Tube bundle heat exchanger

Shell and tube heat exchangers are versatile solutions for efficient heat exchange in a wide range of industrial applications. They enable the precise temperature control of gaseous and liquid media by reliably transferring thermal energy. Typical fluids used in these heat exchangers include natural gas, biogas, hydrogen, process gas, LNG, nitrogen, air and various coolants and heat transfer fluids such as water, glycol and glycol mixtures.

Shell and tube heat exchangers play a key role in industries such as chemicals, petrochemicals, polymer production, natural gas extraction, the food industry, shipbuilding and maritime applications. Here they are used to heat, superheat or cool the media in order to meet process requirements and ensure high operating efficiency. They also ensure optimum heat transfer in specialized industrial and customer-specific applications and help to increase system efficiency.

1. chemical and petrochemical industry

• Reactor cooling: Shell and tube heat exchangers are used for temperature control in chemical processes to keep reactors at an optimum temperature.
• Heat recovery: Utilization of waste heat from chemical processes to preheat other process media.
• Distillation: They are used in distillation columns to condense vapors or to heat mixtures.

2. oil and gas industry

• Condensation of steam in refineries: In refineries, they condense water vapor or other process gases.
• Cooling of lubricating oils: RBWTs help to control the operating temperature of machines by cooling oils.
• Natural gas processing: Heat exchangers are used to heat or cool the gas before it is processed further.

3. power plants

• Steam-water circuits: In power plants, they are used to recover heat from exhaust gases or to heat feed water.
• Condensers for steam turbines: They condense the water vapor escaping from the turbine.
• District heat transfer: In district heating networks, they ensure heat exchange between primary and secondary circuits.

4. food and beverage industry

• Pasteurization of milk and juices: Heating and cooling of liquids for preservation.
• Heating of process water: Use in breweries and dairies for temperature control.
• Cooling of production plants: shell and tube heat exchangers help to keep the operating temperature of machines stable.

5. marine and shipping industry

• Cooling of marine machinery: RBWTs are used to cool engines, generators and lubricants.
• Seawater cooling systems: Seawater is used as a cooling medium to regulate the operating temperature of equipment on ships.

6. HVAC and air conditioning systems / district heating and cooling / refrigeration technology for distribution warehouses / distribution centers

• Cooling and heating of buildings: They are used for heat recovery in ventilation systems or air conditioning systems.
• Industrial cooling systems: shell and tube heat exchangers help to operate large cooling circuits efficiently.

7. metal and steel industry

• Cooling of furnaces and rolling mills: RBWTs are used to efficiently dissipate process heat.
• Heating metal solutions: During electroplating or in chemical baths for temperature control.

Shell and tube heat exchangers are indispensable in a wide range of industries as they enable efficient and reliable heat transfer. Thanks to their robust design and adaptability to different operating conditions, they can be used in a wide variety of applications.

Mechanical and plant engineering

In mechanical and plant engineering, shell and tube heat exchangers play a decisive role in the temperature control of operating media. They are used in complex production systems to dissipate process heat or bring it to a desired level. They make a significant contribution to increasing efficiency and operational safety.

Chemical, petrochemical & polymer plants

In the chemical and petrochemical industry, shell and tube heat exchangers are used to control the temperature of process media. They are essential for reaction processes where exact temperature conditions are required. They also play an important role in polymer plants by optimizing heat transfer during the production and processing of plastics.

Natural gas production

In natural gas production, shell and tube heat exchangers are used to heat, cool or superheat gases in a targeted manner. They ensure reliable temperature regulation in compressor stations and in the further processing of natural gas, which increases the efficiency of the overall process.

Food industry

The food industry places high demands on hygienic and thermal processes. Shell and tube heat exchangers enable the precise temperature control required for processing, pasteurizing or cooling food. They ensure uniform heat transfer without compromising the quality of the products.

Shipbuilding and maritime applications

In maritime applications, shell and tube heat exchangers are essential for cooling engines, drive systems and other technical components. They ensure reliable heat dissipation and contribute to the operational safety of ships and offshore installations.

