Why Is Copper Used in Heat Exchangers?

Copper tubes are used in industrial heat exchangers for their excellent thermal conductivity, corrosion resistance, strength, and easy fabrication. Copper and copper-nickel alloys ensure efficient, durable, and low-maintenance performance in power plants, marine systems, HVAC units, and process industries.

In power generation, petrochemical refining, marine cooling, and HVAC manufacturing, heat exchangers are critical components. Their performance directly affects plant efficiency, equipment lifespan, and operating cost.

Copper (and copper-based alloys like copper-nickel and aluminum brass) remain the materials of choice for industrial heat exchangers worldwide. Their unmatched combination of thermal conductivity, corrosion resistance, mechanical strength, and workability make them indispensable in demanding environments.

At Admiralty Industries, we supply copper, aluminum brass, and copper-nickel tubes specifically engineered for condensers, chillers, desalination units, and cooling systems operating under tough thermal and corrosive conditions. Here’s why copper continues to set the standard.

The primary function of a heat exchanger is to transfer heat efficiently. Copper’s thermal conductivity (around 390 W/m·K) is among the highest of all industrial metals, significantly higher than stainless steel or titanium.

In practice, this means:

• Faster heat transfer between fluids

• Smaller heat exchanger size for the same duty

• Lower energy consumption and improved system efficiency

In high-demand systems, from refinery condensers to power plant coolers, copper tubes help operators achieve maximum heat transfer in minimal space, keeping processes energy-efficient and cost-effective.

Industrial heat exchangers operate in harsh conditions: seawater, brine, chlorinated cooling water, or hydrocarbon condensates. Copper’s resistance to corrosion, particularly in its alloyed forms, ensures reliability over decades of continuous service.

CuNi 90/10 and CuNi 70/30 alloys are the backbone of marine and offshore cooling systems. They provide:

• Excellent resistance to general and pitting corrosion in seawater

• Natural biofouling resistance, reducing marine growth in tubes

• Superior resistance to erosion at high flow velocities

For shipbuilding, desalination, and coastal power generation, CuNi tubes extend operating life and minimize unplanned shutdowns, a critical factor in environments where maintenance access is limited and downtime is costly.

Aluminum brass (CuZn28Sn1As) is widely used in thermal power stations and industrial condensers. Its protective oxide film resists impingement attack and dezincification in brackish or polluted water systems.

Where flow rates are high and water quality fluctuates, aluminum brass provides the balance between cost, durability, and corrosion control that many plant operators seek.

Each alloy’s composition is tailored to its operating environment, and choosing the right one is key to ensuring heat exchanger longevity.

Industrial heat exchangers must withstand high internal pressures, fluctuating temperatures, and vibration. Copper and its alloys maintain dimensional stability and fatigue resistance while offering excellent ductility for manufacturing.

This balance simplifies production processes such as:

• U-bending and finning for compact coils

• Tube expansion into tube sheets

• Brazing and welding for assembly and repair

For OEMs and fabricators, this translates into easier forming, consistent quality, and faster lead times, all without compromising mechanical integrity.

Material cost is only one part of the equation. In industrial facilities, lifecycle cost, including fabrication, installation, and maintenance, determines long-term ROI.

Copper’s advantages extend beyond initial performance:

• Ease of fabrication reduces production time and tooling wear.

• Simple joining and retubing minimize downtime during overhauls.

• Global material availability ensures reliable sourcing and shorter turnaround.

These factors make copper tubes the cost-efficient solution for both new heat exchanger builds and retrofit projects.

Power generation

Copper-nickel and aluminum brass tubes are essential in steam condensers, cooling water systems, and feedwater heaters. Their reliability under continuous load supports consistent plant efficiency.

Marine and offshore

In shipboard condensers, oil coolers, and ballast water systems, CuNi tubes resist seawater corrosion and biofouling, ensuring long-term durability in aggressive marine conditions.

Desalination and water treatment

Multi-stage flash (MSF) and reverse osmosis (RO) plants rely on copper-nickel tubes for their combination of thermal efficiency and seawater resistance, critical to maintaining output and minimizing maintenance.

HVAC and refrigeration

Commercial HVAC coils, chillers, and evaporators use finned copper tubes for high heat transfer efficiency in compact spaces, improving energy ratings and reducing refrigerant charge.

The best tube material depends on several operating parameters:

• Cooling medium composition and velocity

• Temperature and pressure conditions

• Expected service life and maintenance intervals

• Environmental and industry standards (ASTM, ASME, MIL-T)

At Admiralty Industries, our engineering team works closely with OEMs, EPCs, and plant operators to select the optimal alloy and tube specification for each project, balancing performance, cost, and longevity.

Our product range includes:

• Copper tubes (C12200)

• Aluminum brass tubes (C68700)

• Copper-nickel tubes (C70600 / CuNi 90-10, C71500 / CuNi 70-30)

All tubes are manufactured to ASTM B111/B111M standards with rigorous dimensional control and non-destructive testing (Eddy Current, Hydrostatic, or Pneumatic), ensuring reliability in every installation.

From marine condensers to power plant cooling loops, copper and copper-nickel tubes remain the foundation of reliable heat transfer. Their efficiency, corrosion resistance, mechanical strength, and serviceability consistently outperform alternatives in real-world industrial environments.

Whether you are designing new equipment or planning a retube, selecting the right copper alloy can significantly extend service life and reduce operational cost.

Looking for high-performance copper tubes for your next heat exchanger project?
Contact Admiralty Industries to request a technical datasheet or alloy recommendation tailored to your system’s pressure, temperature, and fluid conditions.