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10% of plant maintenance annual capital costs are attributed to Heat Exchangers
90%
of all heat exchangers
experience fouling
Fouling is the largest contributor to inefficient heat exchanger operations, where deposits can coat and build up on coils and tubes.
Just a 2% restricted throughput can result in 10% wasted energy, costing up to $1 million in energy loss per plant.
$6.9B
is the cost of
corrosion across the
chemical industry
Heat exchangers are responsible for 6% of Tier 1 and 2 safety incidents (AFPM).
Corrosion can lead to reduced integrity of the asset, considerable downtime, safety risks, loss of containment and increased maintenance costs.
up to
5%
loss of energy due
to inefficient
control schemes
Inefficiencies can be due to variabilities of the process fluid, steam quality and speed of valve response.
up to
50%
higher costs due to
reactive maintenance
versus preventative
Reliance on reactive maintenance can result in missed failure signs leading to unplanned downtime, production interruptions, and overpressure leading to unsafe conditions, increased emissions and reduction in asset life.
INDUSTRY CHALLENGES
Heat Exchanger Inefficiencies