Brass Tube Bundle Heat Exchanger

Brass Tube Bundle Heat Exchanger


A Brass Tube Bundle Heat Exchanger is a type of heat transfer equipment designed to move heat from one fluid to another. It operates using a set of brass tubes grouped together, known as a tube bundle, which is enclosed within a protective outer shell. In this system, one fluid flows through the inside of the brass tubes, while the other fluid moves around the outside of the tubes, but still within the shell. As the fluids flow past each other, heat is transferred from the warmer fluid to the cooler one, without the fluids ever mixing. Brass is selected for the tubes because it has good heat conductivity, resists corrosion, and is cost-effective. These qualities make brass tube bundle heat exchangers useful in a wide range of systems, including air conditioning units, marine cooling systems, and industrial water heaters.


Why Choose Brass in Heat Exchangers?


Corrosion Resistance and Thermal Conductivity Brass is an alloy of copper and zinc that offers a unique combination of excellent corrosion resistance, superior thermal conductivity, and mechanical strength. Unlike steel or aluminum, brass resists biofouling and scaling, making it particularly effective in seawater and process water applications.

  • Thermal conductivity:Up to 120 W/m·K
  • Corrosion resistance:Exceptional against saline and acidic environments
  • Compatibility: Ideal for both organic and inorganic media


How a Brass Tube Bundle Heat Exchanger Works


A Brass Tube Bundle Heat Exchanger operates using the same principles as other shell and tube or fin tube heat exchangers but uses brass tubes in the bundle. Brass is chosen for its excellent thermal conductivity, corrosion resistance, and anti fouling properties, especially in marine, HVAC, or water based applications.


What is the size of brass tube bundles used in heat exchangers

  • Tube Dimensions
    • Outer Diameter (OD): Common range: 12 mm to 25 mm (approx. 0.5 inch to 1 inch)
    • Wall Thickness: Typically ranges from 0.7 mm to 1.5 mm, though it may vary based on pressure and design requirements.
    • Tube Length:
      • Common lengths range from 1 meter to 6 meters (3 ft to 20 ft)
      • Custom lengths can be fabricated for specific installations
  • Tube Bundle Characteristics
    • Number of Tubes per Bundle: The number of tubes can range from as few as 20 to several hundred, depending on the overall size and capacity of the heat exchanger.
    • Tube Arrangement: Typically triangular or square pitch for optimized heat transfer and fluid flow
    • Tube Material: Brass alloys (e.g., C26000, C27200, Admiralty Brass) are used for good corrosion resistance and thermal conductivity
  • Overall Bundle Size
    • Bundle Diameter: Can range from 200 mm to 1000+ mm (8 inches to 40 inches)
    • Length of Bundle: Matches the tube length (1–6 meters typically)


Design Features of Brass Tube Bundle Heat Exchanger



Tube Bundle Configuration United Cooling Systems offers straight tube and U-tube bundle configurations to accommodate various operating pressures, thermal expansion needs, and cleaning requirements.

Straight Tube vs. U-Tube Design
FeatureStraight TubeU-Tube
CleaningEasier to cleanMore complex
Space requirementLargerCompact
Thermal expansionLimitedBetter compensation


Shell and Tube Arrangement

We offer both single-pass and multi-pass configurations with baffles for enhanced turbulence and thermal contact. Tube sheets are machined to precise tolerances, and expansion joints are added for applications involving high differential temperatures.

Gasketed, Welded, and Expansion Joint Options
  • Gasketed flange design for easy disassembly and inspection
  • Welded construction for permanent installations
  • Expansion bellows to compensate for thermal stress


Brass Tube Bundle Heat Exchanger vs. Other Types

Feature Brass Stainless Steel Carbon Steel Copper
Heat Transfer High Moderate Low Very High
Corrosion Resistance Excellent (in water) Excellent Low Good
Anti-Fouling Very Good Moderate Poor Excellent
Strength Moderate High High Moderate
Cost Moderate High Low High
Maintenance Easy Moderate Moderate Easy
Best Use Marine, HVAC, Water Chemicals, Pharma General Industry Specialty Cooling


Comparing Brass to Other Materials in Tube Bundle Heat Exchangers


Tube bundle heat exchangers play a vital role in thermal energy transfer across various industrial applications. One of the most important design decisions is selecting the right material for the tubes. Among the many options, brass is a popular choice due to its unique balance of performance and cost. However, it’s essential to compare brass with other materials like copper, stainless steel, carbon steel, and titanium to make informed decisions.

