Spiral heat exchanger

Spiral heat exchanger is a device where the heat exchange surface is formed by metal sheets twisted into a spiral. They are located in a cylindrical casing. The use of integral metal sheets from the central pipe to the casing allows virtually eliminating welded seams both inside and in hard-to-reach areas of the heat exchanger.

The media involved in the heat exchange process can be various gases, vapors, and liquids.

Spiral heat exchangers have three major advantages: they are compact, have a wide channel, and have a self-cleaning effect. These factors make spiral heat exchangers versatile equipment. They are used in working with liquid heterogeneous and high-viscosity media prone to deposit formation on heat transfer surfaces. Similarly, spiral heat exchangers are used during the condensation of vapor or gas under conditions of high vacuum.

The history of the spiral heat exchanger began in the late nineteenth century

The design of the spiral heat exchanger

Two long metal sheets are spirally wound around a central tube, forming two single-pass channels. To ensure consistent gap sizes, divider pins are welded to one side of the sheets. The central tube is divided into two chambers by a special partition, forming inlet and outlet manifolds. The twisted spirals are placed in a cylindrical casing. The outer ends of the spiral sheets are welded along the forming flange. To exit the channels externally, holes are drilled in the places where the edges of the channels are fixed in the casing, which are tightly sealed with inlet and outlet manifolds with connecting pipes.

The channels have the same cross-sectional area. Due to the uniform curvature of the channel, turbulence occurs within the fluid flow. High fluid turbulence in spiral heat exchangers is achieved at much lower flow velocities compared to straight tubular heat exchangers. Thanks to turbulence, solid particles remain suspended in the flow and do not settle on the heat transfer surfaces, thus eliminating the possibility of stagnant zones forming inside the heat exchanger channels.

• 1 Classic Type: The fluids flow in counterflow, and each side is accessible for cleaning. This type is primarily used for liquid-liquid processes.
• 2 Spiral Condenser Type: The fluids flow in crossflow relative to each other. On the coolant side, which moves along the spiral, the heat exchanger is inaccessible for mechanical cleaning.
• 3 Spiral Gas Cooler Type: The operational process is organized similarly to the second type, with the difference being in the divider partitions on the gas side.
• 4 Spiral Evaporator Type: The flow of the fluids is crossflow, and the heating fluid is inaccessible for cleaning.

Technical specifications of spiral heat exchangers

Spiral heat exchangers are devices that efficiently transfer heat between working media such as liquids or vapour with liquid. They are widely used in various industrial applications due to their high heat transfer efficiency and compact size. To better understand the capabilities of these heat exchangers, it is important to familiarise yourself with their specifications.

table Technical characteristics of spiral heat exchangers

These heat exchangers are versatile and can be used in a variety of operating conditions. They transfer heat efficiently, withstand high temperatures and pressures, and are easy to maintain due to access from both sides. The variety of materials and parameters allows the heat exchanger to be optimally matched to your specific needs.

Advantages of spiral heat exchangers

Spiral heat exchangers are often the most optimal and cost-effective solution for heat exchange tasks. They have a number of advantages:

• High heat transfer coefficient, reaching 3820 kcal/m² × hr × °C, which is 2-3 times higher than that of shell-and-tube heat exchangers.
• Reliable construction. Due to the sealing of each of the two passages, counter flows do not mix.
• Spiral heat exchangers occupy much less space compared to shell-and-tube heat exchangers.
• Spiral heat exchangers are characterized by compactness, low hydraulic resistance, and significantly higher heat transfer intensity at increased fluid velocities.
• Self-cleaning capability.
• Reduced fouling;
• Less maintenance downtime.

Disadvantages of spiral heat exchangers

Manufacturing spiral heat exchangers is technologically challenging. Repair work and servicing of heat exchange equipment are very difficult. Assembly, disassembly, and cleaning of spiral heat exchangers are very complex, making it difficult to penetrate deep into the structure. Therefore, only chemical cleaning with special acidic solutions is used for this type of heat exchanger.

Alongside spiral heat exchangers, FREE FLOW heat exchangers are used for highly viscous fluids. These heat exchangers are easier to disassemble and operate.

Spheres of application of spiral heat exchangers

Let’s take a look at the applications in which spiral heat exchangers are most commonly used.

• Oil refining (Heavy oils, wash oils)
• Pulp and paper industry (Spent sulfate and sulfite liquors, aqueous solutions of SO2, deodorization during condensation)
• Chemical industry (PVC, latex, acrylic acetate, TiO2, etc.)
• Purification of municipal and chemical wastewater (sludge disposal, thermal sterilization, wastewater and effluents)
• Mining industry (aluminate liquors, bauxite suspensions, magnesium oxides)
• Steelworks, gas processing, and coking plants (benzene, wash oils, NH3 solution, cooling condensers)
• Textile industry (recovery of heat from dyes and wash liquids)
• Sugar industry (press water, raw juice, diffusion juice)
• Alcohol industry (cooling of grain mash, cooling of stillage, heating of mash)
• Food industry (wastewater, vegetable oil, potato, grain, tomato, or corn pastes)
• Pharmaceutical industry

Teplo-Polis’ spiral heat exchangers are used in enterprises throughout Ukraine, including oil refineries and food production facilities. We pride ourselves on the fact that our equipment successfully operates in complex production facilities, ensuring high efficiency and long service life. See examples of our successful deliveries and read customer testimonials on our Shipped Products page.

How to buy a spiral heat exchanger

The process of buying a spiral heat exchanger at Teplo-Polis is simple and convenient. You need to follow a few steps:

1. Request an Estimate: To get an accurate price for a spiral heat exchanger, you can contact us in a number of ways:
   • Call the phone number listed on our website and clarify all details. Our specialists will help you to choose the right heat exchanger and answer all your questions.
   • Fill in the questionnaire with technical parameters and heat exchanger requirements, then send it by e-mail. We will use this information to accurately calculate the cost of the equipment.
   • Fill in the form on the website with all the necessary data about your project. Our specialists will then contact you to clarify details and provide an estimate.
2. Calculation Process: After receiving your application, our engineers carry out a thorough calculation of the spiral heat exchanger based on your needs and operating conditions. This will enable us to propose an optimal solution that will fulfil all technical requirements at the lowest possible cost.
3. Order confirmation: After all details and calculations have been agreed, we provide you with a quotation. If this is satisfactory, we place the order and start the production or delivery process.
4. Delivery and installation: After confirming your order, we will organise the delivery of the spiral heat exchanger to the region you specify. We can also offer installation and commissioning services if required.

So, if you are looking to buy a spiral heat exchanger, the process with us is as simple and flexible as possible, with the ability to get accurate calculations and advice on the best choice of equipment.