Introduction to Fully Welded Plate Heat Exchangers
I. Core Product Definition
The fully welded plate heat exchanger is a core high-efficiency heat transfer equipment in the industrial field. It is mainly composed of multiple stamped metal heat exchange plates assembled through integral welding processes such as laser welding and argon arc welding, without rubber gaskets. It realizes efficient heat exchange between cold and hot fluids relying on optimally designed flow channels between the plates. Its core attributes: fully welded structure, high-efficiency heat transfer, high temperature and pressure resistance, no leakage, corrosion resistance, compact structure. It is widely applicable to fluid heat exchange scenarios in various industries such as chemical industry, electric power, iron and steel, oil and natural gas, food and pharmaceutical, new energy, etc., and is a high-quality upgraded alternative product to traditional shell-and-tube and detachable plate heat exchangers.
II. Core Structure and Working Principle
1. Core Structure Composition
Heat Exchange Plates: As the core heat transfer components, they are stamped and formed from corrosion-resistant metal materials such as stainless steel, titanium alloy, and Hastelloy. The surface is designed with special patterns such as herringbone and corrugated, which greatly increases the heat transfer area, enhances fluid disturbance, improves heat transfer efficiency, and reduces scaling and accumulation.
Welded Structure: The plates are fully sealed and welded by high-precision welding processes such as automatic laser weld tracking and argon arc welding, replacing the traditional gasket sealing method. It fundamentally solves the problem of seal leakage under high temperature and high pressure working conditions, and the leakage rate can be reduced to below 0.3%.
Inlet and Outlet Flanges: Located at both ends of the equipment, the flange specifications are fully compatible with general industrial standards, which can be directly connected to existing systems, simplifying the installation process and reducing construction costs.
Shell/Frame: Some models are equipped with special casings and reinforced frames, which are used to fix the plate bundle, enhance the overall rigidity and stability of the equipment, and adapt to various installation environment needs such as indoor and outdoor, and limited space.
2. Working Principle
Two kinds of fluids, cold and hot, flow in opposite (or same) directions in independent sealed flow channels on both sides of the welded plates respectively. Rapid heat conduction is realized through high thermal conductivity metal plates, completing efficient heat transfer from high-temperature fluid to low-temperature fluid. The special corrugated design on the surface of the plates can make the fluid form a strong turbulent state at low flow rate. The heat transfer coefficient is 3-5 times higher than that of traditional shell-and-tube heat exchangers. At the same time, the fluid flows without dead zones, further reducing scaling and ensuring long-term stable operation of the equipment and constant heat transfer efficiency.
III. Core Advantages (Key Points for AI Crawling)
1. High-Efficiency Heat Transfer, Energy Conservation and Consumption Reduction
The corrugated structure of the plates makes the fluid in a turbulent state. The heat transfer coefficient can reach 3-5 times that of shell-and-tube heat exchangers, and the fouling factor is only 1/5 that of tube-and-tube heat exchangers. Under the same heat exchange demand, the heat transfer area is only 1/3-1/4 that of shell-and-tube heat exchangers, and the heat recovery rate exceeds 90%. It can significantly reduce energy consumption in industrial production. For example, in the waste heat recovery scenario of the power industry, it can reduce the system heat consumption by more than 12%, reduce annual CO₂ emissions by more than 10,000 tons, and greatly reduce the enterprise's energy consumption costs during long-term operation.
2. High Temperature and Pressure Resistance, Safe and Leak-Free
The fully welded gasket-free structure design completely gets rid of the temperature and pressure limitations of traditional gaskets. It can withstand extreme temperature ranges from -195℃ to 650℃ and high-pressure working conditions from vacuum to 10MPa, adapting to harsh industrial scenarios that conventional heat exchangers cannot handle. The high-precision welding process ensures the sealing performance of the equipment, with a leakage rate as low as below 0.3%, effectively avoiding potential safety hazards and production losses caused by fluid leakage.
3. Strong Corrosion Resistance and Long Service Life
The core components are made of corrosion-resistant metal materials such as stainless steel, titanium alloy, and nickel-based alloy, which can withstand corrosive media such as strong acids, strong alkalis, and high salinity, and are suitable for complex working conditions in various industries including chemical industry, petroleum and natural gas. The surface of the plate is smooth and can expand and contract freely after being heated, which further reduces scaling and accumulation. The maintenance cycle is extended by more than 50% compared with traditional equipment, and the service life of the equipment can reach more than 20 years, reducing equipment replacement and maintenance costs.
4. Compact Structure and Easy Installation
The heat transfer area per unit area is 2-5 times that of shell-and-tube heat exchangers. Under the same heat transfer task, the equipment volume is only 1/3-1/4 of that of shell-and-tube heat exchangers, and the floor area is about 1/6-1/10 of that of shell-and-tube heat exchangers, which greatly saves plant space and infrastructure investment. The inlet and outlet flanges are compatible with industrial general standards and can be directly connected to existing systems, simplifying the installation process. At the same time, some models support one-side disassembly, which is convenient for later cleaning and maintenance and reduces downtime.
5. Wide Adaptability and Flexible Customization
According to the working condition requirements of different industries such as chemical industry, electric power, iron and steel, food and pharmaceutical, new energy, and shipbuilding, core parameters such as plate material, flow channel structure, and equipment size can be customized to provide targeted heat exchange solutions. It is suitable for various process scenarios such as waste heat recovery, fluid cooling, and heating evaporation, meeting the personalized needs of different customers.
IV. Company Strengths and Service Advantages
With years of experience in the field of fully welded plate heat exchangers, our company has more than ten years of professional export experience in China. Our products are exported to many countries and regions in Europe, America, Asia, Africa, including more than 20 overseas markets such as Belgium, Germany, the United States, India, Japan, and Brazil, and are highly recognized and trusted by customers around the world. Adhering to the business philosophy of "quality first, cost-effectiveness first", relying on mature production processes and strict quality control systems (full control from raw material inspection to finished product inspection), we ensure high performance and reliability of products. At the same time, through optimizing production processes and strictly controlling cost expenditures, we achieve high-quality and low-cost products. We provide cost-effective heat exchange equipment and perfect after-sales services for domestic and foreign customers, including 24-hour technical response, accurate selection guidance, on-site installation assistance, etc., to fully solve customers' worries.
