Custom Industrial Heat Exchangers for Process Heating and Cooling
Shell and tube, stainless steel, condenser, evaporator and process cooler solutions built for chemical, food, pharmaceutical, water treatment and industrial process systems.
Heat Exchangers Built for Different Process Requirements
Different projects need different heat exchanger structures. Some buyers need high-pressure shell and tube units, while others care more about corrosion resistance, vapor condensation, evaporation, process cooling or limited installation space. Use the cards below to find the direction that fits your process first.
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Shell and Tube Heat Exchangers
For industrial heating, cooling, condensation and heat recovery applications where stable operation and pressure resistance are important.
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Stainless Steel Heat Exchangers
For corrosive, sanitary or clean process systems using SS304, SS316L or other stainless steel materials based on the medium.
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Condensers
For vapor condensation, solvent recovery, steam systems and process cooling lines where vapor must be converted back into liquid.
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Evaporators
For concentration, evaporation and thermal separation processes where controlled heat transfer is required.
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Process Coolers
For reducing the temperature of liquid, gas or process streams before storage, filtration, packaging or the next production stage.
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Custom Heat Exchangers
Designed around your medium, flow rate, temperature range, pressure, fouling tendency, cleaning method and installation layout.
Send us your medium, flow rate, inlet and outlet temperature, operating pressure and installation space. We can help review the suitable direction before quotation.
What We Need to Size a Heat Exchanger for Your Process
Reliable heat exchanger design and quotation depend on accurate process data. Please provide the key details below so we can deliver the right solution for your application.
Prepare These
Details Before
Quotation
The more complete your data, the more accurate our sizing, performance prediction, and quotation will be.
Send Your Process ParametersHot Side Medium
Cold Side Medium
Flow Rate
Inlet / Outlet Temperature
Operating Pressure
Design Temperature
Allowable Pressure Drop
Fouling Tendency
Installation Space
Required Code
Custom Heat Exchanger Design Based on Real Operating Conditions
Every heat exchanger is sized according to real operating conditions, not only by model name. ChannelVessel can customize shell diameter, tube size, tube length, heat transfer area, pressure rating, material, testing method and surface finish based on your medium, temperature, flow rate, pressure and installation layout.
Technical Capability Matrix for Custom Heat Exchanger Projects
| Item | Available Range / Options | Project Consideration |
|---|---|---|
| Heat Transfer Area | 1 m² to 1,000 m² custom range | Selected according to heat duty, flow rate, temperature difference and fouling factor. |
| Shell Diameter | DN200 to DN3000 | Customized based on capacity, tube bundle arrangement, pressure rating and installation space. |
| Tube Diameter | 19 mm / 25 mm / 32 mm options | Selected according to medium property, fouling tendency, velocity and cleaning requirement. |
| Tube Wall Thickness | 1.5 mm to 3 mm | Based on design pressure, corrosion allowance, material and service life requirement. |
| Tube Length | 1 m to 8 m | Customized according to heat transfer area, layout, maintenance space and transport limit. |
| Design Pressure | Vacuum to 10 MPa | Higher pressure can be reviewed according to project design, material and code requirement. |
| Design Temperature | -20°C to 350°C | Higher temperature can be designed with suitable material, sealing and expansion allowance. |
| Common Materials | SS304, SS316L, 2205 duplex stainless steel, carbon steel, Q345R, SA516 Gr.70 | Material is selected according to medium corrosion, temperature, pressure and project standard. |
| Testing | Hydrostatic test, air tightness test, RT / UT / PT / MT as required | Testing plan can follow drawing, inspection requirement, client standard or code requirement. |
| Surface Finish | Pickling, passivation, polishing, blasting, coating | Surface treatment is selected according to corrosion resistance, cleanliness and installation environment. |
Heat Transfer Area
1 m² to 1,000 m² custom range
Selected according to heat duty, flow rate, temperature difference and fouling factor.
Shell Diameter
DN200 to DN3000
Customized based on capacity, tube bundle arrangement, pressure rating and installation space.
Tube Diameter
19 mm / 25 mm / 32 mm options
Selected according to medium property, fouling tendency, velocity and cleaning requirement.
Tube Wall Thickness
1.5 mm to 3 mm
Based on design pressure, corrosion allowance, material and service life requirement.
