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Category Archive: Brewing Heat Exchangers

Tag Archive: Brewing Heat Exchangers

  1. Heat Exchanger Material Guide: Factors That Impact Performance and Lifespan

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    Choosing the right material for a shell and tube heat exchanger, or any type of thermal process equipment, directly affects performance, reliability, maintenance requirements, and total lifecycle cost. With multiple alloys and material combinations available, the best option is rarely about a single factor. Instead, successful material selection balances performance requirements, operating conditions, and long-term value.

    This guide outlines the most important criteria to consider when selecting heat exchanger materials and explains how common alloys compare across those criteria.

    Key Criteria for Heat Exchanger Material Selection

    Before comparing materials, identify which factors matter most for your application. Common priorities include:

    • Thermal efficiency
    • Cost and availability
    • Corrosion resistance
    • Cleanability and sanitation
    • Durability and service life

    In many cases, trade-offs are unavoidable. A material with excellent heat transfer may not meet sanitary requirements, while the most corrosion-resistant alloy may exceed budget constraints. The goal is to find the material, or combination of materials, that best balances your priorities.

    Thermal Efficiency

    The primary function of a heat exchanger is to transfer heat efficiently between a process fluid (typically on the tube side) and a utility fluid (typically on the shell side). For this reason, the thermal conductivity of tube material is an important consideration.

    • High thermal conductivity: Copper and copper-nickel alloys
    • Moderate conductivity: Carbon steel, stainless steels, and most high alloys
    • Low conductivity: Plastics, graphite composites, and ceramics

    Thermal performance can also be enhanced through modification to tubes, such as corrugating, adding external fins to the tubes, or by adding twisted tape turbulators to the inside of the tubes. However, because thermal performance among metals is so similar, this is not usually a high priority factor in heat exchanger material selection.

    Cost and Availability

    Material cost and lead time vary based on market conditions, alloy composition, and quantity required. In general:

    • Alloys with higher nickel content tend to be more expensive
    • Common materials are more readily available and have shorter lead times
    • Specialty alloys often require longer procurement and fabrication timelines

    Relative Cost Ranking of Common Materials

    (From highest to lowest cost, subject to market variation)

    1. Nickel 200 (UNS N02200): Typically the most expensive and is a commercially pure nickel alloy. It is one of the most widely used nickel alloys due to its excellent mechanical properties and high corrosion resistance. Nickel 200 consists of 99.6% pure nickel, with small amounts of impurities such as iron, copper, and manganese.

    2. Alloy 625 (Inconel 625): Nickel-based superalloy known for its excellent strength, corrosion resistance, and high temperature performance. It is composed mainly of nickel, with significant amounts of chromium and molybdenum, along with smaller additions of niobium, iron, and other elements. Alloy 625 is widely used in various industries, including aerospace, chemical processing, oil and gas, and marine applications.

    3. Monel 400: Nickel-copper alloy known for its excellent corrosion resistance in various environments. It is composed of approximately 67% nickel and 30% copper, with small amounts of iron, manganese, carbon, and silicon. Monel 400 is highly resistant to corrosive substances such as acids, alkaline solutions, and saltwater. It is often used in applications where resistance to corrosion, erosion, and high temperatures are essential.

    4. Hastelloy C22: Nickel-chromium-molybdenum alloy known for its exceptional corrosion resistance in a wide range of aggressive environments. Hastelloy C22 is particularly resistant to pitting, crevice corrosion, and stress corrosion cracking. Hastelloy C22 is often chosen for chemical processing and waste treatment.

    5. Hastelloy C-276: Nickel-molybdenum-chromium alloy that is renowned for its corrosion resistance and high-performance properties. While similar to Hastelloy C22, Hastelloy C-276 has lower chromium content, easier weldability, and slightly higher upper temperature limits. Hastelloy C-276 is used in various industries, including chemical processing, pollution control, pulp and paper production, and petrochemical applications.

    6. Duplex 2507: Super duplex stainless steel alloy that offers excellent strength, corrosion resistance, and durability. It is part of the duplex stainless steel family, which combines the desirable properties of both austenitic and ferritic stainless steels. Duplex 2507 is characterized by its high levels of chromium, molybdenum, and nitrogen, providing superior resistance to corrosion and high mechanical strength.

    7. AL6XN: High-performance austenitic stainless steel alloy that offers exceptional corrosion resistance and mechanical properties. It is specifically designed to withstand highly corrosive environments, including chloride-rich environments, acids, and seawater. AL6XN is known for its versatility, making it suitable for various applications in industries such as chemical processing, pulp and paper, oil and gas, and desalination.

    8. Titanium: Lightweight metal known for its high strength, low density, and excellent corrosion resistance. Titanium is widely used in various industries due to its unique combination of properties.

    9. Duplex 2205: Stainless steel alloy with a combination of austenitic and ferritic microstructures, known as a duplex structure. It offers excellent strength, corrosion resistance, and durability, making it suitable for a wide range of applications. Duplex 2205 is highly popular in industries such as oil and gas, chemical processing, marine, and pulp and paper.

