Shell and Tube Heat Exchangers consist of shells, heat transfer tubes, tube sheets, channel boxes, baffles and sealing assemblies.
Two fluids flow separately through the tube side and shell side, with heat transferred across the walls of heat transfer tubes. Units can be engineered into the following types to meet various process requirements:
● Fixed Tube Sheet Heat Exchanger
● Floating Head Heat Exchanger
● U-Tube Heat Exchanger
● Single-Pass / Multi-Pass
● Horizontal / Vertical
Structural selection is critical if your process media is prone to fouling, operates under large temperature differences, or requires frequent equipment maintenance. We will adopt fixed tube sheet, floating head or U-tube configurations based on your actual working conditions, rather than applying a uniform design to all projects.
Key Considerations for Procuring Shell and Tube Heat Exchangers
Sufficient Heat Transfer Area
The heat transfer area determines whether the equipment can achieve the designed outlet temperature. GYRO conducts precise calculations based on heat load, medium flow rate, inlet and outlet temperatures, heat transfer coefficient and fouling resistance. The heat transfer area of standard units ranges from 10 ㎡ to 2,000 ㎡, while large-scale equipment can be assembled or custom-engineered as per project demands.
Acceptable Pressure Drop
Insufficient flow velocity inside the exchanger impairs heat transfer performance; excessive velocity, on the other hand, causes high pressure drop and elevated operational energy consumption. We optimize pipe diameter, tube pass quantity, baffle spacing and flow channel layout to satisfy heat exchange demands while minimizing unnecessary pump power consumption.
Ease of Cleaning After Fouling
If your process medium contains solid particles, high-viscosity components or crystallization-prone substances, maintainability for post-operation cleaning must be prioritized during model selection. For such working conditions, removable tube bundles can be selected according to on-site maintenance conditions. When the exchanger is installed in chemical or petrochemical plants, we reserve sufficient pulling space for tube bundle extraction in line with on-site hoisting constraints.
Reference Technical Parameters
|
Parameter |
Typical Range |
|
Heat Transfer Area |
10–2,000 m² |
|
Design Pressure |
Vacuum–10.0 MPa |
|
Design Temperature |
-20°C–450°C |
|
Tube Diameter |
Φ16–Φ38 mm |
|
Tube Length |
1,500–12,000 mm |
|
Tube Thickness |
1.5–4.0 mm |
|
Tube Passes |
1–8 Passes |
|
Tube Material |
CS / SS304 / SS316L / Duplex / Alloy |
|
Shell Material |
Carbon Steel / Stainless Steel |
|
Tube Sheet Type |
Fixed / Floating / U-Tube |
|
Connection Size |
DN25–DN800 |
|
Design Standard |
ASME / GB / HG/T / Customer Specification |
Actual parameters are determined based on thermal calculations, mechanical design, fluid properties, and project standards.
Our Manufacturing Process of Shell and Tube Heat Exchangers
Thermal Calculation
We first confirm key parameters including heat load, medium flow rate, inlet & outlet temperatures, design pressure, allowable pressure drop and fouling resistance, to determine the required heat transfer area, tube diameter, number of tube passes and overall equipment configuration.
01
Mechanical Design
Complete structural design for shells, tube sheets, tube bundles, baffles, channel boxes and connecting nozzles, with full consideration of pressure bearing, thermal expansion and later equipment maintenance.
02
Raw Material Quality Control
Purchase steel plates, heat transfer tubes, tube sheets and other raw materials as per project specifications, and carry out material certification verification and strict quality inspection.
03
Tube Bundle Fabrication
Implement a full set of procedures: cutting heat transfer tubes, machining tube sheets, tube threading, tube expansion and tube-to-tube sheet welding.
04
Welding & Non-Destructive Testing (NDT)
Conduct NDT inspections such as RT, UT, MT and PT in accordance with project standards to guarantee the integrity of critical weld joints.
05
From Single Shell and Tube Heat Exchanger to Complete Turnkey Projects
GYRO offers two cooperation modes tailored to your specific requirements.
Single Equipment Procurement
If you have finalized the equipment model and technical parameters, we will manufacture heat exchangers strictly in accordance with your drawings or technical specifications.
Full-Scope EPC Projects
For new chemical, petrochemical or energy plant construction projects, we can participate from the preliminary equipment selection phase. We provide integrated design and fabrication services for shell and tube heat exchangers, reactors, towers, pressure vessels and other process equipment, alongside supporting on-site installation and commissioning services.
Custom Shell and Tube Heat Exchanger Inquiry Guide?
Need a custom shell and tube heat exchanger? Simply send us the following data: fluid name, flow rate, inlet & outlet temperatures, design pressure, design temperature and on-site installation conditions.
Incomplete parameters are acceptable. ZIBO GYRO can first confirm the optimal exchanger structure, material grade and design scheme for you. After finishing full thermal calculation, we will deliver a complete technical proposal and formal quotation accordingly.
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