Authors : Dhawi A. Al-Otaibi

Volume/Issue : Volume 11 - 2026, Issue 3 - March

Google Scholar : https://tinyurl.com/5n7mzb8n

Scribd : https://tinyurl.com/562jbhd7

DOI : https://doi.org/10.38124/ijisrt/26mar1038

Note : A published paper may take 4-5 working days from the publication date to appear in PlumX Metrics, Semantic Scholar, and ResearchGate.

Abstract : Shell-and-tube heat exchangers (STHEs) are the most commonly utilized heat transfer equipment in the refining, petrochemical, and power generation industries. Heat exchanger effectiveness (ε) is a widely adopted metric for evaluating thermal performance. While high effectiveness is generally advantageous in terms of energy recovery, practical experience and established design guidelines indicate that STHEs designed for effectiveness values above approximately 0.85 may encounter diminishing performance benefits and operational difficulties. These challenges may include elevated pressure drops, heightened fouling susceptibility, flow maldistribution, and reduced design robustness. This paper presents a comprehensive technical review of the performance characteristics of high-effectiveness STHEs, supported by a thorough examination of existing literature and industry design practices. It also proposes practical strategies to mitigate potential issues and enhance the reliability of industrial operations.

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