Shell and Tube heat exchangers are critical and complex components used in multiple industries (e.g., power, petrochemical, oil & gas, marine, etc.). These units present challenges to prevent and mitigate corrosion due to configuration and a combination of metals.
The shell of a shell and tube heat exchanger is normally made from carbon steel. However, the shell, tube sheets, tubes, baffles, nozzles, and channel covers of shell and tube heat exchangers can be manufactured from carbon steel, copper, copper-nickel, stainless steel, Hastelloy, Inconel, or titanium. Material selection for the various components is driven by the fluids being managed, the temperature, mechanical and thermal stress, and corrosion resistance. Even though the design is such that there is clearance between the tubes and baffles, there is line contact between the two due to tube deflection and weight of the baffle, which can lead to galvanic corrosion.