    10. 316L stainless steel: Commonly used and known for its corrosion resistance, high strength, and versatility. It is an austenitic stainless steel alloy with low carbon content, making it suitable for various applications where resistance to corrosive environments is essential. It is widely used in marine applications, chemical processing, dairy, and pharmaceuticals.

    10. 304L stainless steel: Commonly used and known for its corrosion resistance, versatility, and ease of fabrication. It is an austenitic stainless steel alloy with low carbon content, which enhances its weldability and reduces the risk of sensitization to intergranular corrosion. In comparison to 316L SS, 304L SS has no molybdenum content and it’s less resistant to chloride-induce corrosion. It is suitable for general-purpose uses that don’t require the enhanced corrosion resistance of 316L SS.

    12. Carbon steel: Lowest cost steel that primarily consists of iron and carbon, with other elements present in smaller amounts. It is one of the most commonly used materials in the manufacturing and construction industries due to its affordability, strength, and versatility.

    Higher-cost alloys are often produced in smaller volumes, which can significantly affect availability and pricing for small orders. Fabrication complexity and welding requirements can also influence overall cost.

     

  2. Shell and Tube Heat Exchangers Used to Cool Wort in Craft Brewing

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    Making beer is a complex art, requiring precise execution of each step to ensure a high-quality final product. One crucial step in this process is wort cooling, which occurs after wort boiling and just before fermentation.

    Importance of Wort Cooling

    Cooling the wort brings the liquid down to the optimal temperature for yeast activity. Ale yeasts thrive at temps between 68 and 72°F, while lager yeasts prefer it cooler – between 45 and 57°F. This is a significant drop from the boiling temperature of wort, which is above 212°F, depending on the liquid’s specific gravity.

    Cooling the wort also slows the production of dimethyl sulfide (DMS), which can give beer an unwanted cooked corn smell. While some commercial beers intentionally retain DMS, many brewers aim to eliminate it.

    Another important reason for rapid wort cooling is to control contaminants that can affect the final taste. Bacteria thrive when wort cools below 160°F, so rapid cooling helps minimize bacterial growth.

    Additionally, rapid cooling maximizes the cold break, a process where proteins, tannins, and other materials solidify and can be removed from the wort. The quicker the wort is cooled, the more cold break forms, reducing cloudiness and improving the taste of the final product.

    Methods for Wort Cooling

    There are several ways to cool wort after boiling, though some methods are only efficient for small quantities. For example, an ice bath might work for home brewers but is impractical for craft or commercial beer production. A widely efficient method for wort cooling in these settings is using a shell and tube heat exchanger, also known as a counterflow chiller in the craft beer industry.

    The shell and tube heat exchanger cools the wort quickly, bringing it to the desired temperature in minutes. This speed is beneficial for several reasons: it allows for faster yeast addition and fermentation, minimizes DMS production, and reduces bacterial growth. Additionally, the heated water from the exchanger can be reused for the next batch, enhancing efficiency.

    When using a shell and tube heat exchanger, the cold break remains in the wort and can be seen as cloudiness. To address this, direct the wort from the exchanger to a sanitary vessel, let the cold break settle, then transfer the liquid to the fermenter and add the yeast.

    Maintaining Clean Equipment

    Keeping all brewing equipment clean is crucial for preventing contamination and ensuring a high-quality product. Fouling can ruin a batch of beer and damage a brewery’s reputation. Therefore, it’s essential to clean all equipment thoroughly after use and periodically inspect the shell and tube heat exchanger for leaks or deformities. Stainless steel exchangers are particularly easy to clean and resistant to fouling.

    For a quote on a shell and tube heat exchanger for your brewing process, contact Enerquip.

     

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  4. Enerquip Attends Craft Brewer’s Conference in Philadelphia

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    Brewers Association
    Learn more about this conference [ Here ].

    Craft beer has been a fast growing trend for several years now. According to the National Brewers Association, even as overall beer sales and production dropped 0.2 percent in 2015, craft beer profits went up. Sales of craft beer spiked 12.8 percent while production increased 13 percent.

    Over the past two years alone, various types of craft beer businesses have grown immensely. In 2015, there were:

    • 19,079,780 regional craft breweries
    • 3,927,063 microbreweries
    • 1,281,991 brewpubs
    • 234,181 contract brewing companies

    This represents the addition of more than 7 million regional craft breweries, upwards of 1.5 million microbreweries, more than 300,000 brewpubs and nearly 58,000 contract brewing companies, all in just a two-year time span.

    Celebrating craft brewing

    With so many people dedicating their careers to craft beer and many more becoming enthralled with the trend, it makes sense that industry leaders and budding entrepreneurs alike should come together to discuss all things hops and barley at the upcoming Craft Brewer’s Conference.

    CBC is an annual event that brings brewpubs and packaging breweries together. This year, it will take place from May 3 to 6 in Philadelphia.

