Full shell-and-tube exchanger dynamics
Real-time simulation of shell-and-tube heat transfer, not a static heat-balance snapshot.
PiHEx is real-time dynamic heat exchanger simulation software that models full exchanger dynamics: shell-and-tube heat transfer, fouling effects, and dual-stream temperature control. Built by PiControl Solutions, PiHEx is process control simulation software for chemical engineering education and process control training. It reproduces the closed-loop response of a real heat exchanger network, hot-side and cold-side temperatures, controller output, and the gradual performance loss caused by fouling, so learners can practice on a realistic dynamic model instead of a static heat-balance calculation.
Most heat exchanger coursework stops at steady-state heat-balance math: LMTD, effectiveness-NTU, overall heat transfer coefficient. That math never shows how an exchanger actually behaves when a flow rate shifts, a control valve moves, or fouling slowly degrades performance over weeks of operation. PiHEx closes that gap by putting the same dynamic behavior on screen in real time, so engineers and students build intuition for exchanger dynamics before they meet the equipment in a plant.
PiHEx simulates the real-time dynamics of a shell-and-tube heat exchanger network so engineers and students can observe closed-loop temperature response, experiment with fouling, and build heat-exchanger intuition under realistic operating conditions. PiHEx runs on standard Windows hardware, requires no DCS hardware, and fits the goals of Industry 4.0 by enabling online teaching and virtual laboratories. Because it models the same dual-stream behavior engineers later encounter in real exchanger networks, the skills transfer directly from simulator to plant.
Real-time simulation of shell-and-tube heat transfer, not a static heat-balance snapshot.
An adjustable fouling factor degrades the overall heat transfer coefficient over time.
Independent hot-side and cold-side control loops respond to each other's dynamics.
Adjust flow rates, inlet temperatures, and exchanger geometry to match different scenarios.
Setpoint, PV trend, and valve output in a layout familiar to plant operators.
Runs entirely on a Windows PC, well suited to online teaching and virtual laboratories.
Process engineers use PiHEx to build intuition for shell-and-tube heat transfer, fouling behavior, and dual-stream temperature control before they work on live exchanger networks. Practicing on PiHEx lets engineers see how fouling degrades performance over time and how dual-stream control loops respond to disturbances, without risking product quality or energy efficiency on a real industrial process control system.
Engineering colleges and universities use PiHEx in courses and lab sessions covering heat transfer, unit design, and process control, particularly within chemical engineering. PiHEx replaces static heat-balance homework with hands-on simulator practice, letting students experiment with process conditions and see the effect on heat transfer rates in real time, a fit for Industry 4.0 online teaching and virtual laboratories.
PiHEx's feature set is built for one outcome: engineers and students who understand how a real heat exchanger network actually behaves, not just how it balances on paper.
Simulates shell-and-tube exchanger response in real time with adjustable flow, temperature, and geometry.
Reflects actual exchanger timing, so learners see how heat transfer behaves under realistic dynamics, not textbook idealization.
An adjustable fouling factor gradually reduces the overall heat transfer coefficient during a run.
Shows exactly how fouling erodes exchanger performance over time, a behavior no static calculation can show.
Independent hot-side and cold-side control loops, each responding to the other stream's dynamics.
Captures the interaction between two coupled control loops, the behavior that trips up single-loop thinking.
Flow rates, inlet temperatures, and exchanger geometry are adjustable to match different scenarios.
Lets instructors and engineers build the specific exchanger scenario their course or plant needs.
Setpoint, PV trend, valve output, and control parameter entry in an operator-familiar layout.
Removes the interface learning curve, so learners focus on exchanger behavior, not navigation.
Installs and runs entirely on a Windows PC, no cloud dependency, no DCS hardware.
Fits Industry 4.0 online teaching and virtual laboratories, wherever the student or engineer is located.
Heat exchangers are among the most common pieces of equipment in a process plant, and most engineers first meet them through steady-state heat-balance math: LMTD, effectiveness-NTU, a single overall heat transfer coefficient. That math produces a correct design point, but it says nothing about how the exchanger behaves after a flow upset, a control-valve move, or months of fouling. A training gap here touches nearly every exchanger network a plant runs.
A steady-state LMTD or NTU calculation produces one design point. It never shows how the exchanger responds when flow shifts, inlet temperature changes, or fouling reduces the heat transfer coefficient. Engineers who can solve the textbook problem are often unprepared for how the real exchanger behaves.
Fouling develops over weeks or months of real operation, far too slowly to observe in a semester and far too slowly to see in a static design calculation. Students graduate having never watched fouling erode exchanger performance in real time.
A single-loop mental model breaks down on a heat exchanger, where the hot-side and cold-side control loops interact. Engineers who have only tuned isolated loops can be caught off guard the first time they see two coupled streams respond to each other.
PiHEx removes the structural problem: real-time dual-stream response, an adjustable fouling factor that compresses months of degradation into a single session, and dynamic models that behave like the actual exchanger network, not the design-point calculation. Engineers and students who train on PiHEx build intuition that a static heat balance cannot provide.
PiHEx is part of PiControl's family of real-time process simulators, each built around a different loop or unit operation.
PiTemp is a simpler, single-loop temperature-control simulator, a natural starting point before moving on to PiHEx's fuller shell-and-tube exchanger network, fouling effects, and dual-stream control.
PiFlow simulates a flow control loop in real time, complementing PiHEx's exchanger-level view with a closer look at the flow dynamics that feed a heat exchanger network.
PiDeltaP simulates differential-pressure control dynamics, another loop type engineers meet alongside heat exchanger networks in real plant operations.
Engineers and students train on PiHEx across every sector PiControl serves — each runs heat exchanger networks with different fouling and dual-stream control challenges.
PiHEx is deployed in chemical engineering departments and industrial training programs, giving students and process engineers a real-time, dynamic view of heat exchanger behavior that a static heat-balance calculation cannot provide. Read more in our customer success stories.
Request the PiHEx installer and licensing details for your department or plant.
See PiHEx run in real time and watch fouling and dual-stream temperature control play out live. A PiControl engineer will demonstrate the simulator on scenarios relevant to your plant or curriculum, and discuss licensing options for your team.