.
• Copper: Provides efficient heat transfer thanks to its high thermal conductivity.
• Titanium: Offers superior corrosion resistance against aggressive fluids, especially in the maritime and chemical sectors.
• Bafon: Is one of the special alloy materials preferred in certain processes.
In material selection, not only chemical resistance but also wall thicknesses, welding technologies, and surface treatments are considered. Especially in high-pressure and corrosive environments, tubular exchangers produced with the right material combinations work smoothly for many years.
Ekin Industrial's production approach aims to offer reliable and efficient solutions by selecting the most suitable material for process needs, not limited to standard materials.
Hygienic Tubular Exchangers: Solutions for Food and Chemical Applications
In the food and chemical industries, hygiene, safety, and process continuity are the most critical factors. Equipment used in these sectors must be resistant to high temperature and pressure, as well as easy to clean and have a hygienic design. At this point, tubular heat exchangers offer reliable solutions by surpassing the limits of plate exchangers.
While the gaskets used in plate exchangers show limited durability at high temperatures and pressures, tubular exchangers work smoothly under these conditions. Removable and fully hygienic tubular exchangers developed by MIT engineers can withstand temperature values up to 350 °C. Moreover, the welding processes performed on these products are carried out with special techniques to provide smoothness on the flow surface.
The production of hygienic tubular exchangers is secured with certified welders and a three-stage quality control process. While designs suitable for food processing processes are made, the capacity need, installation area, and the characteristics of the product to be processed are considered in detail.
In high-pressure applications, not only capacity calculations but also material wall thicknesses and welding technologies are of vital importance. Therefore, Ekin Industrial tests each hygienic tubular exchanger it produces at 1.5 times the normal operating pressure for 72 hours. Products that pass these tests successfully are dispatched for safe use.
For businesses looking for reliable, hygienic, and long-lasting solutions in the food and chemical sectors, tubular exchangers are one of the best choices.
Stainless and Titanium Pool Exchangers
One of the prominent areas of use for tubular exchangers is pool heating systems. Stainless steel and titanium pool exchangers developed by MIT provide high efficiency when integrated with solar pool heating systems or boiler solutions. These products not only heat the pool water but also protect heating systems from the corrosive effects of chlorine, salt, and other chemicals, offering long-lasting use.
MIT pool exchangers have much higher heat transfer performance than their counterparts thanks to their spiral and twisted designs. With their compact and durable structures, they can be easily adapted to pool projects of different sizes. These exchangers, which can be produced in a wide capacity range from small spa pools to Olympic-scale facilities, are offered with different models ranging from 15 kW to 1750 kW.
The prominent advantages of pool exchangers are as follows:
• High heat transfer efficiency (up to 10000 W/m² °C, 5–6 times more efficient than traditional exchangers)
• Compact design (occupies 1/10 of the space compared to classic exchangers)
• High corrosion resistance with stainless steel and titanium options
• Production in accordance with ASME VIII-1 standards
• Resistance to 205 °C temperature and 1.3 MPa pressure
These exchangers are indispensable in pool and spa systems in terms of both comfort and operational safety. MIT stainless and titanium pool exchangers are an ideal choice for facilities looking for long-lasting, low-cost, and efficient solutions.
Oil Cooler Tubular Exchanger Types (BYS and MOR Series)
Tubular exchangers offer effective solutions not only in liquid or gas heat transfer but also in the oil cooling needs of industrial machines. Especially in hydraulic systems, compressors, and heavy industry machines, keeping the oil temperature under control is critically important for system efficiency and safety. The BYS and MOR series oil cooler tubular exchangers developed for this need stand out with their durable structures and high performance.
BYS Oil Cooler Exchangers
The grooved copper tubes used in the BYS series offer high durability with a wall thickness of 1.2 mm and a diameter of Ø16 mm. They provide safe use up to 140 °C temperature and 9 bar pressure as standard. With 24 different capacity models ranging from 18,100 kcal/h to 371,000 kcal/h, they adapt to different applications.
• Outer tube material: ST 35.8
• Inner tube material: Copper
• Covers: Cast
MOR Oil Cooler Exchangers
The tubes used in the MOR series have a wall thickness of 0.6 mm and a diameter of Ø9.52 mm. They are designed to be suitable for a maximum of 120 °C temperature and 6 bar pressure. There are 9 different capacity models ranging from 60 lt/min to 1200 lt/min.
• Outer tube material: ST 35.8
• Inner tube material: Copper
• Covers: Cast
Both series offer advantages of high efficiency, compact structure, and long-lasting use. The correct model selection in oil cooling applications increases machine performance and guarantees the safe operation of the system.
