The corrugated tube heat exchanger is an innovative heat exchange device that combines enhanced heat transfer and mechanical principles. It is widely used in industrial fields. Based on the design of traditional heat exchangers, it has been optimized to retain the advantages of traditional tubular heat exchangers, such as strength, durability, safety, and reliability, while overcoming their shortcomings, such as poor heat transfer capacity and easy scaling. Through the special design of the corrugated tube, the corrugated tube heat exchanger shows significant advantages in heat transfer efficiency, automatic cleaning, and energy saving. It is widely used in industries such as petrochemical, metallurgy, and power generation.
Structure and Design of the Corrugated Tube Heat Exchanger
The structural design of the corrugated tube heat exchanger combines the advantages of the corrugated tube and shell-and-tube heat exchangers, giving it high heat transfer performance and reliability.
1. Corrugated Tube Design
The core component of the corrugated tube heat exchanger is the corrugated tube, which uses thin-walled corrugated tubes instead of traditional smooth tubes. The inner and outer walls of the corrugated tube are rolled into a corrugated shape. This design effectively increases the heat transfer surface area of the heat transfer tubes, improving heat transfer efficiency. The inner wall's corrugation disrupts the fluid's boundary layer flow, enhancing the contact between the fluid and the tube wall. The outer wall's corrugation further increases the surface area, improving heat exchange capability. This dual-sided enhanced heat transfer design makes the heat transfer coefficient of the corrugated tube heat exchanger 2 to 3 times higher than traditional heat exchangers.
2. Shell-and-Tube Structure
The outer shell of the corrugated tube heat exchanger is usually cylindrical, similar to traditional heat exchangers. The difference lies in the fact that the corrugated tube is welded to the tube sheet with strong welds. The corrugated tube does not directly contact the tube sheet, effectively avoiding local stress caused by thickness differences. The tube bundle uses thin-walled corrugated tubes, which increase the heat exchanger's pressure resistance, making it suitable for higher working pressures.
Heat Transfer Performance of the Corrugated Tube Heat Exchanger
The corrugated tube heat exchanger stands out in heat transfer performance. Compared to traditional tubular heat exchangers, the corrugated tube heat exchanger, with its unique corrugated design, can generate strong turbulence during fluid flow. Even at low flow rates, the turbulence still disrupts the fluid's boundary layer, significantly improving heat transfer efficiency.
1. Double-Sided Heat Transfer
The corrugations on both the inner and outer surfaces of the tube enhance heat transfer. The corrugations on the inner wall alter the flow state of the fluid, allowing the fluid to make more complete contact with the tube wall, increasing heat exchange efficiency. The corrugations on the outer wall increase the tube's surface area, allowing heat to be transferred more efficiently.
2. Turbulence-Enhanced Heat Transfer
The fluid flow inside the corrugated tube is highly turbulent. Turbulence not only improves the heat exchange efficiency between the fluid and the tube wall but also helps reduce solid particle deposition in the fluid, preventing fouling. As a result, the heat transfer performance of the corrugated tube heat exchanger is significantly better than that of traditional heat exchangers.
Automatic Cleaning and Anti-Scaling Functions
The unique structure of the corrugated tube heat exchanger also provides automatic cleaning and anti-scaling functions, avoiding the fouling problems common in traditional heat exchangers.
1. Turbulence-Aided Anti-Scaling
The turbulent flow inside the corrugated tube effectively disrupts the fluid's boundary layer, reducing the deposition of solid particles. Even if a small amount of fouling occurs, the temperature difference-induced stress on the corrugated tube promotes microscopic deformation, creating sufficient force to dislodge the fouling and maintain the heat exchanger's continuous efficient operation.
2. Automatic Descaling
During operation, the corrugated tube undergoes slight axial expansion and contraction due to temperature differences. This deformation causes frequent changes in curvature inside and outside the tube. The difference in thermal expansion coefficients between the corrugated tube and the fouling layer leads to cracking and detachment of the fouling, further enhancing the anti-scaling effect and ensuring long-term high efficiency in the heat exchanger.
Reliability and Durability
The corrugated tube heat exchanger is designed with considerations for long-term stability and reliability, greatly enhancing its service life and pressure resistance.
1. Reduced Thermal Stress
The unique structural shape of the corrugated tube effectively reduces thermal stress, avoiding the expansion issues that may occur in traditional tubular heat exchangers under high temperature conditions. Therefore, the corrugated tube heat exchanger does not require additional expansion joints, simplifying the device structure and improving reliability.
2. High Pressure Resistance
The design of the corrugated tube enhances the pressure resistance of the heat transfer tubes, making the heat exchanger suitable for high-pressure environments. This makes it an ideal choice for operations under high-pressure conditions, offering greater operational flexibility and higher safety.
3. Seismic Performance
The structure, with the corrugated tube welded to the casing and tube sheet, reduces local stress caused by thickness differences. The tube sheet welding uses a cushioning structure, which further enhances the heat exchanger's seismic performance, ensuring stable operation in environments with significant vibrations.
Maintenance and Energy-Saving Effects
The corrugated tube heat exchanger performs excellently in terms of maintenance and energy saving, significantly reducing both operational and maintenance costs.
1. Low Maintenance Requirements
Thanks to its anti-scaling and self-cleaning functions, the corrugated tube heat exchanger does not require frequent maintenance, and the workload during repairs is minimal. This greatly reduces equipment downtime and operational costs.
2. Energy-Saving Effects
The corrugated tube heat exchanger has a higher heat transfer coefficient, allowing for more efficient heat exchange in the same heat exchange area. Its compact structure design makes the device more energy-efficient, reducing energy consumption. By improving heat transfer efficiency, the corrugated tube heat exchanger significantly lowers operational costs, achieving energy savings.
Application Fields
The corrugated tube heat exchanger has been widely used in various industries, especially in situations where high heat transfer efficiency and low maintenance are required.
1. Industrial Applications
The corrugated tube heat exchanger performs excellently in industries such as petrochemical, power generation, and metallurgy, particularly in applications that require heating or cooling media. Its efficient heat transfer performance and anti-scaling functions have resulted in significant economic benefits in these industries.
2. Applicable Conditions
The corrugated tube heat exchanger is suitable for designs with fixed tube sheets and has a compensating function, eliminating the need for expansion joints required in traditional designs. Furthermore, the heat exchanger has certain thermal requirements for the medium to ensure optimal performance under appropriate operating conditions.
Conclusion
The corrugated tube heat exchanger, with its high heat transfer performance, unique anti-scaling and self-cleaning functions, and excellent durability and reliability, has become an important choice in modern industrial heat exchange equipment. Its successful applications in various industries have proven its potential in improving heat transfer efficiency, saving energy, reducing maintenance costs, and more. As technology continues to develop, the corrugated tube heat exchanger will play an even more important role in many fields, driving industrial production towards greater efficiency and energy savings.
