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  2. Shell-Side Fluid Challenges: Increasing the Pressure Drop

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    Before constructing a shell and tube heat exchanger, it’s crucial to carefully design it to ensure it performs optimally within the specific system it’s meant to serve. The design process involves multiple considerations, with one of the most important being pressure drop.

    What is Pressure Drop?

    Pressure drop refers to the loss of pressure that occurs as a fluid moves through the heat exchanger. It’s a critical factor in determining the heat exchanger’s efficiency. However, there is no one-size-fits-all target for pressure drop. The ideal pressure drop depends on the heat exchanger’s application, its design, and the type of fluid being processed.

    Every heat exchanger has a maximum allowable pressure drop — the upper limit beyond which performance or equipment safety could be compromised. The goal of the designer is to get as close as possible to this maximum without exceeding it. Achieving this balance often requires careful adjustments — in some cases reducing pressure drop, and in others, strategically increasing it.

    Pressure Drop and Fluid Velocity: A Balancing Act

    Generally, higher fluid velocities lead to higher pressure drops. So, when the pressure drop is too high, engineers typically reduce the flow rate to bring it within acceptable limits. On the other hand, if the pressure drop is well below the maximum allowable value, this could signal that the heat exchanger isn’t operating at its full potential. In such cases, increasing fluid velocity could help enhance heat transfer efficiency.

    In essence, when there’s room to approach the maximum pressure drop, designers may look for ways to increase the fluid velocity, improving the heat exchanger’s overall performance.

    Strategies for Increasing Shell-Side Pressure Drop

    Pressure drop is closely tied to the flow rate of the fluids within the heat exchanger, especially on the shell side. If the goal is to increase pressure drop for better performance, several design modifications can help achieve this:

    1. Opt for a Smaller Shell Diameter
      A smaller shell diameter can increase shell-side fluid velocity, which in turn can increase pressure drop. Custom-built heat exchangers can be designed to maximize this effect. However, designers must be cautious of the potential impact on tube-side pressure drop. A shell that’s too small may cause the fluid in the tubes to flow too quickly, potentially surpassing the maximum allowable pressure drop.
    2. Adjust Baffle Spacing and Cut
      Baffles play a vital role in controlling the direction and speed of the shell-side flow. By reducing the spacing between baffles, you can increase fluid velocity, leading to a higher pressure drop and a greater heat transfer rate. However, it’s important to ensure that baffles are spaced according to specific guidelines: for example, in exchangers with a shell diameter of 10 inches, baffles should be spaced at least 2 inches apart. For larger shells, baffle spacing should be a minimum of one-fifth of the shell’s internal diameter.
    3. Optimize Tube Configuration
      The arrangement of the tubes within the heat exchanger impacts the flow characteristics of the shell-side fluid. For instance, triangular tube patterns allow for higher fluid velocity compared to square patterns, which can help achieve a higher pressure drop and stronger heat transfer. However, this configuration can make cleaning more challenging, which is why it’s typically chosen for applications where chemical cleaning is used.

    Pressure Drop: A Double-Edged Sword

    While pressure drop challenges are most commonly associated with excessively high flow rates, there are instances where engineers intentionally work to increase both velocity and pressure drop to achieve a more efficient heat exchanger. This delicate balancing act is essential for designing heat exchangers that perform at their best.

    At Enerquip, our engineering team specializes in solving complex design challenges. We work closely with our clients to craft custom shell and tube heat exchangers that meet their unique operational needs. If you’re facing pressure drop or heat exchanger performance issues, don’t hesitate to reach out. Let’s work together to create the perfect solution for your system.

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  3. Five Important Qualities to Look for in Pharmaceutical Process Equipment

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    In recent decades, there has been a notable surge in regulations and oversight pertaining to pharmaceutical manufacturers. This heightened scrutiny has resulted in stricter design specifications for process equipment. Notably, pharma-grade shell and tube heat exchangers must adhere to stringent criteria. These criteria include ease of cleaning, compatibility with appropriate heat transfer fluids, resistance to contamination and corrosion, and overall reliability. Let’s delve further into why these factors are crucial.