Energy Efficiency and Environmental Sustainability
Today, increasing energy costs and the need for environmental sustainability play a decisive role in the selection of every equipment used in industrial facilities. Modern businesses aim not only to increase production capacity but also to reduce energy consumption and develop environmentally friendly production processes. At this point, tubular heat exchangers stand out with the advantages they offer in terms of energy efficiency and environmental sustainability.
Tubular exchangers provide a twofold benefit to businesses thanks to low energy consumption and waste heat recovery: they reduce operating costs and shrink the carbon footprint. Especially counterflow designs make maximum heat transfer possible by using the temperature difference most efficiently. In this way, less energy is consumed for the same process, continuity and stability are maintained in processes. Ensuring energy efficiency not only reduces costs but also reduces the risk of failure in production lines.
The energy recovery feature provides a particularly critical advantage in large-capacity facilities. Waste heat released from boilers, compressors, or processes can be recovered back into the system through tubular exchangers. Thus, unnecessary energy consumption is prevented, and additional costs in production processes are minimized.
In terms of environmental sustainability, tubular exchangers are an integral part of modern production understanding. Thanks to their long-lasting designs, the need for frequent renewal does not arise, which provides significant savings in raw material and resource use. Their structures requiring less maintenance increase energy and labor efficiency while contributing to the conservation of natural resources.
Moreover, with the use of tubular exchangers, businesses gain an advantage in complying with environmental regulations and international standards. These equipment are seen as a strategic investment in line with sustainable production certificates, green energy projects, and environmentally friendly production vision.
Tubular exchangers developed by Ekin Industrial not only provide high-performance heat transfer but also serve the sustainable industries of the future with environmentally friendly engineering solutions. These products, which achieve both energy savings and environmental protection goals simultaneously, increase the competitiveness of businesses while supporting responsible production understanding.
In conclusion, tubular heat exchangers are not just equipment in today's industry, but also a strategic tool for energy efficiency, sustainability, and environmentally friendly production.
Installation and Maintenance Guide: Tips for Long Life in Tubular Exchangers
Correct installation and regular maintenance are critically important for tubular exchangers to operate with high performance and have a long lifespan. Errors made during installation or maintenance deficiencies can lead to both efficiency loss and unexpected failures.
Pre-Installation Preparation
The area where the exchanger will be mounted should be wide, accessible, and protected from environmental factors. A solid foundation should be prepared to prevent vibrations, and necessary pipe connections and flanges should be positioned appropriately.
Installation Process
During assembly, gaskets should be placed carefully, and connection points should be subjected to a leak test. After all connections are completed, a pressure test should be applied to confirm the safety of the system.
Maintenance and Monitoring
Regular maintenance is essential for tubular exchangers to operate efficiently. Sediment and scaling that can accumulate in fluids negatively affect heat transfer. Therefore, periodic cleaning should be performed, and the inner surface of the tubes should be checked. Additionally, pressure and temperature values should be constantly monitored to detect possible abnormalities early.
In Ekin Industrial's production process, each exchanger is subjected to a 1.5 times pressure test before being dispatched. These tests guarantee reliability and durability during the usage period. The complete implementation of installation and maintenance steps extends the life of the exchanger and reduces operating costs.
Sectoral Areas of Use
Tubular heat exchangers play a critical role in many industries thanks to their wide range of applications and process-specific design opportunities. Solutions suitable for the needs of different sectors make these products indispensable.
Food Industry
Tubular heat exchangers play a critical role in the food sector in terms of hygiene and safety. They provide reliable use in production lines of dairy products, fruit juices, beer, and other beverages thanks to their hygienic designs made of stainless steel.
Their easy-to-clean structures increase compliance with food safety standards, while their resistance to high temperature and pressure allows them to work smoothly in sensitive processes such as pasteurization and sterilization. Thus, both product quality is preserved and continuity is ensured in production lines.
Energy Sector
Tubular heat exchangers are critical equipment for efficiency and continuity in the energy sector. They provide reliable performance in power plants, cogeneration systems, and heat recovery applications.
Thanks to their structures resistant to high temperature and pressure, they provide long-lasting use and reduce energy costs by recovering waste heat. Thus, businesses gain both economic advantage and contribute to sustainability goals.
Metal Industry
Tubular heat exchangers offer reliable solutions with their structures resistant to high temperature and pressure in metal processing processes. Thanks to being made of durable materials, they provide long-lasting use and do not experience performance loss even in harsh working conditions.
Additionally, they support process stability and ensure production continuity. This feature increases efficiency in the metal sector and contributes to the uninterrupted operation of production lines.
