What are the applications of carbon steel spiral plate heat exchangers in the metallurgical industry
Information summary：Carbon steel spiral plate heat exchangers have core advantages such as compact structure (high heat transfer area/volume ratio), strong anti fouling ability (spiral flow channels are not easy to scale), high temperature and high pressure resistance (carbon steel material can withstand ≤ 400 ℃, pressure ≤ 2.5MPa), and cost-effectiveness. They are suitable for the harsh working conditions of "high t
Carbon steel spiral plate heat exchangers have core advantages such as compact structure (high heat transfer area/volume ratio), strong anti fouling ability (spiral flow channels are not easy to scale), high temperature and high pressure resistance (carbon steel material can withstand ≤ 400 ℃, pressure ≤ 2.5MPa), and cost-effectiveness. They are suitable for the harsh working conditions of "high temperature, high dust, and impurity containing media" in the metallurgical industry and are widely used in heat exchange scenarios throughout the entire process of ironmaking, steelmaking, steel rolling, and non-ferrous metal smelting. The following provides a detailed analysis of the specific application and adaptability value of metallurgical processes:
1、 Ironmaking process: waste heat recovery and process medium cooling
1. Recovery of residual heat from blast furnace gas (core application scenario)
Application scenario: The blast furnace gas generated during the ironmaking process (temperature 150-250 ℃, containing dust, CO, H ?, etc.) needs to be recovered through a heat exchanger to preheat the combustion air or boiler feedwater and reduce energy consumption.
Specific application: A carbon steel spiral plate heat exchanger is used as a blast furnace gas waste heat recovery device. The gas flows through the shell side, and the combustion air/soft water flows through the pipe side (or reverse flow channel). Through the strong turbulence effect of the spiral flow channel, the heat transfer efficiency is improved (heat transfer coefficient K=150~300W/(㎡·℃)). The recovered heat can raise the temperature of the combustion air to 100~150 ℃, reducing the fuel consumption of blast furnace ironmaking (saving 5%~8% of coke for every 100 ℃ heat recovered).
Adaptation advantages: The spiral flow channel is not easily blocked by dust in the gas, and the carbon steel material is resistant to trace corrosive gases in the gas (such as CO ?, H ? S), with a long maintenance cycle (cleaned every 6-12 months).
2. Blast furnace cooling water cooling
Application scenario: The cooling system of blast furnace body, tuyere, cooling wall and other equipment (with circulating cooling water temperature of 40-60 ℃) needs to be cooled by a heat exchanger and circulated to avoid equipment overheating and damage.
Specific application: Using carbon steel spiral plate heat exchanger as the cooler, circulating cooling water exchanges heat with industrial water/river water. After cooling, the water temperature drops to 30-35 ℃ and is then sent back to the blast furnace cooling system.
Adaptation advantages: Compact structure, suitable for installation in narrow spaces around blast furnaces; Spiral flow channel is anti fouling and can withstand a small amount of rust, sediment and impurities in cooling water.
3. Cooling waste heat recovery of sintered ore
Application scenario: The sintered ore produced by the sintering machine (temperature 600~800 ℃) needs to be cooled by a cooling machine (temperature 150~200 ℃), and the waste heat of the cooling air needs to be recovered.
Specific application: Using carbon steel spiral plate heat exchanger to preheat boiler feedwater or heating water, cooling air flows through spiral channels, high heat transfer efficiency, can raise the feedwater temperature to 80-100 ℃, and achieve waste heat resource utilization.
2、 Steelmaking process: process cooling and flue gas waste heat recovery
1. Converter/electric furnace flue gas cooling
Application scenario: The flue gas generated by converter steelmaking (temperature 800~1200 ℃, containing CO, dust, FeO, etc.) needs to be cooled to 200~300 ℃ before entering the dust removal system (such as electrostatic precipitator) to avoid high temperature damage to the dust removal equipment.
Specific application: Carbon steel spiral plate heat exchanger (with high temperature resistant coating) is used as the flue gas cooler. The flue gas flows through the shell side (high temperature side), and industrial water flows through the tube side. Through reverse heat exchange, the flue gas is quickly cooled, and heat is recovered to produce low-pressure steam (pressure 0.3~0.5MPa), which is used for workshop heating or process steam.
Adaptation advantages: The strong turbulence of the spiral channel can flush out dust in the flue gas and reduce ash accumulation; The cost of carbon steel material is lower than that of stainless steel, making it suitable for large-scale applications, and its high temperature resistance meets the requirements of flue gas cooling.
2. Cooling system for steelmaking equipment
Application scenario: Cooling of equipment such as converter oxygen lance, electric furnace cover, continuous casting crystallizer, etc. (cooling medium is water or oil-water emulsion), and the temperature of the cooling medium needs to be maintained stable through a heat exchanger.
