Air-Cooled Heat Exchanger Design & Sizing Calculator
Process engineers need quick sizing estimates for air-cooled heat exchanger (ACHE) project planning. This calculator provides ballpark estimates for feasibility studies and budget development.
These are preliminary estimates only. Results are suitable for initial planning and RFQ preparation. They are not intended for final equipment specification.
Professional engineering analysis is required for actual Air-Cooled Heat Exchanger design and selection. Use this tool as a starting point for project evaluation.
Have questions? Need an accurate quote?
How This ACHE Calculator Works
This calculator uses the fundamental heat transfer equation: Q = U × A × ΔT. Heat duty (Q) equals the overall heat transfer coefficient (U) times surface area (A) times temperature difference (ΔT) (source)
The calculations are simplified using industry-average values and conservative assumptions. Real ACHE designs require site-specific data and detailed analysis. This tool uses typical heat transfer coefficients and standard tube configurations.
| What the Calculator Estimates | What It Doesn’t Calculate |
|---|---|
| Required heat transfer surface area | Detailed tube-side and air-side pressure drops |
| Approximate bundle dimensions (length, width, depth) | Material selection and corrosion considerations |
| Estimated fan power requirements | Code compliance requirements (ASME, API standards) |
| Basic air flow requirements | Structural design and foundation loads |
| Â | Site-specific environmental factors |
These estimates are good enough for planning. They are not suitable for purchasing or final design.
Interactive Air-Cooled Heat Exchanger Calculator
Understanding Your Calculator Results
The calculator uses fundamental heat transfer principles with conservative assumptions. The heat duty calculation Q = w × c × (T1-T2) determines total heat removal requirements. Surface area follows the basic relationship A = Q / (U × ΔT).
Overall heat transfer coefficients (U-values) are simplified estimates. Water systems typically achieve 120 Btu/hr·ft²·°F, while process gases average 15 Btu/hr·ft²·°F. These conservative values account for typical fouling and operational variations.
Temperature difference uses Log Mean Temperature Difference (LMTD) principles. This accounts for changing temperature profiles as fluids exchange heat. The approach temperature in your results shows the thermal driving force available.
Fan power calculations combine air flow requirements with pressure drop correlations. The calculator estimates air volume needed based on temperature rise, then applies industry-standard pressure drop formulas. Face velocity affects both pressure drop and noise levels.
Bundle geometry determines the number and arrangement of tubes. Total tube count, row configuration, and fan requirements all stem from the required surface area and air flow calculations.
Why These Are Preliminary Estimates
Real-world variables significantly affect actual performance. Fouling factors vary by application and operating conditions. Site elevation changes air density and fan performance. Tube arrangements and fin configurations alter heat transfer coefficients.
The calculator cannot account for specific engineering requirements. Detailed pressure drop analysis requires fluid properties and precise tube geometries. Structural design depends on wind loads, seismic conditions, and foundation requirements. Code compliance involves ASME and API standards not addressed in preliminary sizing.
Material selection affects both thermal performance and corrosion resistance. Custom operating conditions may require specialized designs or enhanced surface treatments.