How to make a flue gas plate heat exchanger

The manufacturing process of flue gas plate heat exchanger

The manufacturing of flue gas plate heat exchangers involves multiple links, including design, material selection, processing, assembly and testing, etc., to ensure that it has high-efficiency heat exchange, high temperature resistance and corrosion resistance. The following is a detailed production process:

1. Design stage

Before manufacturing, design calculations are first carried out to meet the customer's working conditions. The main design contents include:

1.1.Heat exchange area calculation: Calculate the heat exchange area according to the flue gas temperature, flow rate and heat exchange medium parameters.

1.2.Flow channel structure design: Optimize the plate corrugated structure to improve heat exchange efficiency and reduce flue gas resistance.

1.3.Material selection: According to the flue gas composition and temperature, select suitable corrosion-resistant and high-temperature resistant materials such as stainless steel (such as 304, 316L) or titanium alloy.

1.4.Pressure and sealing design: ensure that the heat exchanger can withstand the flue gas pressure and has good sealing performance.

2. Material preparation

Prepare the required metal plates, frame materials, sealing gaskets, etc. according to the design requirements. Common materials include:

2.1.Stainless steel (304, 316L, 310S, etc.): corrosion-resistant and high-temperature resistant

2.2.Titanium alloy: suitable for flue gas containing acidic gas

2.3.Aluminum alloy: suitable for low-temperature flue gas heat exchange

Shandong Beichen Mechanical and Electrical Equipment Co., Ltd. generally uses 304 stainless steel.

3. Plate shearing, stamping and forming

3.1.Plate shearing: according to the selected stainless steel coil, cut into plates of designed size on the fully automatic Kaiping cross-cutting production line

3.2.Stamping plates: use molds to stamp out heat exchange plates with corrugated structures to improve heat exchange efficiency and rigidity.

3.3.Shearing and trimming: cut the plates and trim the edges to ensure dimensional accuracy.

3.4.Punching: punch out fluid inlet and outlet holes on the plates, and strengthen the holes to enhance sealing.

4. Plate surface treatment

4.1.Cleaning and degreasing: remove oil and impurities on the plate surface to ensure welding quality.

4.2.Anti-corrosion coating (optional): for special working conditions, an anti-corrosion layer can be sprayed on the plate surface to improve corrosion resistance.

5. Welding and assembly

5.1.Plate welding (for fully welded heat exchangers):

Use laser welding or vacuum brazing to ensure uniform welds and no leakage.

Perform X-ray flaw detection on welded heat exchange plates to ensure weld quality.

5.2.Assembly frame: fix the heat exchange plate in the frame and assemble the flue gas inlet and outlet connections.

6. Inspection and testing

In order to ensure the performance of the flue gas plate heat exchanger, 6.1.multiple tests are required:

6.2.Air tightness test: fill with helium or nitrogen for leak detection to ensure no leakage.

6.3.Pressure test: apply high pressure to test the pressure resistance of the heat exchanger.

6.4.Heat exchange performance test: simulate working conditions, measure heat exchange efficiency, and verify whether the design meets the standards.

6.5.Corrosion resistance test: perform corrosion resistance experiments in a simulated flue gas environment.

7. Spraying and packaging

7.1.Surface protection treatment: Spray high temperature resistant anti-corrosion paint on the external frame of the heat exchanger to increase the service life.

7.2.Packaging and delivery: Use wooden box packaging or protective film wrapping to prevent damage during transportation.

8. Installation and commissioning

8.1.On-site installation: According to the process requirements, install the heat exchanger in the flue gas system and connect the flue gas pipeline and the heat exchange medium pipeline.

8.2.Commissioning operation: Conduct a trial run to check the heat exchange effect and operation stability to ensure that it is delivered for use after normal operation.

9.Summary

The manufacturing process of the flue gas plate heat exchanger involves multiple links such as precision machining, welding, assembly and testing to ensure that it has the characteristics of efficient heat exchange, high temperature resistance, corrosion resistance and reliable sealing. Reasonable design, high-quality material selection and strict quality control are the key to ensuring the long-term stable operation of the heat exchanger.

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