All-Welded Heat Exchanger Series
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Structural features:
A fully welded heat exchanger is a new, highly efficient heat‑transfer device that combines the advantages of plate‑type heat exchangers while addressing the limitations of shell-and-tube designs. By completely eliminating gaskets, it is well suited for medium‑ and high‑pressure, as well as medium‑ and high‑temperature service conditions. It retains the full counterflow heat‑transfer characteristics of plate‑type exchangers and delivers 3–5 times the efficiency of conventional shell-and-tube units. Depending on the specific application, fully welded heat exchangers are available in three configurations: non‑removable, single‑side removable, and double‑side removable. In removable‑design models, the removable flow passages can be mechanically cleaned to meet operational requirements.
Heat transfer principle:
For all-welded heat exchangers with either non‑removable or single‑side removable designs, the flow configuration of the cold‑side and hot‑side media—whether entering the upper or lower channels, or the left or right channels—is selected based on operating conditions and fluid properties. Typically, the hot side is fed from above and discharged from below, while the cold side enters the left or right channels and exits from above, thereby achieving a purely counter‑current heat exchange between the hot and cold streams.
For fully welded heat exchangers with detachable side structures, rectangular or square plates may be selected based on operating conditions and fluid characteristics. The inlet and outlet ports for the hot and cold streams are arranged either in the front–back or left–right direction, with the fluids flowing in a cross‑flow pattern across the heat transfer plate surfaces.
In certain operating conditions where space constraints impose height limitations, a horizontal configuration can be selected to reduce the heat exchanger’s overall height.
The left-hand diagram shows a non-detachable vertical structure, suitable for applications involving relatively clean media.
Single-sided detachable horizontal structure
Depending on the operating conditions, a vertical configuration may also be designed.
This structure is suitable for applications where one side of the medium contains a high level of impurities or requires frequent cleaning.
Remove the bolts and nuts; once the one‑sided cover plate is opened, mechanical cleaning can be performed.
Adopting a dimple‑plate configuration, it can be designed as a wide‑channel, free‑flow heat exchanger.
Dual-sided detachable vertical structure
Depending on the operating conditions, it can also be designed as a horizontal configuration.
This structure is suitable for applications where both sides of the medium contain significant impurities, or where both sides require frequent cleaning.
After removing the bolts and nuts and opening the side cover plates on both sides, mechanical cleaning can be performed.
All-welded heat exchanger plate types:
Ametech’s all-welded heat exchanger plates come in two main types: herringbone corrugations and dimple plates. Depending on the operating conditions, these two plate designs can be configured in various sizes to meet specific flow rate and heat transfer temperature difference requirements.
Structural features of herringbone corrugated panels:
· Normal, relatively clean operating conditions.
· Excellent heat transfer performance.
· High pressure resistance.
Characteristics of the dimple plate structure:
· There are two types of bubbles, differing in size and depth.
· Suitable for operating conditions with significant flow rate deviations on both sides.
· Establish free-flow lanes.
· Suitable for non‑clean operating conditions where the medium contains solid particles.
· It withstands moderate to high temperatures and moderate to high pressures, offering a broader range of applications compared to detachable plate heat exchangers.
· The plate edges are welded automatically by laser, eliminating the need for rubber gaskets; this design is suitable for applications where the process medium is corrosive to conventional sealing gaskets.
· High heat transfer efficiency, with nearly the entire plate surface participating in heat exchange.
· It occupies a small footprint; for the same heat-transfer area, its required floor space is only one-third that of a shell-and-tube heat exchanger.
· The inlet and outlet接管 dimensions are non-standard, offering high flexibility.
· It can be designed as a double-sided, detachable unit, facilitating inspection and cleaning, with low operating and maintenance costs.
· A single-sided detachable structure, which can be designed as a wide-channel free-flow heat exchanger.
It is widely used across various sectors, including the chemical industry, petrochemicals, pharmaceuticals, district heating and combined heat-and-power generation, mechanical engineering, and wastewater treatment. In particular, wide‑channel, free‑flow, all‑welded heat exchangers are extensively employed in metallurgy, coal chemical processing, steel production, and power plants. Typical applications include waste‑heat recovery from blast‑furnace slag‑quenching water, cooling of intermediate processes in alumina digestion units, heat exchange for desulfurization solutions in coal‑chemical plants, oil‑to‑rich‑oil heat exchange, and high‑temperature flue‑gas waste‑heat recovery.
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Frequently Asked Questions
Precautions for Shutting Down a Plate Heat Exchanger
When shutting down the heat exchanger, first slowly close the hot-side inlet valve, then slowly close the cold-side inlet valve, and finally close both the cold- and hot-side outlet valves. After all valves are closed, stop the pump; if necessary, open the drain valve.
Precautions for Starting a Plate Heat Exchanger
Inspect the clamping bolts and tighten them to the specified torque, ensuring even diagonal tightening. Verify that the inlet and outlet valves and the vent valve are in good condition and that all instruments are functioning properly. During startup, vent the system first, then introduce the cold medium before introducing the high‑temperature medium. Gradually open the inlet and outlet valves while carefully controlling the pressure differential between the two sides.
Precautions for Disassembling Plate Heat Exchangers
Before dismantling the plate heat exchanger, the clamping dimensions shall be measured and recorded. L; Loosen the clamping bolts alternately in a diagonal sequence.
Precautions for Storing Plate Heat Exchangers
Plate heat exchangers should be stored in a dry, well-ventilated warehouse, with the ambient temperature not exceeding 45 °C 。
When a plate heat exchanger has been out of service for more than six months, the internal fluid must be completely drained. It is advisable to loosen the clamping bolts in advance to ensure that the gap between the two clamping plates reaches 1.2 times L is recommended; clamp it to L when in use.
Causes of Leakage in Plate Heat Exchangers
1) Gasket aging; 2) System overpressure; 3) Loose clamping bolts causing external leakage; 4) Plate corrosion leading to internal leakage.
What are the characteristics of a plate heat exchanger?
Ametech has introduced advanced technologies and design principles, placing user reliability and optimal operational performance at the core, to maximize heat exchange efficiency and minimize energy losses. Ametech has introduced advanced technologies and design principles, placing user reliability and optimal operational performance at the core, to maximize heat exchange efficiency and minimize energy losses.
If you require a customized product, please…Contact us!
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