    Five Necessary Features of Pharma-Grade Shell and Tube Heat Exchangers

    1. Easily Cleaned

    Pharmaceutical products must be as pure as possible, and one step in achieving maximum purity is using clean equipment. Residue remaining from the previous batch or product type can taint the next round of product.

    Any amount of product left behind that could feasibly be removed through normal cleaning methods should not be present in equipment before production begins, according to the U.S. Food & Drug Administration’s Current Good Manufacturing Practices.

    Instruments that test for cleanliness today are highly accurate, able to detect even tiny amounts of residue. As such, it’s not always feasible to clean equipment to the point where absolutely no amount of previous product is detected. However, it’s always best to clean as thoroughly as possible.

    Choosing equipment that’s easily cleaned is a good step toward ensuring product batches are as pure as possible. Certain configurations of shell and tube heat exchangers are more easily cleaned than others. For example, straight tube exchangers are often easier to clean than U-tube style exchangers because there are no bends to maneuver around.

    Drainability can affect how easy it is to clean a shell and tube heat exchanger. If it’s hard to get the last ounces of liquid out of an exchanger, it’s harder to rid the equipment of all traces of the fluids. Exchangers that are designed to promote drainability, such as those offered by Enerquip, are best for this purpose.

    2.Compatible Heat Transfer Fluid

    Your equipment needs to be compatible with the substances that will pass through it – both on the tube side and the shell side. The heat transfer fluid used plays a large role in how effective the heating or cooling process is, as well as how well the equipment will hold up in time.

    Fluids that aren’t effective for heat transfer will require a longer process time and more energy to run. Additionally, fluids that can be corrosive can cause equipment to wear out faster. Some fluids are flammable, creating potential risks in the work environment if products or equipment are mishandled.

    3. Leak-Free

    Enerquip Double Tubesheet DesignNo manufacturer or equipment operator wants to have leaks. But for pharmaceutical processing equipment, leaks are particularly troublesome. Leaks create the possibility of product contamination, as well as corrosion or other chemical reactions that may occur when process and utility fluids mix.

    One way to reduce the risk of leaks is with a fully welded tubesheet. Another method to minimize the risk of leaks – or at least the negative impacts of them – is to design an external leak path to prevent any possible leakage from interacting with the fluid on the opposite side of the exchanger.

    Shell and tube heat exchangers constructed with double tube sheets are designed to drain any leakage away from the exchanger to minimize the chances of cross-contamination. At the same time, the operator is alerted to the problem so he or she can address it promptly.

    4. Resistant to Contamination and Corrosion

    Equipment used to create any product should not pose any risk of contamination. However, avoiding contamination means different things for different industries, processes and products.

    To minimize the risk of contamination as much as possible, equipment used for pharmaceutical production should be pharma-grade. Enerquip’s high purity exchangers are ideal for this industry. Our knowledgeable heat exchanger experts have ample experience fabricating shell and tube heat exchangers for pharmaceutical purposes, and are even used by companies like Bristol-Myers Squibb, Pfizer and Unilever.

    Corrosion-resistant materials also help to lower the risk of product contamination. Corrosion can be caused by chemical or physical processes, and the residue that emerges through this process can be reactive or can put the purity of the product at risk. Stainless steel and stainless-steel alloys are highly resistant to corrosion, making them smart choices for pharmaceutical construction.

    5. Highly Dependable

    All manufacturers, regardless of industry, strive to reduce or eliminate downtime. Every minute of downtime has a real impact on the company’s bottom line.

    Choosing reliable equipment is one of the most effective ways to reduce downtime. The less frequently equipment requires maintenance or spare parts, the more often it’s contributing to your facility’s production.

    Enerquip prides itself on fabricating equipment that is long-lasting and can be counted on. To learn more about choosing the right pharmaceutical process equipment for your facility, contact us today.

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    Editor’s note: This content was originally published in 2018 but was updated in 2024.

  4. Enerquip Helps Design a Fountain That Flows During Freezing Temperatures

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    Outdoor fountains are designed to be eye-catching features, but keeping them functional in all weather conditions can be a challenge—especially when temperatures dip below freezing. When Ascend Federal Credit Union in Tullahoma, Tennessee, wanted a fountain at its corporate headquarters that would run reliably year-round, Signature Fountains turned to Enerquip for a solution.