Key factors to consider when comparing materials:

  • Thermal Conductivity
    Evaluate how efficiently each material transfers heat, which directly affects exchanger performance.
  • Corrosion Resistance
    Consider how well the material withstands different fluid types, environmental conditions, and chemicals.
  • Mechanical Strength and Durability
    Assess the material's ability to handle pressure, stress, and long-term wear.
  • Cost and Availability
    Balance your budget with material efficiency and longevity; some high-performance metals may be cost-prohibitive.
  • Sustainability and Lifespan
    Factor in recyclability and the expected service life of the material in your specific application.


Technical Specifications


Material Composition

  • Tubes: Admiralty Brass, 70/30 Brass, or Cu-Ni alloys (on request)
  • Tube Sheets:Carbon steel, stainless steel, or clad material
  • Shell: Mild steel, stainless steel, or FRP-lined variants
Heat Transfer Surface Area Custom-built units range from 2 m² to over 1000 m² of surface area, with variable tube diameters (12.7mm, 15.9mm, 19.05mm) and lengths up to 6 meters.

Flow Rates and Pressure Drops
  • Max flow:2500 m³/h
  • Maximum Pressure: Rated up to 16 bar; higher pressure capacities available upon request.
  • Optimized for minimal pressure drop and maximum energy recovery
Temperature Ranges
  • Operating range: -20°C to +200°C
  • Design temperature: Up to 300°C (with special gaskets and materials)


ASME and TEMA Compliance All designs adhere to:
  • ASME Section VIII Div.1
  • TEMA standards (Types A, B, C)
  • ISO 9001:2015 quality procedures


Performance Advantages


High Thermal Efficiency

Brass conducts heat efficiently, ensuring fast temperature changeovers and less heat loss per unit volume of material.

Anti-Fouling Characteristics The alloy's composition resists:
  • Biofilm formation
  • Algae growth
  • Mineral scaling
Customization Capabilities We offer:
  • Special coatings (epoxy, rubber-lined)
  • Dual-media design (liquid-liquid, gas-liquid)
  • Modular assemblies for multi-phase operation


Applications Across Industries


Oil & Gas Sector

Used in cooling turbine oil, glycol dehydration units, and flue gas condensers, brass tube bundle exchangers endure the harshest chemical exposures.

HVAC Systems

Ideal for chiller condensers, cooling towers, and heat recovery systems, especially in coastal or marine environments due to their salt resistance.

Power Generation

Used in generator and turbine cooling, waste heat recovery, and boiler feedwater heaters, contributing to higher plant efficiency.

Food & Beverage Processing

Utilized for pasteurization, evaporative cooling, and heat reclaim, they meet hygiene standards and resist frequent CIP (clean-in-place) cycles.

Chemical and Petrochemical Plants

Applied in reactor cooling, solvent condensers, and exothermic process heat removal—a proven solution for high-throughput systems.


Installation and Maintenance Guidelines


Installation Best Practices

Proper installation is crucial to ensure the optimal functioning of your Brass Tube Bundle Heat Exchanger from United Cooling Systems.

Key steps include:
  • Foundation and Mounting: Ensure a level and vibration-free surface for anchoring. Use resilient mounts where thermal expansion is expected.
  • Use flexible connectors or expansion bellows to manage thermal movement, absorb vibration, and compensate for misalignment.
  • Orientation: Follow directional flow arrows. Vertical or horizontal installation should be based on application and gravity drain requirements.
  • Bypass Valves: Install isolation and bypass valves to enable service without full system shutdown.
Cleaning and Inspection Schedules

Regular maintenance improves efficiency and extends service life,Recommended intervals:

TaskFrequency
Visual inspectionMonthly
Pressure drop monitoringWeekly
Chemical cleaningBi-annually
Tube bundle inspectionAnnually
Gasket replacementEvery 2-3 years

Brass tubing resists scaling, but in environments with hard water or high organic content, descaling agents like citric acid or specialized cleaning fluids may be used.

