Fusion-Welded Heat Exchanger

Core Principle & Structure

1. Process Definition

   Edge and contact points of corrugated metal plates (usually 316L stainless steel, titanium, Hastelloy, etc.) are permanently welded by laser autogenous welding, argon arc welding or patented fusion technology, forming alternating hot and cold fluid channels without any rubber gaskets.

   Heat is efficiently transferred through the metal wall while the corrugations enhance turbulence.
2. Structure Composition

   The core is a welded plate pack (non-detachable), matched with end plates, inlet/outlet flanges and supports. Single-pass or multi-pass configurations are available, and some high-end models adopt double-wall plates to prevent cross-contamination.

Key Technical Advantages

• Zero leakage & wide temperature-pressure range

  Completely eliminates gasket aging and softening leakage. Withstands temperatures up to 550°C, pressures up to 10 MPa, and low temperatures down to -196°C (for LNG applications).

• High efficiency & compactness

  Heat transfer area per unit volume is 2–5 times that of shell-and-tube exchangers, with high heat transfer coefficient and 60%–80% smaller footprint.

• Strong corrosion resistance

  All-stainless steel / special alloy materials, avoiding copper or nickel pollution, suitable for drinking water, food, pharmaceutical and strong acid-alkali media.

• Low maintenance

  No gasket replacement, stable long-term operation, significantly longer service life than gasketed types.

Typical Applications

1. Petrochemical Industry: Syngas cooling, sulfuric acid/hydrochloric acid recovery, hydrogenation units, offshore natural gas processing.

2. Energy & Power: LNG regasification, boiler feedwater preheating, nuclear power emergency cooling.

3. Food & Pharmaceutical: Clean steam heating, sterile liquid cooling, FDA-compliant hygienic applications.

4. District Heating & Cooling: High-temperature hot water networks, industrial waste heat recovery.

5. Water Treatment: Seawater desalination, high-pressure RO concentrate energy recovery, chlorinated wastewater cooling.

Comparison with Other Heat Exchangers

Selection & Notes

1. Material (316L / titanium / Hastelloy) depends on medium composition (corrosiveness, particles).

2. Flow rate, temperature difference and allowable pressure drop determine plate type, passes and heat transfer area.

3. Prioritize products with 100% weld inspection (helium leak detection).

4. Higher initial investment than gasketed types; non-detachable on-site, so chemical cleaning ports are recommended.