!e concept of a spiral heat exchanger is as simple as it is sophisticated. Two or four long metal strips, onto which spacer studs are welded, are wound around a core, thus
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Spiral Heat Exchanger
HES GmbH Heat Exchanger Systems HES Heat Exchanger Systems GmbH originated in 1997 from the company Kapp Apparatebau and is now a worldwide operating enterprise with more than 30-years experience in the design and manufacture of spiral heat exchangers (SHE). HES is located in Schopfheim in the south of Baden-Württemberg, Germany, about 20 km north-east of Basel, Switzerland. We develop, design, manufacture and market heat exchangers for a wide range of applications. Our customers include well-known plant builders, engineering firms, the chemical and pharmaceutical industries, the mining and paper industries, steel works, refineries, water treatment facilities and many others. The spiral heat exchanger was developed in the twenties for use in the paper industry by the Swedish engineer Mr Rosenblad. For the first time, a heat exchanger became available, that allowed trouble-free heat transfer between particle-loaded process streams. In the beginning of the seventies, Kapp Apparatebau started manufacturing spiral heat exchangers on the basis of an own design that has distinct advantages over the Rosenblad-design which had been exclusively employed until then. Nowadays, HES is the only company capable of manufacturing spiral heat exchangers both to its own design and to the Rosenblad concept in almost any size from any cold-workable and weldable material.
The spiral heat exchanger – a solution for a wide range of applications
The concept of a spiral heat exchanger is as simple as it is sophisticated. Two or four long metal strips, onto which spacer studs are welded, are wound around a core, thus creating two or four equally spaced singlepassage channels. The concentric shape of the flow-passages and the studs yield turbulence already at low Reynolds numbers. By optimising the flow pattern heat transfer is enhanced, whilst fouling is reduced. This yields a compact and space-saving construction that can be readily integrated in any plant and reduces installation costs. Because of the all-welded and robust design and the low fouling properties, maintenance costs are reduced to a minimum. From the viewpoint of Total Cost of Ownership, the spiral heat exchanger is frequently the most cost-effective solution.
HES have developed a wide range of cores, each of which is tailored to accomplish specific tasks, which enables us to choose the right solution for any application. An important feature of our design is the use of continuous strips from core to shell that enables internal and almost unreachable welding seams to be avoided entirely. The execution of a unit can be chosen freely to our, or to the Rosenblad-design, which enables us to offer replacements units for all applications without the need of costly piping adjustments.
Different types for different tasks Type A:
Tailored to the requirements As the channel geometry can be varied with great flexibility, a spiral heat exchanger can be adapted ideally to the existing requirements and desires. Notwithstanding varying mass flows and desired temperature differences, a spiral heat exchanger often enables heat transfer in a single unit and offers an excellent turn-down ratio. The long single-flow passage channels offer almost any desirable thermal length by which difficult process flows can be heated or cooled in a single device, while avoiding any sharp turns of flow that so often cause blockages.
COUNTER- OR CO-CURRENT-FLOW Both covers closing the spiral body Liquid/liquid as well as vapour/liquid-applications
CROSS-FLOW Both covers at a distance from the spiral body (Overhead) condensation and evaporation applications
CROSS-/COUNTEROR CO-CURRENT-FLOW One cover closes the spiral body; the other is at a distance Condensation applications with the possibility of condensate sub-cooling
Manufacturing capabilities: Design and fabrication are executed in accordance with international pressure-vessel codes including PED (CE-Stamp), AD-Merkblätter, ASME (U-Stamp), AS1210 etc.; Quality is ensured by maintaining own written practises from proposal to delivery. Corresponding certifications to ISO 9001:2000 and Safety Quality License (SQL) are a matter of course.
