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Heat Exchanger Material Selection: Chemical Compatibility Guide | BOIXAC Technical guide › Material selection Heat Exchanger Material Selection: Chemical Compatibility by Industrial Application Technical reference guide to support material selection for heat exchangers based on process fluid, industrial sector and operating conditions. From AISI 304/316 stainless steel to Hastelloy, titanium and cupronickel. BOIXAC Tech SL Updated: 2026 Reading time: ~8 min Note on the scope of this guide The information on this page is intended as orientation and general reference only. Material chemical compatibility depends on multiple variables — temperature, pressure, concentration, presence of contaminants, thermal cycling — that cannot be comprehensively captured in a general reference table. The data presented is based on specialist technical literature and BOIXAC’s practical project experience, but does not in any way constitute an engineering specification for a given application. Final material selection validation must always be carried out by a qualified specialist. BOIXAC assumes no liability for decisions made exclusively on the basis of this guide. Material selection is the engineering decision with the greatest impact on a heat exchanger’s lifecycle cost and reliability. An inappropriate material leads to accelerated corrosion, process contamination or premature failure; an over-specified material drives unnecessary cost. This guide provides a structured starting point for engineering, procurement and technical management teams. 1. Standard materials: application range and key characteristics Industrial heat exchangers are typically manufactured in a spectrum of materials covering the majority of process applications. Each presents a distinct profile of chemical, mechanical and thermal resistance. Copper Cu Excellent thermal conductivity. Suitable for non-oxidising fluids, oils and gases. Sensitive to ammonia and oxidising acids. Aluminium Al Lightweight, good conductor. Used in HVAC, automotive and food. Limited in strong alkaline and chloride environments. Carbon Steel CS Robust and cost-effective for general steam, hot gas and non-aggressive oil applications. SS 304 AISI 304 Versatile in food, beverage and light chemical duties. Lower chloride resistance than 316. SS 316 AISI 316 Benchmark for chemical and marine environments. Mo addition improves crevice corrosion and chloride resistance. Hastelloy C-276 / B-3 Maximum resistance in highly corrosive environments: oxidising and reducing acids, mixed media. Titanium Ti Gr. 2 Outstanding in seawater, nitric acid, chlorides and oxidising media. Low density. Cupronickel Cu-Ni 90/10 Reference material for marine and desalination applications. Notable biofouling resistance. Specialist materials for demanding applications For the most demanding environments — concentrated chlorides, strongly oxidising media, extreme temperatures or pharmaceutical hygiene requirements — BOIXAC manufactures heat exchangers in Hastelloy C-276 and B-3, titanium Gr. 2, cupronickel 90/10, AISI 309 and AISI 310. These materials deliver solutions where standard stainless steels cannot meet the required performance. 2. Key factors determining compatibility A material’s chemical resistance is not a fixed value: it is a function of several variables interacting simultaneously in the real process. Any extrapolation beyond the documented conditions range requires specific validation. Temperature: Corrosion accelerates exponentially with temperature. A material compatible at 20 °C may be unsuitable at 80 °C for the same fluid. Fluid concentration: Acids and bases exhibit non-linear behaviour. Stainless steel, for instance, resists high concentrations of nitric acid but not intermediate ones. Chloride content: Pitting and crevice corrosion in stainless steels is particularly sensitive to Cl⁻ concentration and temperature. Fluid velocity: Erosion-corrosion and cavitation are velocity-dependent. Copper, for example, has velocity limitations in seawater service. pH and redox potential: These determine the passivation or active attack zone on the material’s Pourbaix diagram. Contaminants and trace impurities: Unexpected compounds (sulphides, oxidants, metal ions) can drastically alter material behaviour even at trace concentrations. 3. Compatibility table by fluid and sector The table covers the most common process fluids and compounds across the main industries using industrial heat exchangers, indicating materials for which documented compatibility exists under representative conditions. Empty cells indicate absence of standard-condition compatibility data, not necessarily incompatibility. How to read this table — limitations Compatibility marks (✓) indicate general suitability documented in technical literature under moderate temperature, pressure and concentration conditions. They do not guarantee compatibility under all process conditions. Definitive validation requires reference to ASTM G31, specialist corrosion databases, and where applications are critical, laboratory or pilot testing. Always consult our technical team before finalising a specification. Sector Typical application Fluid / Compound Copper Aluminium CS AISI 304 AISI 316 Notes Food Baking, margarine, hospitality Wheat oil ✓ ✓ ✓ ✓ Energy Machinery, engines Lubricating oil ✓ ✓ ✓ ✓ ✓ Beverages Soft drinks, perfumery Amyl acetate ✓ ✓ Textile Dyeing, perfumery Ethyl acetate ✓ ✓ ✓ ✓ Plastics / Pharma Plastic, fibre, pharmaceuticals Acetone ✓ ✓ ✓ ✓ ✓ Plastics / Textile Pharma, dyes, additives Acetic acid ✓ Conc. <20%. Validate temp. Chemical Pharma, chemical Hydrobromic acid ✓ ✓ Consider Hastelloy Food / Beverage Carbonated drinks, confectionery Citric acid ✓ ✓ ✓ Food Palm oil substitute Stearic acid ✓ ✓ Textile / Paper Dyeing, paper, leather Formic acid ✓ ✓ Avoid Cu and Al Chemical Water treatment Phosphoric acid ✓ ✓ Concentration & temp. dependent Agriculture Fertilisers, metals Nitric acid ✓ ✓ Titanium for high conc. Food / Beverage Olive oil, cocoa Oleic acid ✓ ✓ ✓ Chemical / Petrochem. Fertilisers, refined petroleum Sulphuric acid ✓ High conc. only. Hastelloy recommended Beverages Wine & viticulture Tannic acid ✓ Food / Beverage Baking, gelatine, desserts Tartaric acid ✓ ✓ ✓ Marine Vessels, offshore plants Seawater Cupronickel: reference material Textile Fertiliser, dyeing, cleaning Ammonia ✓ ✓ Avoid copper and Cu alloys Plastics / Textile Plastic, pharma, dye, perfume Acetic anhydride ✓ Validate with stabilisers Chemical Resin, herbicide, varnish Aniline ✓ ✓ Chemical Rubber, lubricant, detergent Benzene ✓ ✓ ✓ ✓ ✓ Beverages Brewing industry Beer ✓ ✓ ✓ Beverages Butter, yoghurt, dairy Milk ✓ ✓ Food Butter, yoghurt, dairy Lactic acid ✓ ✓ 316 preferred >5% Oil & Gas Petrochemical by-products Crude oil ✓ ✓ Titanium: premium option Energy Heating and power Natural gas ✓ ✓ ✓ ✓ Agriculture Fertiliser, hydroponics Potassium sulphate ✓ ✓ Chemical Ink, dye, varnish Resin ✓ ✓ Food Dietary supplements Cereals ✓ ✓ Food Dietary supplements Pickling brine / Vinegar ✓ ✓ 316 for more acidic … Read more