Tube Length
1 m to 8 m
Customized according to heat transfer area, layout, maintenance space and transport limit.
Design Pressure
Vacuum to 10 MPa
Higher pressure can be reviewed according to project design, material and code requirement.
Design Temperature
-20°C to 350°C
Higher temperature can be designed with suitable material, sealing and expansion allowance.
Common Materials
SS304, SS316L, 2205 duplex stainless steel, carbon steel, Q345R, SA516 Gr.70
Material is selected according to medium corrosion, temperature, pressure and project standard.
Testing
Hydrostatic test, air tightness test, RT / UT / PT / MT as required
Testing plan can follow drawing, inspection requirement, client standard or code requirement.
Surface Finish
Pickling, passivation, polishing, blasting, coating
Surface treatment is selected according to corrosion resistance, cleanliness and installation environment.
The ranges above are typical customization capabilities for heat exchanger projects. Final dimensions, pressure rating, material thickness and testing requirements are confirmed after reviewing your process data, drawing requirements and applicable standards.
Key Engineering Factors That Affect Heat Exchanger Performance
Heat exchanger performance depends on more than equipment size. In real projects, flow rate, temperature difference, material, fouling tendency, pressure drop and thermal expansion all affect the final design.
Heat Duty Is Not Decided by Size Alone
A larger shell does not always mean better performance. Heat duty depends on flow rate, temperature difference, fluid properties, tube arrangement and allowable pressure drop. We review these conditions before confirming heat transfer area and structure.
Material Must Match the Medium
For clean water or low-corrosion media, carbon steel may be suitable. For corrosive liquids, food process lines or pharmaceutical applications, stainless steel such as SS304 or SS316L is usually considered. Material selection affects service life, cleaning and maintenance cost.
Pressure Drop Needs to Be Controlled
If the pressure drop is too high, the system may require a larger pump or suffer unstable flow. We consider pressure drop during both tube side and shell side design, instead of only focusing on heat transfer area.
Fouling Changes the Design
For media that can crystallize, scale, contain solids or leave residue, the exchanger may need suitable tube diameter, removable structure or easier cleaning access. Fouling is considered early because it affects long-term performance, not only first-day operation.
Expansion and Temperature Difference Matter
When hot and cold sides have a large temperature difference, thermal expansion must be considered in tube sheet, shell and support design. This helps reduce stress, leakage risk and deformation during long-term operation.
These engineering factors help us recommend a heat exchanger that fits the process, not just a unit that matches a rough size or material description.
Heat Exchanger Construction Options for Maintenance and Operation
Product type is only one part of heat exchanger selection. The mechanical construction also affects thermal expansion, cleaning access, maintenance time, installation clearance and lifecycle cost. ChannelVessel reviews these factors before the fabrication drawing is finalized.
Fixed Tube Sheet Heat Exchanger
In a fixed tube sheet design, the tube sheets are welded or otherwise fixed to the shell. The construction is compact and straightforward, making it a practical choice when operating conditions are stable and the shell-side fluid is relatively clean.
U-Tube Heat Exchanger
U-tube construction allows the tube bundle to expand and contract more freely as process temperatures change. This makes it useful where the shell side and tube side may experience a significant temperature difference or repeated thermal cycling.
Floating Head / Removable Tube Bundle
A floating head or removable bundle construction is selected when shell-side inspection, cleaning or bundle removal is important. It also allows the shell and tube bundle to expand more independently under changing operating temperatures.
Custom Nozzle, Support and Installation Layout
For project equipment, nozzle direction and support arrangement can be as important as thermal performance. ChannelVessel can review piping orientation, equipment footprint, lifting requirements, support positions and maintenance clearance before drawings are approved.
Send the medium, flow rate, inlet/outlet temperature, operating pressure, fouling tendency, cleaning method and available installation space. We can review the mechanical construction together with the thermal duty.
Material Options for Different Media and Corrosion Conditions
Material selection affects corrosion resistance, service life, cleaning method and long-term maintenance cost. ChannelVessel selects heat exchanger materials according to the medium, chloride content, temperature, pressure, cleaning requirement and project standard.
