When it comes to efficient heat transfer in various industrial processes, Shell & Tube heat exchangers have long been the go-to solution. These devices effectively transfer heat between two fluids, making them crucial in applications ranging from chemical and petrochemical plants to power generation facilities. One significant factor in enhancing the performance and durability of Shell & Tube heat exchangers is the utilization of exotic materials like Titanium, High Nickel Alloys, and Stainless Steel.
Langfields Heat Exchanger Track Record
Over the years our experts have completed numerous heat exchanger projects using exotic materials. Check out a select few below:
| Project | Details | Exchanger Size | Tube dimensions | Material Grade | Test Pressure |
| G35 Condenser | Carbon Steel Shell with Bellows, G35 Tubes & Tubeplate. Tubes Seal Welded only. | 406.4 O/D x 1595 long x 9.5mm thick | 197 off 19.05 O/D x 2.11 wall x 1593mm long | G35 Hastelloy | 11.4 Barg |
| B3 Exchanger Retube | Carbon steel existing shell. B3 Tube Side. Challenge retubing existing equipment as there is likely distortion and debris inside the shell from the baffles. | 1206 O/D x 2200 long x 13mm thick | 422 off 1”NB SCH 40S x 2209 long | B3 Hastelloy | 23.14 Barg |
| MCP2 Caustic Nickel Evaporator | Alloy 200/201 Tube Side, Carbon Steel Shell Side. Explosion clad tubeplate, tubes full strength welded. | 1230 O/D x 6964 long x 15mm thick | 290 off 38.1 O/D x 1.65 wall x 2209mm long | Alloy 200 | 17.2 Barg |
| Exchanger Upgrade Alloy 825 | Alloy 825 Tube side, carbon steel shell side with bellows. Tubes full strength welded and flushed off on one side. | 18”NB SCH 20 x 2986mm long | 124 off 25.4 O/D x 1.9 wall x 3000mm long | Alloy 825 | 17.9 Barg |
| Duplex/C/S Exchanger | Duplex Tubes & Tubeplate. Tubes fillet welded only. | 480 O/D x 2500 long x 10mm thick | 127 off 19.05 O/D x 2.77 wall x 2516mm long | Duplex | 7.82 Barg |
| Vapouriser Bundle | Fully Alloy 400 unit. Tubes were full strength welded one end and had caps butt welded on the other end and radiographed. | 16”NB SCH 40 x 1680 long x 10mm thick | 109 off 25.4 O/D x 2.11 wall x 1680mm long | Alloy 400 | 25.9 Barg |
| HCN Still Main Condenser | Duplex Tube Side, Carbon Steel Shell Side. Tube ends full strength welded and lightly expanded. | 1076 O/D x 8988 long x 13mm thick | 1094 off 19.05 O/D x 1.65 wall x 9000mm long | Duplex | 11.5 Barg |
| Overhead Condenser | Sellafield Project. NAG Grade material. Back face welding technique and tube welds radiographed. | 1563 O/D x 7600 long x 35mm thick | 302 off U Tubes 26.67 O/D x 2.87 wall x 9000mm long | Stainless Steel NAG Grade 18/10L | 5.3 Barg |
| 2 Nickel Exchangers | Fully Nickel design. Tubes fillet welded. | 178 O/D x 4493 long x 4mm thick | 55 off 15 O/D x 1.2 wall x 4500mm long | Alloy 200 | 15.9 Barg |
| 3 off Sets of Duplex Port & Starboard Rectangular Condensers | Fully Duplex Units. Rectangular shape and tubes expanded only. U Tube design. | 904 x 344 x 1830 long x 12mm thick | 19.05 O/D x 1536 long x 1.65mm wall | Duplex | 3.45 Barg |
| 2 off Titanium Heat Exchangers | Tubes expanded only. | 546 O/D x 2736 long x 8mm thick | 351 off 19.05 O/D x 1.245 wall x 2750mm long | Titanium Grade 2 | 10.6 Barg |
| Alloy 400 Tube Bundle | 42 off baffles. Tubes seal welded and expanded. | 399 O/D x 2986 long x 6mm thick | 112 off 19.05 O/D x 1.65 wall x 4877mm long | Alloy 400 | 22.5 Barg |
| 3 off EDC Reactor Cooler Exchangers | 70 ton each and designed to ASME VIII Div 1. Tube Cage was loaded within a purpose designed structure with FE Analysis performed for PWHT. Tube ends digitally expanded. | 2800 I/D x 5946mm long | 2828 off 38.1 O/D x 3.4 wall x 5946mm longCarbon Steel | Carbon Steel | 12.24 Barg |
Understanding the Importance of Exotic Materials
Shell & Tube heat exchangers operating in challenging environments require materials with exceptional corrosion resistance, mechanical strength, and thermal conductivity. Exotic materials such as Titanium, High Nickel Alloys, and Stainless Steel offer superior properties that make them ideal choices for demanding applications.
Use of Hastelloy in Heat Exchanger Design & Manufacture
Hastelloy, known for its outstanding resistance to corrosion and high-temperature environments, excels in applications involving aggressive chemicals.
High Nickel Alloys: Enhancing Heat Transfer Efficiency
High Nickel Alloys possess excellent resistance to extreme temperatures and offer remarkable strength and durability. Using High Nickel Alloys for Shell & Tube heat exchangers, engineers can maximize heat transfer efficiency and ensure the longevity of the equipment.
Harnessing the Power of Stainless Steel
Stainless Steel, with its wide range of grades and properties, provides an excellent balance of corrosion resistance, mechanical strength, and cost-effectiveness. Stainless Steel is seen as one of the most versatile materials for heat transfer projects.
Design Considerations for Exotic Material Heat Exchangers
Designing Shell & Tube heat exchangers with exotic materials requires careful consideration of factors like fluid compatibility, pressure and temperature constraints, and mechanical design parameters.
In conclusion, the design and manufacture of Shell & Tube heat exchangers using exotic materials like Titanium, High Nickel Alloys, and Stainless Steel offer numerous advantages in terms of performance, durability, and resistance to harsh environments. By leveraging the unique properties of these materials, engineers can optimize heat transfer efficiency and extend the service life of heat exchangers in various industrial applications. Stay ahead in the heat transfer game by embracing the potential of exotic materials in your Shell & Tube heat exchanger projects by working with Langfields.
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