What happens when a condensate stream is much cooler than another stream in a heat exchanger?

When a condensate stream is significantly cooler than another stream in a heat exchanger, heating becomes necessary to balance the temperature differences between the two streams. In a heat exchanger, the goal is to transfer heat from the hotter fluid to the cooler fluid until they reach a desired operational equilibrium or setpoint.

If one stream (in this case, the condensate) is much cooler, it indicates that it cannot effectively absorb heat from the hotter stream without additional heating. This situation may result in inadequate heat transfer efficiency, leading to potential operational issues.

In practical terms, if the lower temperature of the condensate is not addressed, it can result in an imbalance in the heat exchange process and reduced efficiency. Consequently, to maintain optimal system performance, the cooler condensate will often need to be pre-heated or otherwise adjusted to ensure that effective thermal transfer occurs, safeguarding against equipment strain and maintaining operational parameters.