Common Material Options and Typical Applications
| Material | Suitable For | Project Note |
|---|---|---|
| Carbon Steel | General industrial water, steam and low-corrosion process fluids. | Cost-effective for non-corrosive or low-corrosion applications. |
| SS304 | Clean water, food-related process and mild chemical media. | Common stainless steel option for clean and mild service conditions. |
| SS316L | Corrosive liquids, chloride-containing environments and sanitary applications. | Better corrosion resistance than SS304, often considered for sanitary or more demanding media. |
| Duplex Stainless Steel 2205 | Higher corrosion resistance and higher strength requirements. | Suitable when both corrosion resistance and mechanical strength are important. |
| Titanium | Seawater, strong chloride media and special corrosion conditions. | Available by project requirement after material and process review. |
| Nickel Alloy | High-corrosion chemical process applications. | Available by project requirement for special chemical or high-corrosion service. |
Carbon Steel
General industrial water, steam and low-corrosion process fluids.
Cost-effective for non-corrosive or low-corrosion applications.
SS304
Clean water, food-related process and mild chemical media.
Common stainless steel option for clean and mild service conditions.
SS316L
Corrosive liquids, chloride-containing environments and sanitary applications.
Better corrosion resistance than SS304, often considered for sanitary or more demanding media.
Duplex Stainless Steel 2205
Higher corrosion resistance and higher strength requirements.
Suitable when both corrosion resistance and mechanical strength are important.
Titanium
Seawater, strong chloride media and special corrosion conditions.
Available by project requirement after material and process review.
Nickel Alloy
High-corrosion chemical process applications.
Available by project requirement for special chemical or high-corrosion service.
Final material selection should be confirmed after reviewing the medium composition, operating temperature, chloride content, cleaning method and applicable project standard.
Manufacturing and Inspection for Reliable Heat Transfer Equipment
As a pressure vessel and process equipment manufacturer, ChannelVessel controls heat exchanger fabrication from tube sheet machining, shell welding and tube bundle assembly to pressure testing, NDT inspection, surface treatment and final shipment inspection.
Key Manufacturing and Inspection Steps
Each custom heat exchanger is manufactured according to approved drawings, process requirements and project inspection standards.
Machining & AssemblyTube sheet drilling, tube bundle assembly and baffle plate fabrication.
Tube Sheet Drilling and Machining
Tube sheets are drilled and machined according to drawing requirements to ensure tube layout accuracy and assembly fit.
Tube Bundle Assembly
Tube bundles are assembled according to tube arrangement, baffle spacing and heat transfer design.
Baffle Plate Fabrication
Baffle plates are fabricated to support the tube bundle and guide shell-side flow for stable heat transfer performance.
Welding & FabricationTube-to-tube-sheet connection, shell welding, nozzle and flange welding.
Tube-to-Tube-Sheet Welding or Expansion
Tube ends can be welded or expanded according to design requirement, pressure rating and medium condition.
Shell Fabrication and Welding
Shells are rolled, fitted and welded according to approved drawings and pressure vessel fabrication procedures.
Nozzle and Flange Welding
Nozzles and flanges are welded with attention to alignment, sealing surface, pressure rating and connection requirements.
Testing & ShipmentPressure testing, air tightness testing, NDT, surface treatment and final inspection.
Hydrostatic Pressure Testing
Hydrostatic testing is performed to verify pressure resistance before delivery.
Air Tightness Testing
Air tightness testing can be arranged when sealing performance is required by the project.
RT / UT / PT / MT Inspection as Required
NDT inspection can be performed according to drawing, project specification or inspection requirement.
Surface Treatment
Pickling, passivation, blasting or coating can be selected according to material, corrosion condition and installation environment.
Final Dimensional Inspection Before Shipment
Dimensions, nozzles, flanges, nameplate, surface condition and shipment protection are checked before packing.
Heat Exchangers for Industrial Process Applications
Industrial heat exchangers are used in many process systems for heating, cooling, condensation, evaporation and heat recovery. ChannelVessel manufactures custom heat exchangers for chemical, petrochemical, food, pharmaceutical, water treatment and new energy applications based on real operating conditions and project requirements.
Chemical Processing
Heating, cooling, condensation and solvent recovery for chemical production, synthesis, separation and process reaction systems.