CAPABILITIES AND APPLICATIONS CAPABILITIES Channel spacings Channel widths Surface per unit Design pressure Design temperature Materials
PV Codes Quality Certification for
APPLICATIONS from 5 mm 50 mm 0.1 m2 Vacuum
to 70 mm 2000 mm to 800 m2 45 bar and above -100°C 450°C and above Carbon steel, (super-) austenitic stainless steel, duplex, Nickel and Nickel alloys, Titanium, Zirconium and others AD-2000, PED, ASME, AS1210, etc. ISO 9001:2000, SQL Europe, China, USA, Australia
Application in the following industries
Liquids, suspensions, fibre- and particle-loaded liquids, (highly) viscous fluids, non-Newtonian fluids including slurries and sludges, vapour with and without inert gases Cooling, heating, heat recovery, (near-vacuum) condensation, evaporation, thermosyphon, reboiler (Petro-) chemical, food, pharma, vegetable oil, water treatment, paper, steel and mining industries 5
Liquids and slurries
Because of the single-flow passages, the spiral heat exchanger is State-of-the-Art-Technology especially in the case of fouling, viscous and/or particle-loaded fluids and is therefore frequently the first, if not the only choice. This is because bypassing is intrinsically avoided resulting in a self-cleaning effect by which potential blockages are washed away before they become a problem. Also as a result of its execution, in the case of ‘difficult’ fluids, high heat transfer coefficients are established and in case of particle-loaded fluids sedimentation is avoided. The spiral heat exchanger is almost free of dead-space and can be executed without any dead spaces. Cold- and/or hot spots are therefore excluded and temperature differences between the fluids of less then 3°C can be reached.
Leakage is practically excluded by the all-welded channel construction. For this reason the spiral heat exchanger is ideal in the case of sensible, dangerous and/or aggressive fluids. Because of the single-flow passage, chemical cleaning is extremely effective. The covers are mounted with hook-bolts to enable easy access to the channels, which can also be readily cleaned mechanically. In particular for sludge or slurry applications, covers can be executed with hinges or davits, thus enabling very fast access that reduces down-time.
In particular, for sludge or sludge-alike applications the spiral heat exchanger is executed without spacer studs so that the risk of blockages is reduced to the absolute technical minimum.
0,35 m2, ∅ 245 mm, Ti-Gr.2 Chlorine Application
40 m2, ∅ 1900 mm, Sludge Application
Out Hot Fluid
Condensation and Evaporation
In case of condensation applications, the spiral heat exchanger demonstrates its versatility. It is almost the ideal condenser, especially in case of condensing mixed vapours, with or without inert gases.The concentric, single-flow passage constitutes a perfect geometry for this task and is therefore a basis for maximised product recovery.
In the case where pressure-drop needs be minimised, such as in near-vacuum applications, the vapour is condensed in a cross-flow arrangement with the cooling fluid. As a result of the short flow passage, but high cross-sectional area available, high flow rates of vapour can be condensed at pressure-drops of less than 1 mbar. Also in this case, inert gases can be removed readily.
For condensation applications, there are three possible flow arrangements: Counter-current, co-current, cross-current and a mixture of these.
In the case where the condensate needs be sub-cooled, while having only a small pressure-drop at disposal, the combination of cross-/counter-flow is used.
If pressure-drop is allowed, a unit with counter- or co-current flow is a good solution. Vapour, particularly with a high inert gas concentration, needs a sufficiently long condensation path, which can be realised by means of a spiral heat exchanger. In addition, the condensate and/or inert gases can be sub-cooled within the same unit.
An outstanding advantage of the spiral heat exchanger as a condenser is that it can be flanged or welded directly onto a column as an overhead condenser. It is also frequently used to realise multiple-stage condensers. The assembly of the spiral condenser onto a column greatly reduces installation costs, because connecting pipework is reduced to the minimum.
3-stages overhead condenser
Standard condenser Steam/vapour
Out Cooling Fluid
In Cooling Fluid
Overhead Condenser Outlet uncondensed vapours Cooling Fluid stage II
Cooling Fluid stage II
In Bottom condenser
Condensate outlet stage Il
Cooling Fluid stage I
Cooling Fluid stage I
Condensate outlet stage I Vapour inlet
Know-how, flexibility and service With our experience in all applications of the spiral heat exchanger, we can assist our customers in many ways. As a result of development, design, engineering and fabrication all being carried out by us in our facilities at one single location, we can quickly respond to customer requirements and wishes. The excellent team-work with our worldwide network of representatives and co-operation partners provides local and direct access. Apart from the high standards of our engineering work and fabrication, exemplary quality management and full technical documentation belong to every unit we deliver. Customer feedback and the resulting experience play a vital role. Our customers contribute importantly to the development of our company, which is required in a rapidly changing world, and ensures the continuous improvement process within our company. By our development and manufacturing of ever more mechanically sophisticated units and prototypes, we have repeatedly set new standards and technical possibilities for the spiral heat exchanger. For new applications, test units are available that enable a co-operative elaboration of solutions that respond to given process heat transfer challenges. Repairs and overhauls of existing units of all brands can be executed effectively and efficiently both in the plant and in our shop. Always prepared to take new challenges, we look forward to receiving your next inquiry.