Maritime
Tubular heat exchangers used in the maritime sector show high resistance to the corrosive effects of saltwater and harsh environmental conditions. Models made of titanium and stainless steel provide reliable performance in cooling and heating applications in ship systems. Thus, they offer long-lasting use and low maintenance needs.
HVAC Systems
Tubular exchangers play an important role in comfort air conditioning, hot water production, and ventilation solutions. They provide sustainable use in buildings by increasing energy efficiency. Thanks to their compact designs, they can be easily integrated into new or existing building technologies.
Petrochemical and Pharmaceutical Sector
The processes used in the petrochemical and pharmaceutical sector often involve aggressive chemicals, high temperature, and pressure conditions. Tubular exchangers made of materials resistant to these challenging conditions support safe and uninterrupted production. Thus, process safety is guaranteed, and production continuity is ensured.
Automotive Industry
In the automotive sector, temperature control is critically important in production lines, test systems, and paint applications. Tubular exchangers optimize fluid management thanks to their compact and efficient structures. In this way, operational continuity is maintained in production processes, and efficiency is increased.
Textile Sector
In the textile industry, dyeing, finishing, printing, and drying processes require high temperature control. Tubular heat exchangers optimize energy consumption in these processes, reducing operating costs. At the same time, they support the stable operation of production lines, contributing to efficiency.
The main reason for the widespread use of tubular exchangers in different sectors is their reliability, energy efficiency, and customizable structures suitable for the process.
Ekin Industrial's Tubular Exchanger Solutions
Ekin Industrial is one of Turkey's leading companies with its engineering experience and production capacity in tubular heat exchangers. The company, which develops solutions suitable for the needs of different sectors, offers products focused on high efficiency, durability, and long life.
Tubular exchangers produced under the MIT brand are delivered to customers with both standard and special designs. These products, used in many fields such as food, energy, metal, maritime, chemistry, automotive, and HVAC, are developed with material and design options suitable for process conditions.
The prominent features of the solutions offered by Ekin Industrial are as follows:
• High heat transfer efficiency and energy savings
• Different material alternatives such as ST37, AISI 316L, titanium, copper
• Temperature resistance up to 350 °C and safe use under high pressure
• 72-hour quality control at 1.5 times pressure test for each exchanger
• Possibility of series/parallel connection for process-appropriate insulation and capacity increase
The engineering team determines the most suitable solution by conducting special analysis for each project. Ekin Industrial, which progresses meticulously in design, manufacturing, and quality control processes, offers reliable and sustainable solutions with its customer-oriented approach.
Ekin Industrial's Tubular Exchanger Solutions
Ekin Industrial is one of Turkey's leading companies with its engineering experience and production capacity in tubular heat exchangers. The company, which develops solutions suitable for the needs of different sectors, offers products focused on high efficiency, durability, and long life.
Tubular exchangers produced under the MIT brand are delivered to customers with both standard and special designs. These products, used in many fields such as food, energy, metal, maritime, chemistry, automotive, and HVAC, are developed with material and design options suitable for process conditions.
The prominent features of the solutions offered by Ekin Industrial are as follows:
• High heat transfer efficiency and energy savings
• Different material alternatives such as ST37, AISI 316L, titanium, copper
• Temperature resistance up to 350 °C and safe use under high pressure
• 72-hour quality control at 1.5 times pressure test for each exchanger
• Possibility of series/parallel connection for process-appropriate insulation and capacity increase
The engineering team determines the most suitable solution by conducting special analysis for each project. Ekin Industrial, which progresses meticulously in design, manufacturing, and quality control processes, offers reliable and sustainable solutions with its customer-oriented approach.
Conclusion: Reliable and Efficient Heat Transfer in Industrial Processes
Tubular heat exchangers are indispensable equipment in industrial processes with their durable structures, high efficiency, and process-specific design opportunities. They have a very wide range of applications from food safety to energy efficiency, from chemical processes to maritime and metal industry.
Tubular exchangers produced with correct material selection, engineering calculations, and meticulous quality control processes offer long-lasting and reliable solutions. Additionally, thanks to features such as energy savings and waste heat recovery, they reduce costs for businesses while also contributing to environmental sustainability.
MIT tubular exchangers developed with Ekin Industrial's expertise meet all the needs of different sectors with both standard and special production options. These products are not only equipment but also a strategic investment that increases the competitiveness of businesses.
In conclusion, tubular exchangers will continue to guide the sustainable production understanding of the future by providing reliable, efficient, and environmentally friendly heat transfer in modern industrial facilities.