Anodic Protection Sulfuric Acid Cooler with Corrosion Resistant Shell-and-Tube Heat Exchanger for High Thermal Efficiency Dry Acid Cooler
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Process parameters
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Project
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Design parameters
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Performance parameters
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Shell Side
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Tube Side
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Shell Side
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Tube Side
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MEDIUM
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Fluid name
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Sulfuric Acid
93%
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Cooling Water
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Sulfuric Acid
93%
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Cooling Water
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Temperature (Inlet) ℃
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68
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33
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68
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33
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Temperature (Outlet)℃
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40
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41
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40
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37.42
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Liquid Kg/h
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89928
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89928
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200000
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Density(inlet/outlet) Kg/m3
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~1793
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1000
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~1793
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1000
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Viscosity(inlet/outlet)(cp)
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7.02
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0.76
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7.02
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0.76
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Inlet pressure Mpa
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0.45
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0.3
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0.45
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0.3
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Pressure drop, Mpa
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≤0.1
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≤0.1
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0.0043
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0.037
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PERFORMANCE
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Heat exchanged quantity W
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～1023280.7
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Flow rate m/s
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0.163
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0.737
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Heat transfer area affluent coefficient
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1.15
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Heat transfer coefficient W/m2 ℃
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475.361
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Heat transfer area m2
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135
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MATERIAL
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Type
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shell and tube
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The flow form
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counter-current flow
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Sealing form
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welding connection in acid side, flange connection in water side
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Materials and specifications
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shell
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304L δ= 10
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Heat transfer tube
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316L Φ19×2.0×6000
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Tubesheet
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304L δ= 55
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Baffle-crossing
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304L δ= 10
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head
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Q235-B δ= 12
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Flange standard
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Shell Side
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Tube Side
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HG/T20592-2009(B) PN10 DN 150
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HG/T20592-2009(B) PN10 DN 200
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Size
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Φ600×7214×1060
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Operating weight
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5979 Kg
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The scope of supply
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●Complete set ●Control system
●Special cable ●Random accessories
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Sulfuric Acid Cooler
Jiangsu Carpe Diem Ocean Equipment Co., Ltd. specializes in engineering and supplying advanced thermal management systems for the chemical industry, with expertise in Anode Protection Sulfuric Acid Coolers. This critical equipment ensures safe, productive, and durable operations in modern sulfuric acid production facilities.
General Presentation
The Anode Protection Sulfuric Acid Cooler is a shell-and-tube heat exchanger specifically designed to reduce the temperature of concentrated sulfuric acid (typically 93% to 99%) during the drying and absorption phases of contact process plants. The highly corrosive nature of hot concentrated acid would normally cause rapid deterioration of standard construction materials. This system addresses these challenges through anodic protection, an electrochemical method that maintains stainless steel in a passive, corrosion-resistant state.
Technical Fundamentals and Operational Methodology
The system operates on the principle of anodic protection, where stainless steel surfaces (acting as the anode) are maintained at a controlled electrical potential within their "passive range." This is achieved through a cathodic assembly—either extended cathodes running through the shell or pin-type cathodes placed in nozzles—working in conjunction with a reference electrode and a potentiostat that regulates the direct current supply.
- Protective Coating Formation: A low-level direct current initiates the formation of a durable oxide layer across all internal surfaces. This coating serves as a protective barrier, reducing corrosion rates by several orders of magnitude.
- Electrical Potential Oversight: The electrochemical potential between the steel and reference electrode is continuously monitored. The regulation system makes ongoing adjustments to maintain the metal securely within the passive zone, preventing both active corrosion at lower levels and transpassive corrosion at higher levels.
- Engineering Architecture: The cooler is structurally designed to withstand process thermal demands. Advanced construction elements, such as rod-patterned baffles, minimize tube vibration while enhancing heat transfer efficiency.
Key Advantages and Functional Benefits
- Robust Corrosion Management: Anodic protection significantly limits corrosive deterioration, enabling austenitic stainless steels to operate reliably in environments where they would normally be unsuitable—thereby enhancing long-term operational safety.
- Extended Service Life: By consistently maintaining the passive oxide film, the equipment remains protected from chemical degradation, delivering a substantially prolonged operational lifespan compared to non-protected alternatives.
- Enhanced Thermal Exchange: The system design promotes turbulent acid circulation and incorporates high-performance heat transfer surfaces, essential for precise temperature regulation and efficient power consumption.
- System Integrity: Through stable protective parameters and comprehensive monitoring features—including remote diagnostic functions in updated configurations—the risk of acid discharge and unexpected interruptions is greatly minimized.
- Waste Heat Recovery: By enabling secure operation at elevated temperatures (up to 160°C or higher), these systems facilitate the recovery of high-grade waste heat, thereby improving the overall thermal efficiency of sulfuric acid facilities.
Jiangsu Carpe Diem Ocean Equipment Co., Ltd. provides these robust cooling systems, ensuring customers receive durable, low-maintenance equipment engineered to meet the stringent requirements of large-scale sulfuric acid processing operations.