    The Challenge: A Fountain That Works in Freezing Temperatures

    Tennessee winters are generally mild, but temperatures can and do drop below freezing. That presents a problem for outdoor fountains. Ice can restrict water flow, damage equipment, and even shut the system down completely.

    Signature Fountains needed a way to prevent this. They outlined three key requirements for the heating system:

    • Compact design – It had to fit inside a small underground utility pit.

    • Efficient heating – The system needed to draw hot water from a nearby building.

    • Smart controls – Operation should be automatic, kicking in only when temperatures fall.

    At the same time, the project needed to be completed on a tight schedule.

    The Enerquip Solution: A Compact Shell and Tube Heat Exchanger

    Enerquip’s engineering team designed a custom shell and tube heat exchanger that fit the project’s unique needs. Here’s how it works:

    • When the air temperature drops below 45°F, the system automatically activates.
    • A pump draws hot water from the credit union’s office building.
    • The heat exchanger uses a multi-pass design, circulating the hot water multiple times for maximum efficiency.
    • The fountain water is warmed just enough to keep it flowing, even in sub-freezing weather.

    The result was a compact, energy-efficient system that worked seamlessly with the fountain’s existing controls.

    The Results: Reliable Performance, Even in Cold Weather

    “The design worked beyond our best expectations,” wrote Gary Boeyer of Signature Fountains.

    When overnight temperatures in Tullahoma recently dipped below freezing, the system automatically switched on. The fountain stayed fully operational—without ice buildup or damage.

    Both Signature Fountains and Ascend Federal Credit Union praised Enerquip’s quick turnaround and practical design. The solution not only met their needs but will continue to deliver reliable performance for years to come.

    Why Choose Enerquip Heat Exchangers for Outdoor Applications?

    Enerquip’s custom heat exchangers are trusted in industries ranging from food processing to industrial manufacturing—and as this project proves, they’re also ideal for unique applications like fountain design.

    Whether you need a compact heat exchanger for a small installation or a large-scale solution for industrial use, Enerquip delivers:

    • Custom engineering to meet unique challenges
    • Energy-efficient multi-pass designs
    • Durable, long-lasting construction
    • Quick turnaround to keep projects on schedule

    Looking for a heating or cooling solution for your sanitary or industrial system? Contact Enerquip today to discuss your project with our team of experts.

     

    More from the Enerquip Blog

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    7 Shell Configurations to Consider When Designing a Shell and Tube Heat Exchanger

    How to Store Your Process Equipment Before Installation

    TEMA Types Explained

    5 Smart Maintenance Tips to Keep Your Shell & Tube Heat Exchanger Performing at Its Best

    How Almost Any Industry Can Benefit from Waste Heat Recovery

  5. Exchanger System Helps Food Packager Put the Soup On

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    A Chicago liquid-foods packager found themselves in a make-or-break moment. A major customer was ready to hand them a lucrative soup-packaging contract—but only if they could guarantee one thing: every batch had to be cooled from 198°F (92°C) to exactly 77°F (25°C) before it hit the packaging line.

    That precise temperature wasn’t the only challenge. The packager needed a system that could handle different soup recipes, meet strict food-grade sanitation rules, and fit into a footprint about the size of a walk-in closet—14 feet by 6 feet, under a 12-foot ceiling. Oh, and it had to keep utility costs in check by using cooling tower water whenever possible.

    No pressure, right?

    The Challenge: Cooling, Cleanability, and a Tight Fit

    Different soups meant different thermal properties, so the system had to be flexible. It also needed to be easy to clean between batches. If any leftovers lingered, flavors could mix or bacteria could grow. Accuracy mattered, too. If the soup was too warm, it could spoil. Too cool, and the containers could sweat, causing labels to slide off. Not exactly ideal for a product on shelves.

    The space issue made everything trickier. The heat exchangers had to meet strict 3-A sanitary standards while also staying compact, cleanable, and efficient.

    First Attempt: Two Large Exchangers, One Big Problem

    The packager’s engineering partner first proposed a simple setup: two large, straight-tube shell-and-tube exchangers in series. The first would knock down the temperature using cooling tower water. The second would finish the job using a 45°F (7°C) glycol/water mix from a chiller. Both were inclined for draining and built with davit swing arms for easier inspection.

