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In order to reduce capital cost, in practice a minimum temperature difference (Δ T) at the pinch point is demanded, e.g., 10 °F. It is possible to estimate the heat exchanger area and capital cost, and hence the optimal Δ T minimum value. However, the cost curve is quite flat and the optimum may be affected by "topology traps".
When the purchase price of all the pumps, heat exchangers, pressure vessels, and other process equipment are multiplied by 5.0, a rough estimate of the total installed cost of the plant, including equipment, materials, construction, and engineering will be achieved. The accuracy of this estimate method usually is +/- 35%.
By periodically calculating the overall heat transfer coefficient from exchanger flow rates and temperatures, the owner of the heat exchanger can estimate when cleaning the heat exchanger is economically attractive. Integrity inspection of plate and tubular heat exchanger can be tested in situ by the conductivity or helium gas methods.
However, these costs can often be outweighed by the cost saving produced by the added heat transfer. Plate-fin heat exchangers are generally applied in industries where the fluids have little chances of fouling. The delicate design as well as the thin channels in the plate-fin heat exchanger make cleaning difficult or impossible.
The number of transfer units (NTU) method is used to calculate the rate of heat transfer in heat exchangers (especially parallel flow, counter current, and cross-flow exchangers) when there is insufficient information to calculate the log mean temperature difference (LMTD).
Assume heat transfer [2] is occurring in a heat exchanger along an axis z, from generic coordinate A to B, between two fluids, identified as 1 and 2, whose temperatures along z are T 1 (z) and T 2 (z). The local exchanged heat flux at z is proportional to the temperature difference:
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