Specific application:
Oxygen lance cooling: Carbon steel spiral plate heat exchanger is used to cool the circulating water of the oxygen lance, with an inlet temperature of 30-35 ℃ and an outlet temperature of 45-50 ℃, ensuring that the oxygen lance works normally in high temperature environments;
Crystallizer cooling: The cooling water (temperature 25-30 ℃) of the continuous casting crystallizer needs to be cooled through a heat exchanger to avoid uneven solidification of the molten steel on the inner wall of the crystallizer, which affects the quality of the cast billet.
Adaptation advantages: high heat transfer efficiency, can quickly remove equipment heat; Strong anti fouling ability, suitable for working conditions where the cooling medium contains a small amount of metal impurities.
3. Waste heat recovery of ladle roaster
Application scenario: The ladle roaster uses natural gas/heavy oil combustion to heat the ladle (exhaust temperature of 300-400 ℃), and needs to recover the waste heat of the flue gas to preheat the combustion air.
Specific application: Using a carbon steel spiral plate heat exchanger as a preheater, the flue gas and air exchange heat in reverse. After preheating, the air temperature is increased to 150-200 ℃, improving combustion efficiency and reducing fuel consumption.
3、 Rolling process: cooling of rolled pieces and hydraulic system cooling
1. Steel rolling process cooling (hot rolling/cold rolling)
Application Scenario:
Hot rolling: After the steel billet is heated in a heating furnace (temperature 1100~1200 ℃), it needs to be cooled by cooling water during the rolling process of the rolling mill to prevent overheating and deformation of the rolled piece;
Cold rolling: During the operation of the cold rolling mill, the friction between the rolling mill and the strip steel generates heat, which needs to be cooled by a cooling system to maintain rolling accuracy.
Specific application: Carbon steel spiral plate heat exchanger is used to cool the circulating cooling water of steel rolling. The cooling water exchanges heat with industrial water, and the water temperature is controlled at 20-30 ℃ after cooling to ensure stable temperature of the rolling mill and rolling piece.
Adaptation advantages: compact structure, can be installed next to the rolling mill, saving space; Spiral flow channel is anti fouling and can withstand impurities such as iron oxide scale and oil stains in cooling water.
2. Cooling of hydraulic and lubrication systems
Application scenario: The hydraulic transmission system (hydraulic oil temperature 40~60 ℃) and lubrication system (lubricating oil temperature 35~50 ℃) of the rolling mill need to be cooled by a heat exchanger to avoid high-temperature deterioration of the oil and affect equipment operation.
Specific application: Using carbon steel spiral plate heat exchangers as oil coolers, hydraulic oil/lubricating oil flows through the shell side, and industrial water flows through the tube side. Through efficient heat transfer in the spiral channel, the oil temperature is cooled to 30-35 ℃, extending the service life of the oil and improving the stability of the hydraulic system.
Adaptation advantages: high heat transfer coefficient (oil-water heat exchange K=80~150W/(㎡·℃)), good cooling effect; Carbon steel material has strong compatibility with oil and has no corrosion risk.
4、 Nonferrous metal smelting process (copper, aluminum, zinc smelting)
1. Recovery of waste heat from smelting furnace flue gas
Application scenario: The flue gas (temperature 400~800 ℃, containing SO ?, dust, metal oxides) generated by copper flash furnaces, aluminum electrolytic cells, zinc roasting furnaces and other equipment needs to be cooled and enter the desulfurization/dust removal system, while recovering waste heat.
Specific application: Carbon steel spiral plate heat exchanger (surface anti-corrosion coating treatment) is used to cool the flue gas, recover heat to preheat process water or generate steam, and the flue gas is cooled to 200-250 ℃ before entering the subsequent treatment system.
Adaptation advantages: Strong anti fouling ability, able to tolerate dust and small amounts of corrosive gases in flue gas; The cost is lower than that of stainless steel heat exchangers, making it suitable for large-scale applications in non-ferrous metal smelting enterprises.
2. Electrolyte/molten salt cooling
Application scenarios: Electrolytes for aluminum electrolysis cells (temperature 950~1000 ℃) and zinc electrolysis (temperature 40~60 ℃) need to be cooled or maintained at a stable temperature through heat exchangers to ensure electrolysis efficiency.
Specific application: Using carbon steel spiral plate heat exchanger (with heat-resistant alloy lining in high temperature scenarios) to cool the electrolyte, industrial water flows through the tube side, and the electrolyte flows through the shell side. Through efficient heat exchange, the electrolyte temperature is controlled to improve the purity of electrolytic products.
Adaptation advantages: The spiral flow channel has uniform heat transfer, avoiding local overheating of the electrolyte; Compact structure, suitable for installation in narrow spaces of smelting workshops.
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