    On paper, it looked clean and straightforward. In practice, two issues popped up quickly.

    1. The Temperature Cross Problem

    Because cooling tower water entered at around 70°F (21°C), it warmed up to about 120°F (49°C) inside the shell. That meant the soup couldn’t get any cooler than that in the first stage. The second exchanger—and the chiller—would have to do nearly all the heavy lifting. That meant higher energy use and a bigger, pricier chiller.

    2. Cleaning Bottlenecks

    The exchangers could be backflushed, but hitting the recommended 5 ft/sec cleaning velocity wasn’t possible with the packager’s 200-gallon-per-minute CIP system. Achieving proper cleaning would have required a system nearly eight times larger. Not exactly realistic.

    These limitations pushed the team back to the drawing board.

    Rethinking the System: Smaller Exchangers, Bigger Benefits

    To solve the cleaning issue, the team took a different approach: reduce the tube field size. That meant shrinking the exchanger diameter from 24 inches to 6 inches. With less area in each unit, more units were needed overall—six exchangers for the cooling-tower stage and two for the glycol/chiller stage.

    This redesign fixed more than just cleaning.

    Better Heat Transfer: Fewer tubes meant higher product velocity, which boosted cooling performance.

    No More Temperature Cross: Each small exchanger got its own stream of fresh cooling tower water. That prevented the warm-up effect that stopped the first system from reaching lower temperatures. In winter, when cooling tower water dropped below 70°F, the packager could skip the chiller altogether and cool the soup with ambient water alone.

    Easier Cleaning and Sanitation: The smaller units reached the needed CIP velocity and were easier to polish to 3-A standards. The lighter bonnets also made teardown and inspection much simpler.

    The Final Layout: A Stacked, Flexible, Space-Saving System

    The eight exchangers were mounted on a custom rack, with room left to add two more if future recipes or batch sizes required extra cooling power. All units were pitched for draining and connected with easy-to-reach utilities and jumpers.

    Standardizing on smaller exchangers had bonus benefits:

    • Lower-cost spare parts

    • Readily available gaskets and clamps

    • Interchangeable components across all eight units

    Most importantly, the entire stacked system fit inside the tight footprint and stayed within the project budget.

    Results: A Cooler Process and a Hot Contract Win

    The redesigned cooling system delivered consistent, precise temperatures across multiple soup types. It checked every box: sanitary design, easy cleaning, lower utility costs, space efficiency, and room for future growth.

    With the cooling challenge solved, the packager secured the contract—and gained a more efficient process for years to come.

    If you’re facing tight specs, tight space, or a tight deadline, you don’t have to tackle it alone. Reach out to Enerquip, and let’s build the right solution together.

  6. Sani-Matic Testimonial of Enerquip Heat Exchangers

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    Sani-Matic shares why having a quality partnership with Enerquip means so much for their business. “We consider Enerquip a leader in their product range.” – Aaron Zell, President & CEO of Sani-Matic. “We can count on Enerquip – they do what they say they’re going to do. All foundations are built on trust and we have that firmly in place with Enerquip.”

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  8. GENERON & Enerquip: Partnering for Smarter Gas Separation Solutions

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    When it comes to air and gas separation systems, GENERON has been setting the standard for more than four decades. From nitrogen generators for offshore platforms and FPSOs to compression packages for tankers, GENERON’s custom solutions power some of the toughest environments in oil, gas, marine, and industrial service.

    But behind every system is a network of trusted partners. For over a decade, Enerquip has supplied stainless steel shell and tube heat exchangers that play a critical role in GENERON’s nitrogen generation, compression, and processing packages. Together, the two companies deliver reliable performance for the world’s most demanding industries.

    Innovation That Raises the Bar

    GENERON’s R&D team in California is always pushing boundaries. A great example: the redesigned Dehydration Hollow Fiber Membrane, which trims down size and weight without sacrificing performance. These kinds of innovations are why industry leaders — from Schlumberger and Weatherford to ExxonMobil and Chevron — trust GENERON.

    Quality is baked into every step. With facilities in Houston and Pittsburg certified to ISO-9000, ASME, CE/PED, and more, GENERON ensures each package meets the highest standards.