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Petrochemical & Oil Gas
High-pressure and high-temperature process heat exchange for petrochemical production, oil and gas processing and related industrial systems.
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Food & Beverage
Stainless steel heating, cooling and sanitary process systems for food ingredients, beverages, clean water and process liquids.
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Pharmaceutical
Clean process heating and cooling with controlled material selection, surface finish and inspection requirements for pharmaceutical production lines.
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Water Treatment
Cooling, heating and thermal recovery for process water systems, wastewater treatment, filtration lines and industrial water circulation systems.
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New Energy
Thermal management for battery materials, chemical process lines, energy storage systems and related new energy production processes.
View Industry SolutionsHow We Customize a
Heat Exchanger for Your Project
You do not need a complete drawing to get started. Just send us your process parameters, and our engineers will take care of the rest.
Confirm Medium
and Flow Rate
Review hot side and cold side media, flow rate and fluid characteristics.
Review
Temperatures
Check inlet and outlet temperatures for heating, cooling, condensation or heat recovery.
Calculate
Heat Duty
Review heat duty, temperature difference and allowable pressure drop.
Select Material
and Structure
Choose suitable material, tube size, shell structure and cleaning method.
Confirm Drawings
and Layout
Confirm dimensions, nozzles, flange standards, supports and installation space.
Manufacture
and Test
Fabricate, inspect, pressure test and prepare the heat exchanger for shipment.
Shell and Tube, Condenser or Process Cooler:
Which One Do You Need?
Different processes have different thermal requirements. Use this quick comparison guide to identify the right equipment for your application.
Start With Your Process Requirement
Instead of choosing by equipment name first, start from what your process needs to do: transfer heat between liquids, condense vapor, evaporate liquid, cool a process stream, resist corrosion or fit a special layout.
Questions Buyers Often Ask Before Ordering a Custom Heat Exchanger
These questions focus on quotation data, material selection, cleaning structure, drawings, inspection and process system requirements.
01 What information do you need to quote a custom heat exchanger?
Please send the hot side and cold side media, flow rate, inlet and outlet temperatures, operating pressure, design temperature, material preference and installation layout. If you already have drawings, nozzle orientation or project standards, you can send them together for a more accurate quotation.
02 Can you manufacture shell and tube heat exchangers according to ASME requirements?
Yes. ChannelVessel manufactures pressure vessels and process equipment, and shell and tube heat exchangers can be designed and fabricated according to project requirements, including ASME-related pressure vessel requirements when specified. Final code, material, inspection and documentation details should be confirmed before production.
03 How do I choose between carbon steel and stainless steel?
Carbon steel is often used for general industrial water, steam or low-corrosion media. Stainless steel such as SS304 or SS316L is usually considered for clean process, sanitary applications or more corrosive media. The final material should be selected based on medium composition, chloride content, temperature, pressure and cleaning requirements.
04 Can the tube bundle be removable for cleaning?
Yes, removable tube bundle designs can be considered when cleaning, maintenance or fouling control is important. Whether a fixed tube sheet, U-tube or removable bundle structure is suitable depends on the medium, pressure, temperature difference, space and maintenance method.
05 Can you design heat exchangers for corrosive media?
Yes. For corrosive media, we review the medium composition, concentration, temperature, chloride content and service condition before selecting material. SS316L, duplex stainless steel or special alloy materials may be considered according to project requirements.
06 Do you provide drawings before production?
Yes. After confirming the main process parameters and project requirements, we can provide drawings for review before production. The drawing can include main dimensions, nozzle position, flange standard, support structure, material and key technical details.
07 What tests are done before shipment?
Testing can include hydrostatic pressure testing, air tightness testing, dimensional inspection and surface inspection. RT, UT, PT or MT inspection can also be arranged when required by drawings, pressure rating, welding specification or project standard.
08 Can you make condensers and evaporators as part of a process system?
Yes. Condensers, evaporators, process coolers and shell and tube heat exchangers can be manufactured as individual equipment or as part of a process system. Please send your process flow, medium, temperature, pressure and installation requirements so we can review the suitable equipment scope.
Need a Heat Exchanger for Your Process Line?
Send us your medium, flow rate, inlet and outlet temperature, pressure, material requirement and installation space. Our engineering team will review your process conditions and provide a suitable heat exchanger solution.
