narTC 2025
Achieving high efficiency in heat transfer equipment with HTRI digital twin technologies
Simon Pugh, Hans Zettler, James Kennedy and Edward Ishiyama Heat Transfer Research, Inc.
Attendees at the COP29 conference in Baku, Azerbaijan, reiterated critical pledges to accelerate climate actions across various industrial sectors. Among these, improving energy efficiency in the process industry emerged as a pivotal area of focus. While heat transfer efficiency is just one contributor to overall sustaina- bility goals, its role cannot be overlooked. Achieving high efficiency in heat transfer equipment is integral to reducing energy consumption and emissions, aligning directly with the ambitious climate action targets. In this context, the adoption of digital twin technologies has evolved from a luxury to an operational necessity. Role of Digital Twins in Heat Transfer Efficiency A digital twin should be a highly accurate virtual representation of a physical sys- tem that is directly connected to real-time monitoring data. By creating a near-real- time replica of a heat transfer system, digi- tal twins enable detailed forensic analysis, providing critical insights into system per- formance. They answer pressing opera- tional questions, such as the following: • How well or poorly is the equipment performing? • When might it move outside safe opera- tional ranges? • How can operations be optimised to main- tain safety, reduce emissions, and maxim- ise profitability? Through these capabilities, high-fidelity digital twins empower operators to proac- tively manage equipment, ensuring peak performance and reliability. HTRI: Innovating Heat Transfer Research and Solutions Heat Transfer Research, Inc. (HTRI) is at the forefront of developing solutions to advance predictive and preventive maintenance. At our advanced research facility in Navasota, Texas, we conduct real-world applied research using pilot-scale units designed in collaboration with industry members. These units replicate the conditions of operat- ing refineries and process plants, providing unparalleled insights into the performance of heat transfer equipment. Complementing our physical experiments, we leverage advanced computational tools such as computational fluid dynamics (CFD) and laser anemometry for detailed visuali- sation and analysis. Our experimental data represent the largest repository of heat transfer expertise globally, supporting rig- orous evaluations of thermal and hydraulic performance, vibration analysis, flow mald- istribution, two-phase flow regimes, and their impact on overall performance.
Database including more than 60 years of HTRI knowledge and research
Micro level
Meso level
Macro level
Vibration Corrosion Fouling
0 0.006 0.004 0.002 0.008
Integration of physical models and AI-based digital twin models
Two-way data transfer
Facilitating knowledge transfer and conducting digital experiments to
support informed decision-making
Data historian
Physical assets
Work groups
Figure 1 HTRI heat exchanger ecosystem
from HTRI software to data historians and automates performance analysis (see Figure 2 ). HTRI connect provides the following benefits: • Organising and tagging HTRI files with metadata for streamlined management. • Generating detailed performance reports using precision analytics. • Linking rigorous HTRI exchanger models to data historians for real-time monitoring. • Harnessing parallel processing for effi- cient computation of hundreds of digital twins. HTRI SmartPM™: Performance Monitoring, Predictive and Precision Maintenance HTRI’s SmartPM models are dynamic dig- ital twins that offer predictive capabili- ties. These models integrate advanced AI-driven analytics to deliver high-defi- nition insights into fouling behaviour and system performance. This advanced methodology enables plant operators to optimise maintenance sched- DID YOU KNOW? HTRI’s SmartPM models are dynamic digital twins that offer predictive capabilities delivering high-definition insights into fouling behaviour and system performance
Bind HTRI models to databases holding plant data
Run HTRI models, view any/all calculated data and publish results back to databases
Figure 2 Views from HTRI connect illustrating X changer Suite files for a specific plant and links to a data historian
• Macro level: Total network economics. HTRI’s flagship software, X changer Suite ® , supports the design, simulation, and rating of a wide variety of heat trans- fer equipment, including shell-and-tube exchangers, air coolers, economisers, and fired heaters. This suite is integrated with HTRI connect ™, which serves as a bridge
tools enable users to assess heat trans- fer performance across micro, meso, and macro scales (see Figure 1 ): • Micro level: Tube bundle vibration and skin temperature monitoring linked to cor- rosion and creep. • Meso level: Individual heat exchanger performance.
Integrating Research Insights into Digital Solutions
HTRI incorporates research results into proprietary software solutions. These
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