Spiral heat exchangerProduct Introduction
The stainless steel high-efficiency spiral heat exchanger is a high-efficiency heat transfer device made of high-quality corrosion-resistant materials such as 316L stainless steel and designed with a multi-layer spiral wound tube bundle structure.Its core structure consists of heat exchange tubes tightly wound around a central cylinder at a helical angle of 3°-20°, forming crisscrossing, counter-current fluid channels.Combined with a fully welded tubesheet connection process, stable heat exchange is achieved over a wide temperature range of -196℃ to 400℃ and a high pressure range of 0-20MPa.This equipment overcomes the traditional trade-off between heat transfer efficiency and space occupation, achieving a heat transfer area of 100-170㎡/m³ per unit volume, which is 3-5 times that of conventional shell-and-tube equipment, while reducing weight by more than 40%.Simultaneously, leveraging the corrosion resistance of stainless steel and the fluid optimization capabilities of its spiral structure, it has become a core piece of equipment for industrial energy conservation and process temperature control.ment.
Core Product Features
Spiral-enhanced heat transfer, leading the industry in efficiency.
The three-dimensional helical structure of the heat pipe generates strong secondary circulation in the fluid, increasing turbulence intensity by 3-5 times, effectively disrupting the thermal boundary layer, and achieving a heat transfer coefficient as high as 14000 W/(㎡・℃).Compared to traditional shell-and-tube heat exchangers, this represents a 30%-50% improvement. Utilizing a pure counter-current heat exchange design, it increases temperature difference utilization by 30%.Under the same heat exchange requirements, the thermal efficiency exceeds 98%, and the heat exchange efficiency per unit area is 3-7 times that of traditional equipment.
01
Powered by stainless steel, suitable for harsh working conditions.
The main body is made of 316L stainless steel, with an annual corrosion rate of < 0.01mm in Cl⁻ environments, and can withstand corrosive media such as acid and alkali solutions and wet chlorine gas;For special operating conditions, it can be upgraded to titanium alloy material. It has operated continuously for 5 years in coastal chemical industrial parks without corrosion or leakage, and the equipment has a service life of 30-40 years.It extends the lifespan by 3-5 times compared to traditional carbon steel equipment. The all-welded structure, combined with strength welding and expansion bonding technology, results in a leakage rate of less than 0.001%, making it suitable for 20MPa high-pressure conditions.
02
Compact design + self-cleaning, optimal operation and maintenance costs.
With a volume only 1/10 that of traditional shell-and-tube heat exchangers, infrastructure costs are reduced by 70%, making it particularly suitable for space-constrained scenarios such as offshore platforms and ships.The high design flow rate of 5.5m/s and the scouring effect of the spiral channel reduce the dirt deposition rate by 70%, extend the cleaning cycle to 12-18 months, and reduce annual maintenance costs by 40%.
03
Self-compensating thermal stress, resulting in strong operational stability.
The tube bundle has elastic free sections at both ends, which can expand and contract axially with temperature changes, effectively absorbing thermal expansion stress. Even under extreme working conditions with a temperature difference of up to 300℃, it can still avoid failures such as tube sheet cracking.An application example at a thermal power plant shows that the equipment has been running continuously for 12 years without failure, with reliability far exceeding that of traditional U-tube heat exchangers.
04
Competitive advantage
Improved temperature control accuracy
In pharmaceutical purified water heating applications, temperature fluctuations can be controlled within ±0.2℃, meeting the stringent GMP requirements for temperature control of water for injection and ensuring the sterilization effect of drugs.
01
Energy consumption significantly reduced
In refinery catalytic cracking units, compared to traditional shell-and-tube heat exchangers, the thermal efficiency has increased from 72% to 88%.A single unit of equipment can save 12,000 tons of steam consumption per year, equivalent to about 1,700 tons of standard coal, and reduce carbon emissions by 4,200 tons.
02
Flexible load adaptation
Faced with load fluctuations of 10%-120% in industrial production, the heat transfer efficiency decay rate is ≤5%. For example, in batch heating requirements in food processing, it can operate stably without frequent parameter adjustments.