    According to Communities Digital News, many locations around the city will be celebrating the craft brewing industry. A wide variety of venues will be showing off their best brews throughout the week. From the National Museum of American Jewish History putting on the Amber Waves art exhibit highlighting the art of brewing to the International Beer Run, there is no shortage of activities for craft beer-loving adults to take part in.

    At the conference

    Despite much of Philadelphia celebrating the CBC, the actual conference’s events are off-limits to anyone not officially in the brewing industry. The first day will offer attendees information about accurately measuring wort gravity and counting yeast cells, while the three following days will give participants a wide variety of educational sessions focusing on everything from brewing operations to sustainability to marketing.

    While each of these points is important, it is crucial that craft brewers know how to produce a safe product that meets all requirements set by the U.S. Food and Drug Administration. Errors can result in distributing a potentially dangerous product.

    When shell and tube heat exchangers are important

    There are many aspects that go into creating an enjoyable craft beer that also meets the requirements set by the FDA. According to the National Brewers Association, all craft brewers must follow Good Manufacturing Practices for Craft Brewers, which include the following guidelines:

    • Using only quality raw materials
    • Maintaining lab tests that can be trusted
    • Establishing standard operating procedures and educating staff about them
    • Recognizing and researching deviations in product quality
    • Creating a good quality management system
    • Packaging and labeling the product according to guidelines
    • Meeting sanitary and processing requirements

    Sanitary shell and tube heat exchangers are important in regards to the last GMPCB. Heat exchangers serve an important purpose in cooling the wort (the early liquid that’s later fermented into beer) to the necessary temperature to begin the actual brewing process, though if they are not properly cared for or graded to meet sanitary requirements, they aren’t worth much to a brewer.

    “All craft brewers must follow Good Manufacturing Practices for Craft Brewers.”

    It’s important that brewers are aware of the standards their equipment needs to meet. This is why conferences like the CBC are so important – they give everyone in the craft brewing industry unique opportunities to learn more about the requirements they must adhere to when brewing.

    Another way shell and tube heat exchangers are used in large-scale operations is for waste heat recovery. This can be applied to operations in a wide variety of industries, but for smaller companies, such as a burgeoning craft brewery, it’s important to keep operational costs low. Energy is expensive, but heating and cooling the product to the right temperature at the right time is crucial to producing a high-quality product.

    The energy required to create heat takes time and money, and without the right waste heat recovery method in place, it is only used once before it is released. Collecting and reusing that heat can make an operation more environmentally friendly as well as more economically sound. Shell and tube heat exchangers are great pieces of equipment to achieve this goal.

    For brewers who know their craft better than anything, but don’t know much about what makes a shell and tube heat exchanger food grade, Enerquip’s in-house engineers can be a big help. This is why Enerquip will be attending the CBC. Anyone involved in craft brewing who wants to know more about how a shell and tube heat exchanger can improve his or her operations, or about what kind of configuration will benefit their operation most, can stop by Enerquip’s table to gain some information.

  5. Microbreweries gaining ground in the beer making industry

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    Over the past 15 years, there has been explosive growth in the number of microbreweries elevating the American drinking experience. According to the U.S. Brewers Association, an impressive 13.2% of the beer market, equivalent to $28.4 billion, now proudly belongs to these innovative microbreweries.

    As the market continues to flourish and competition reaches new heights, breweries find themselves compelled to invest in cutting-edge processing equipment that promises a substantial return on investment. Among the indispensable tools shaping the brewing landscape, the shell and tube heat exchanger stands out as a workhorse in ensuring quality and precision.

    The Vital Role of Custom Shell and Tube Heat Exchangers in Elevating Microbrewery Quality

    When using a heat exchanger where two liquids are involved, the heat exchanger uses heat from one fluid in the shell of the exchanger to warm or cool the other liquid in the tubes of the exchanger. Learn how to choose a heat exchanger for your brewing process.

    In the world of brewing, the heat exchanger plays a pivotal role in the art of yeast manipulation. Yeast, a crucial ingredient in beer, harbors bacteria that needs careful handling. Enter the custom shell and tube heat exchanger, the unsung hero ensuring the elimination of harmful bacteria without compromising the essence of the product.

    Having a custom shell and tube heat exchanger allows breweries to reach proper temperatures to kill off the bacteria without damaging the state of the product. According to Serious Eats, there is such a thing as “friendly yeast,” which can be introduced to add numerous flavors while breaking down the sugar. Heating these products can kill off the appropriate yeast needed to craft beer. According to Brew Like a Pro, cleaning and sanitation is essential for the “cool side” of the beer-making process because the thermophilic bacteria can multiply and double every 20 minutes. Enter the stage of the brewing process where precision is not just a preference but a necessity. The rolling action of the boil, the heartbeat of brewing, demands a level of precision only achievable through custom heat exchanger solutions.

    Looking for a heat exchanger solution in your brewing process? Contact us today.

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    This post was last updated 1/22/24.