Corrosion is one of the most common and costly challenges affecting shell & tube heat exchangers. Left unmanaged, it reduces thermal efficiency, weakens structural components, and can eventually cause unplanned shutdowns. The good news: most corrosion issues can be significantly reduced with proper design considerations, operating practices, and monitoring.
This guide explains how corrosion develops and what industrial operators can do to slow or prevent it throughout the life of a heat exchanger.
Why Corrosion Prevention Matters
Corrosion rarely begins as a dramatic failure. It starts slowly—often microscopically—and progresses until performance loss or leakage finally exposes the problem. By that point, repairs or replacements may already be unavoidable.
A strong corrosion-prevention strategy works hand in hand with other reliability practices, including:
- Routine visual inspections
- Performance monitoring (pressure, temperature, and flow)
- Scheduled cleaning and fluid treatment
If you’re not already tracking early warning signals, review
5 Early Warning Signs Your Heat Exchanger Needs Maintenance.
Common Types of Corrosion in Heat Exchangers
Shell & tube heat exchangers can experience several forms of corrosion, often simultaneously. The most common include:
- Uniform corrosion – Predictable, widespread metal loss across a surface.
- Pitting corrosion – Deep, localized attack that can quickly penetrate tube walls.
- Crevice corrosion – Occurs in gasket gaps, under deposits, or in tight spaces with stagnant fluid.
- Galvanic corrosion – Caused by contact between dissimilar metals in the presence of an electrolyte.
- Under-deposit corrosion – Develops beneath fouling, scale, or biological growth.
Identifying the corrosion mechanism helps determine the right mitigation—from material selection to cleaning strategy.
Using the Right Materials for the Application
Material selection is one of the biggest factors in long-term corrosion resistance. Different applications call for different metallurgies, and choosing the right combination for tubes, tube sheets, and shell components dramatically reduces risk.
Common material options include:
- Carbon steel for general-duty or less aggressive services
- Stainless steels and duplex alloys for elevated corrosion resistance
- Copper alloys for thermal conductivity and moderate corrosion resistance
- Nickel-based alloys for highly corrosive or high-temperature environments
When replacing or upgrading tube bundles, KAM Thermal Equipment helps ensure materials match actual operating conditions to maximize service life.
To learn how custom fabrication improves longevity, explore
Benefits of Custom Shell & Tube Manufacturing.
Controlling Fouling to Limit Under-Deposit Corrosion
Fouling and corrosion are closely linked. Deposits trap moisture and aggressive chemicals against metal surfaces, accelerating under-deposit corrosion. Reducing fouling is one of the most effective ways to limit metal loss inside a heat exchanger.
Key strategies include:
- Proper filtration and fluid treatment
- Monitoring pressure drop for signs of fouling buildup
- Cleaning intervals based on operating history and duty conditions
For help choosing the best cleaning method, see
Mechanical vs. Chemical Cleaning for Heat Exchangers.
Monitoring Operating Conditions
Operating outside the intended design range accelerates corrosion. Temperature, velocity, and fluid chemistry all affect how quickly materials degrade.
Operators should routinely monitor:
- Inlet and outlet temperatures
- Flow rate and tube velocity
- pH, contaminants, and chemical balance
- Pressure differential across the unit
If inspection reveals performance decline or unusual readings, refer to
Routine Inspections for Shell & Tube Heat Exchangers
and
How to Troubleshoot Heat Exchanger Leaks.
Preventing Thermal and Mechanical Stress
Thermal shock, improper startup, and water hammer can damage protective oxide layers or cause mechanical distortion, creating pathways for rapid corrosion. These stresses weaken tubes, joints, and gaskets over time.
Recommended practices include:
- Following proper startup and shutdown procedures
- Avoiding sudden introduction of extreme-temperature fluids
- Ensuring proper venting and draining to prevent water hammer
Learn more about managing temperature stress in
Preventing Thermal Shock in Heat Exchangers.
Planning Ahead for Tube Bundle Replacement
Even with perfect prevention, corrosion may eventually require tube bundle replacement. The advantage of catching corrosion early is being able to plan the replacement on your schedule—not during an emergency shutdown.
KAM Thermal Equipment manufactures:
- Replacement tube bundles for all OEMs
- Drop-in replicas of discontinued or legacy units
- Upgraded designs and materials to improve corrosion resistance
See how replacement works in
our tube bundle removal and replacement guide.
Additional Resources
- Preventative Maintenance for Shell & Tube Heat Exchangers
- Straight Tube vs. U-Tube Cleaning Requirements
- Benefits of Custom Shell & Tube Manufacturing
Service Areas
KAM Thermal Equipment supports industrial facilities across the United States. Explore service areas below:
Mid-Atlantic
Southeast
Midwest
South Central
Need a Replacement Tube Bundle?
KAM Thermal Equipment manufactures high-quality replacement tube bundles and complete shell & tube units designed to improve corrosion resistance and long-term performance. If inspection reveals wear or tube degradation, our engineering team can design an exact-fit replacement.