Preventive Maintenance Tips
  • Use automatic back-flush systems in heavily fouling environments.
  • Replace gaskets if signs of leakage appear—especially after pressure surges.
  • Monitor inlet/outlet temperatures and compare against baseline efficiency.


Environmental and Sustainability Benefits


Recyclability of Brass Components

Brass is infinitely recyclable, retaining its original strength and performance with each cycle. This makes brass tube exchangers a sustainable option, reducing the carbon footprint of industrial processes.

  • Scrap value: High
  • Energy recovery: Low embodied energy compared to steel or titanium
  • Compliance: Meets green building certifications (LEED)


Energy Efficiency in Operation

Brass’s excellent thermal conductivity enables rapid energy transfer, leading to:

  • Reduced fuel and utility costs
  • Faster heat recovery in waste systems
  • Better process control and reduced cycle times
These features contribute significantly to your facility’s energy efficiency goals.


Why Partner with United Cooling Systems


At United Cooling Systems, we engineer and manufacture high performance brass tube bundle heat exchangers that meet the rigorous demands of modern industries from petrochemicals to food processing. These units are designed with precision to facilitate optimal thermal transfer between fluids while ensuring longevity, reliability, and corrosion resistance. Built to the latest ASME and TEMA standards, our heat exchangers are suited for operations in some of the most challenging industrial environments.
Engineering Support and Consultation

Our in-house team of thermal engineers and mechanical designers offers full support:

  • Feasibility studies
  • Computational Fluid Dynamics (CFD) simulations
  • 3D modeling with AutoCAD, SolidWorks
Quality Assurance and Certifications

Each unit is tested for:

  • Hydrostatic pressure (up to 1.5x working pressure)
  • Helium leak testing (for gas service models)
  • Material traceability and mill test certifications

We are ISO 9001:2015 certified and provide third-party inspection from agencies like TUV, BV, and SGS on request.

Global Distribution Network

Our brass tube bundle heat exchangers are exported to over 30 countries including:

  • USA
  • UAE
  • Saudi Arabia
  • Germany
  • South Africa
  • Indonesia
Spare parts and service support are available globally through our authorized partners and distributors.

Request a Quote


Client Testimonials and Case Studies


Case Study: Refinery Application – Middle East

A leading refinery in Saudi Arabia replaced carbon steel tube exchangers with brass tube bundle units from United Cooling Systems for their desalter cooling units. The result:

  • 30% reduction in fouling
  • 15% increase in heat recovery
  • ROI achieved in 9 months


Case Study: Dairy Plant Heat Recovery – India

A large-scale dairy plant required a solution for recovering heat from pasteurization lines.

We delivered tailor-made U-tube brass heat exchangers, resulting in:
  • Reduced steam consumption by 22%
  • Improved CIP efficiency
  • Fully CIP-compatible with SS-clad headers


Conclusion


The Brass Tube Bundle Heat Exchanger by United Cooling Systems is a high-performance, low-maintenance, and environmentally friendly solution for industries where thermal efficiency and corrosion resistance are paramount. Whether you're in oil & gas, food processing, or HVAC, our exchangers offer unmatched reliability, backed by decades of engineering expertise. Choose United Cooling Systems—where innovation meets performance.


FAQs on Brass Tube Bundle Heat Exchangers

  1. What are Brass Tube Bundle Heat Exchangers used for?
    They are commonly used in marine cooling systems, HVAC units, power plants, and chemical processing where efficient heat transfer and corrosion resistance are essential.

  2. Why choose brass over other materials for tube bundles?
    Brass offers excellent thermal conductivity, natural resistance to biofouling, and is cost-effective for water-based and low-pressure applications.

  3. Are brass tube bundle heat exchangers suitable for seawater?
    Yes, brass performs well in seawater due to its corrosion resistance and anti-biofouling properties, making it a preferred choice for marine applications.

  4. How often do brass tube bundles require maintenance?
    Maintenance frequency depends on operating conditions, but brass bundles are easier to clean and inspect compared to stainless steel, often requiring less frequent servicing.

  5. Can brass tube bundle heat exchangers be custom built?
    Absolutely. They can be customized in terms of tube length, diameter, number of passes, material grade, and mounting configuration to meet specific requirements.

  6. What standards do your brass heat exchangers comply with?
    Our units can be manufactured to meet ASME, TEMA, or client-specific standards, ensuring high quality and operational safety.


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