Industrial applications

In general industry, shell and tube heat exchangers are used in a wide range of applications, including temperature control of machines, recovery of process heat or cooling of production facilities. They are a key component for efficient thermal processes in almost all areas of industrial production.

Process industry

In the process industry, precise temperature control is crucial for the quality and efficiency of production processes. Here, shell and tube heat exchangers take on central functions in heat transfer processes that are necessary for chemical reactions, distillation processes or energy optimization.

Special applications

In addition to the classic branches of industry, shell and tube heat exchangers are also used in special applications that require individual technical solutions. This includes, for example, high-temperature processes, demanding media or extreme environmental conditions where standard solutions are not sufficient.

Thanks to their high performance and versatility, shell and tube heat exchangers are an indispensable technology for efficient and safe thermal processes in numerous industries.

Shell and tube heat exchangers are constructed and designed according to individual requirements in order to meet the specific technical and regulatory specifications in various markets and applications. The framework conditions include a large number of standards, test requirements and operational specifications that ensure safe and efficient use.

Regulations and international standards

Shell and tube heat exchangers are designed and manufactured in accordance with various national and international standards. Depending on the area of application and requirements, the design can be based on the following regulations:

• ASME (with or without U-stamp) for the international market
• EN 13445 for the European market
• SVTI for applications in Switzerland
• AS1210 for Australia
• PD5500 for the British market

These standards ensure that the heat exchangers meet the applicable safety and quality requirements and can be used in different countries.

Customer-specific tests and approvals

Individual tests and approvals are required for special applications and demanding industrial processes. Shell and tube heat exchangers can be tested and approved according to the specifications of renowned companies and institutions, including

• BASF, OGE, Gascade, Sasol, INGL, ERI, Dolphin, Saudi Aramco, Gasco, MAN, Jenbacher, MAPNA, Siemens, DONG, TEMA and many more. These tests ensure that the heat exchangers meet the highest quality and safety standards and are suitable for specific operating conditions.

Special operating conditions

Depending on the area of application, shell and tube heat exchangers must withstand special operating conditions. These include

• Sour gas applications (NACE): The heat exchangers are designed for use in corrosive environments containing hydrogen sulphide (H₂S).
• Low temperature applications: Designs for operating conditions down to -50 °C ensure reliable performance even at extremely low temperatures.
• High pressures and temperatures: The heat exchangers are designed for a design pressure of up to 300 bar and a maximum operating temperature of 250 °C.

Customized nozzle arrangement

For optimum integration into existing plants and piping systems, the nozzle arrangements are designed individually according to customer requirements. This enables a seamless connection to existing systems and efficient operational management.

Thanks to this flexible framework, shell and tube heat exchangers can be adapted precisely to specific industrial requirements and optimized for a wide range of applications.

Shell and tube heat exchangers are manufactured from a variety of materials to meet the specific requirements of different applications. The choice of material depends on factors such as the medium, temperature, pressure and the chemical and mechanical loads.

Carbon steel:
Carbon steel is often used for heat exchangers that operate in standard applications with moderate temperatures and pressures. It is characterized by high strength, good processability and economic advantages. This material is widely used in industry and mechanical engineering in particular.

Stainless steel:
Stainless steel is used for applications that require high corrosion resistance. This material offers advantages in environments with aggressive media such as acids, alkalis or salt water. Stainless steel heat exchangers are particularly in demand in the chemical and petrochemical industries, in food processing and in maritime applications.

Combination of carbon steel and stainless steel:
In some cases, shell and tube heat exchangers are made from a combination of both materials. This enables an optimum balance between mechanical strength and corrosion resistance. For example, the housing can be made of carbon steel while the tubes are made of stainless steel to ensure greater resistance to corrosive media.

Thanks to this variety of materials, shell and tube heat exchangers can be individually adapted to the respective operating conditions and used efficiently in a wide range of industrial sectors.