03
Wide-range temperature and pressure regulation
Supports operation over a wide temperature range from -196℃ (LNG liquefaction) to 400℃ (chemical reaction).Temperature difference control accuracy is ±0.3℃ to ±1℃, meeting the precise temperature control requirements for pharmaceutical sterilization and low-temperature refrigeration. Pressure resistance exceeds 20MPa.It can be directly adapted to high-pressure processes such as hydrocracking and IGCC gasifiers, without the need for additional desuperheating and pressure reduction devices.
04
Low carbon, energy saving and consumption reduction;
By reducing primary energy consumption through efficient heat transfer, energy consumption in LNG liquefaction plants is reduced by 28%, and carbon emissions are reduced by 25%.The carbon capture process achieves a CO₂ liquefaction rate of 98%, contributing to the goal of carbon neutrality. The equipment manufacturing employs a closed-loop recycling process, with a titanium material utilization rate of 95%, reducing carbon emissions by 30% during the production phase of a single unit
05
Technical Characteristics
Helical Structure Reconstructs Thermodynamic Boundaries.
Highly efficient heat transfer mechanism
Stainless steel spiral wound tube heat exchangers form a three-dimensional heat transfer network through multiple layers of tubes wound in opposite directions at the same angle. This causes secondary circulation of the fluid within the spiral channel, disrupting the boundary layer thickness and increasing the heat transfer coefficient by 20%-40% compared to traditional shell-and-tube heat exchangers, reaching a maximum of 14,000 W/(m²·℃). For example, in ethylene cracking units, the heat exchange efficiency has increased from 72% to 85%, saving 12,000 tons of steam annually.
Compact structure
With the same heat exchange capacity, the equipment volume is only 1/10 of that of a traditional shell-and-tube heat exchanger, and the weight is reduced by 40%-60%. This feature allows it to reduce the footprint by 60% in LNG receiving terminal projects, saving over ten million yuan in land costs.
Corrosion resistance and long service life
Made of 316L stainless steel or titanium alloy, it has a uniform coefficient of thermal expansion, is resistant to high temperatures (up to 400℃), high pressure (20MPa), and corrosion (resistant to acid, alkali, and salt media), with a designed service life of 30-40 years. In highly corrosive media such as hydrochloric acid (20%) and sulfuric acid (15%), the corrosion rate is less than 0.005mm/year.
Self-cleaning function
The spiral channel design enhances the flushing effect of fluid on pipe dirt, making it less likely for scale and solid particles to accumulate, reducing the tendency to scale formation, extending the cleaning cycle to 12-18 months, and reducing maintenance costs by 50%.
Stainless steel high-efficiency spiral heat exchangers, with their characteristics of high-efficiency heat transfer, corrosion and pressure resistance, compact design and energy saving, are suitable for the heat exchange needs of complex processes in various industries.Its core application scenarios cover industrial sectors such as chemical, energy, food and pharmaceutical, and metallurgy, as detailed below:
petrochemical industry
In crude oil processing: used for crude oil preheating, waste heat recovery in atmospheric and vacuum distillation columns, and heat exchange of process media in catalytic cracking and hydrorefining processes.It can efficiently handle corrosive media containing sulfur and acid, and is suitable for high-temperature and high-pressure process environments.
Energy and power industry
In the field of new energy: in the purification of photovoltaic silicon materials and the synthesis of lithium battery electrolytes, it realizes the cooling of high-temperature media and the preheating of low-temperature media; in the production of biomass energy and hydrogen energy, it completes the heat exchange and purification of raw gas.
Food and pharmaceutical industry
Pharmaceutical manufacturing: In the temperature control of drug synthesis reactions, sterilization and cooling of injection solutions, and concentration and cooling processes of traditional Chinese medicine extracts, the sterility and corrosion resistance requirements of pharmaceutical production must be met, while the heat exchange temperature must be precisely controlled.
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