Industrial Plate Heat Exchanger: What It Is and How It Works

An industrial plate heat exchanger is a device designed to transfer heat between two separate fluids through thin metal plates. It is used in industrial processes to heat or cool fluids, recover thermal energy, improve energy efficiency, and reduce operating costs.

In the industrial sector, as the demand for energy savings, efficiency, and sustainability increases, the plate heat exchanger has become a key solution. Many facilities are looking for ways to recover waste heat, reduce consumption, and save space. 

A plate heat exchanger is a type of heat exchanger in which two fluids at different temperatures flow through separate channels formed by stacked, corrugated metal plates. Heat transfers through the plates (by conduction) from the hot fluid to the cold fluid, without the fluids mixing.

The plates can be either gasketed or brazed, depending on the application, operating temperature, and pressure.

Want to learn more about the different types of heat exchangers and how they compare? Check out our complete guide to heat exchangers.

The plates are arranged alternately to allow the two fluids to flow on opposite sides.

The plates are engineered with a corrugated pattern to increase turbulence, enhance heat transfer, and reduce the fluid film thickness between surfaces.

• Conduction: Heat is transferred through the metal plates.

• Convection: Within the channels formed between the plates, the fluids flow and efficiently exchange heat.

• Logarithmic Mean Temperature Difference (LMTD) is a key metric used to evaluate thermal performance.

• Gasketed plates: Can be disassembled, making maintenance easier.

• Brazed plates: Feature no gaskets, offering higher mechanical strength and better performance under demanding operating conditions.

High thermal efficiency

The thin and corrugated plate design promotes a high heat transfer coefficient, allowing for rapid and efficient heat exchange.

Compact design and space-saving

For the same thermal output, plate heat exchangers occupy less space compared to shell-and-tube solutions. This makes them ideal when installation space is limited.

Operational flexibility

The number and type of plates can be adjusted to modify the heat transfer surface, making it easy to adapt to different flow rates and temperature requirements.

Lower energy costs

Improved efficiency means less energy loss and reduced consumption of fuel or electricity for heating and cooling operations.

Greater sustainability

These systems allow for waste heat recovery, lower emissions, reduced waste, and a smaller environmental footprint.

Easy maintenance (in gasketed versions)

When equipped with gaskets, the plates can be easily disassembled, cleaned, and replaced, ensuring simpler upkeep and reduced downtime.

• Limited temperature and pressure tolerance compared to other types (such as some shell-and-tube heat exchangers), especially in gasketed versions.

• Plate displacement or deformation can occur when thermal conditions fluctuate significantly.

• Gasket wear in gasketed models may lead to leakage, higher maintenance needs, and additional costs.

• Fouling and scaling buildup is common when processing dirty fluids or those with particulates, which can reduce overall efficiency.

• Chemical and pharmaceutical plants, where high thermal precision and pure fluids are essential.

• Food and beverage industry, for pasteurization, cooling, and heating processes.

• HVAC systems and district heating, where space-saving and energy efficiency are critical.

• Cooling of oils and process fluids, and waste heat recovery in compressors and other equipment.

• Operating temperature and pressure: Ensure that the plate and gasket materials are suitable for your application.

• Number of plates and heat transfer surface: Should match the required thermal power.

• Type of fluid: Consider viscosity, fouling tendency, and corrosiveness.

Common options include stainless steel (AISI 304, 316), aluminum, and titanium for more demanding conditions. For corrosive fluids or aggressive environments, more resistant materials are recommended.

The floating head design allows one end of the tube bundle to move freely, accommodating thermal expansion and simplifying cleaning. It is a common choice in large-scale industrial exchangers where significant temperature fluctuations occur.

• Gasketed: Easier to maintain, but limited in terms of pressure and temperature resistance.

• Brazed: More robust, no gaskets required, ideal for harsh conditions—but less accessible for cleaning.

It’s important to calculate an acceptable pressure drop. An excessively high drop increases energy consumption due to higher pump requirements.

The plate design should induce turbulence to improve heat transfer, but without causing excessive pressure loss.

Implementing a plate heat exchanger can significantly contribute to a plant’s energy savings, with positive effects on both operating costs and environmental impact.

Useful strategies include:

• Regular cleaning and fouling control

• Using appropriate materials to minimize corrosion

• Designing for minimal pressure drop to reduce energy consumption

• Recovering residual heat for preheating or secondary use

Although plate heat exchangers do not use tubes in the same way as shell-and-tube exchangers, certain hybrid or modular configurations (e.g., compact systems or combined units) may include connection tubes or internal tube modules to handle high-pressure fluids or specific industrial processes. In these cases, the most commonly used materials include:

• Copper-nickel (CuNi 90/10 or 70/30): Excellent resistance to marine corrosion and high thermal conductivity, ideal for naval and offshore applications.

• Stainless steel (AISI 304 or 316): The most widely used in industrial environments for its durability and corrosion resistance, suitable for a broad range of fluids.

• Titanium: Used with highly corrosive fluids or seawater, where exceptional chemical resistance is required.

• Aluminum: Applied in lightweight or HVAC systems, where weight and good heat conductivity are key factors.

The choice of tube type (or integrated modules) depends on the fluid characteristics, temperature, pressure, and chemical compatibility with the system’s materials.

Not sure which material is best for your system? Contact our technical team for expert guidance or request a custom quote now.