    Why GENERON Trusts Enerquip

    Meeting strict specifications is only part of the equation. GENERON often needs custom-engineered heat exchangers to fit unique applications. That’s where Enerquip steps in.

    “Enerquip has the engineering and manufacturing capabilities we need,” says Sergio Gonzalez, GENERON’s Americas Sales Director. “They’re quick to respond, flexible with custom requests, and always reliable.”

    Enerquip’s team can deliver exchangers ranging from two inches to four feet in diameter, fabricated from alloys that stand up to the harshest conditions. And when timing is critical, Enerquip’s fast turnaround and dependable delivery keep projects on track.

    A True Partnership

    The relationship goes beyond just supplying parts. GENERON knows that when a customer needs a heat exchanger — or a solution outside GENERON’s scope — Enerquip is the right referral. That trust speaks volumes about the quality of Enerquip’s engineering support and customer service.

    “Enerquip gives us good service, good products, and good quality,” Gonzalez adds simply.

    Looking Ahead

    As the oil, gas, and industrial service industries continue to evolve, GENERON and Enerquip remain aligned: pushing for higher standards, faster solutions, and stronger performance. With decades of expertise and a shared commitment to excellence, this partnership is built to last.

    Ready to see the difference the right heat exchanger can make? Contact us or request a quote today.

     

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  10. Case Study: Lamberti Employs Enerquip Bayonet Heaters to Maximize Efficiency

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    Heating Challenges in a Complex Chemical Operation

    Lamberti provides specialty chemicals to a wide range of industries—from ceramics to agrochemicals and PVC additives. With operations in 17 countries and a client base spanning 14 industries, Lamberti delivers chemical solutions that help customers enhance product quality across the board.

    At the company’s Tennessee facility, Lamberti Systems USA, Product Manager Bill Ruder oversees operations focused on ethoxylation and propoxylation technology. The Chattanooga plant produces surfactants, polyols, block copolymers, and combinations of these for use in textiles, oil and gas, cosmetics, ceramics, and agriculture.

    To maintain product quality and ensure batch accuracy, temperature control is critical—especially during heating and cooling stages. However, the facility needed a way to heat large storage tanks without disrupting its existing system or production workflow. Installing bulky new equipment simply wasn’t an option.

    Turning To A Trusted Company

    When Ruder began exploring heating solutions, he turned to a familiar name: Enerquip. Lamberti had a history working with Enerquip to source custom shell and tube heat exchangers for its Tennessee and Texas facilities. Despite Enerquip being based in Wisconsin—over 900 miles away—the company consistently delivered high-quality equipment quickly and reliably.

    Lamberti purchased over a dozen shell and tube heat exchangers from Enerquip. According to Ruder, Enerquip’s team stands out for their industry knowledge and responsiveness. Ron Herman, Enerquip’s Director of Business Development, has been a key contact throughout the relationship.

    When Enerquip launched a new line of bayonet heaters, Ruder saw an opportunity and reached out to learn more.

    A Custom-Fit Solution

    Lamberti needed to heat liquids stored in large vessels. After reviewing the setup with Enerquip, Ruder discovered the bayonet heaters were a perfect match. The heaters could be installed directly into the manways at the top of the vessels, allowing for easy insertion and removal—an important factor since Lamberti requires routine equipment inspections.

    What made the bayonet heater especially appealing was its in-vessel installation. Unlike traditional systems that require external loops or extra piping, the bayonet heater heats the fluid directly inside the tank. This eliminated the need for any equipment relocation or system redesign, saving time and money.

    Additionally, preheating the raw material before it enters the unit allows the fluid to reach its target temperature more efficiently. This reduces reaction time and energy consumption—an added bonus for the facility’s production goals.

    Reliable Results

    The bayonet heater continues to perform well. It’s easy to use, simple to remove for cleaning and inspection, and reliably heats liquids to the required temperatures without issues.

    Ruder is pleased with the outcome and confident in recommending Enerquip to others.

    “They’re fast, reliable, and willing to work with you to customize equipment that fits your process,” he said.

    Looking for a custom thermal solution? Meet the team and request a quote today.

     

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