Introduction

Shell-and-tube heat exchangers are the most widely used type of heat transfer equipment in industrial systems. Their modular design, broad pressure and temperature range, flexible material options, and maintainability make them the preferred choice across pulp and paper, petrochemical, power generation, chemical, and metallurgical industries.

Shandong BOOYO Heavy Industry (BOOYO) has recently published a series of in-depth articles highlighting different equipment such as black liquor heat exchangers, hydrogenation reactor units, surface condensers, feedwater heaters, liquid ammonia heat exchangers, oil heaters/coolers, and closed-circuit cooling water (CCCW) exchangers. Although the applications vary, these cases consistently demonstrate the adaptability and strength of the shell-and-tube design. This article provides a structured overview based on those publications.

I. Common Advantages of Shell-and-Tube Heat Exchangers

1. Proven structure – tube bundles within a shell, with heat transfer area scalable up to thousands of square meters.

2. Wide operating range – suitable from cryogenic service (liquid ammonia below –30 °C) to extreme high-pressure, high-temperature processes (hydrogenation reactors over 20 MPa).

3. Material flexibility – available in carbon steel, stainless steel, duplex, titanium, copper-nickel alloys, and other special materials.

4. Maintenance options – fixed tube sheet, floating head, and U-tube designs ensure suitability for different fouling, cleaning, and thermal expansion requirements.

II. Industry-Specific Applications

1. Pulp and Paper: Black Liquor Heat Exchanger

• Application: Black liquor heat exchangers recover waste heat from pulping byproducts.

• Design highlights:

  • Floating-head or removable tube bundles for easier cleaning;

  • Materials resistant to alkaline and corrosive residues;

  • Tube layouts that minimize fouling and maintain high thermal efficiency.

• Value: Energy savings, reduced steam consumption, and alignment with sustainability goals.

2. Petrochemical: Hydrogenation Reactor Units

• Application: Hydrogenation reactors operate under severe high-pressure and high-temperature conditions.

• Design highlights:

  • Heavy-wall tube sheets and high-strength alloy tubes;

  • U-tube or expansion-joint structures to absorb thermal stress;

  • 100% weld inspections (RT/UT/PT) to ensure integrity.

• Value: Reliable process temperature control, maintaining catalyst efficiency and reaction stability.

3. Power Generation: Surface Condenser and Feedwater Heaters

• Applications:

  • Surface condenser – a large shell-and-tube exchanger condensing turbine exhaust steam, maintaining vacuum, and recycling water.

  • High- and low-pressure feedwater heaters – tube bundle designs that preheat boiler feedwater using extracted steam.

• Design highlights:

  • Titanium or copper-nickel tubes to resist cooling water corrosion;

  • Multi-pass arrangements and optimized baffle spacing for higher heat transfer efficiency.

• Value: Higher plant thermal efficiency, reduced fuel consumption, and improved system reliability.

4. Chemical and Refrigeration: Liquid Ammonia Heat Exchanger

• Application: Liquid ammonia heat exchangers in refrigeration and chemical systems.

• Design highlights:

  • Double tube-sheet construction to prevent cross-contamination;

  • Materials with excellent low-temperature toughness;

  • Mandatory helium leak and tightness testing.

• Value: Ensures process safety while handling toxic and cryogenic media.

5. Industrial Systems: Oil Heater and Cooler

• Application: Oil heaters and oil coolers serve lubrication, hydraulic, and high-temperature process systems.

• Design highlights:

  • Internal finned or corrugated tubes for enhanced heat transfer;

  • Anti-erosion baffle plates to protect against high-velocity oil streams;

  • Reinforced supports to prevent vibration.

• Value: Long-term operational stability and extended equipment life.

6. Large-Scale Facilities: CCCW Heat Exchanger

• Application: Shell-and-tube closed-circuit cooling water exchangers (CCCW) used in power, metallurgy, and chemical plants.

• Design highlights:

  • Mechanical cleaning access for fouling-prone water circuits;

  • Corrosion-resistant tube materials such as stainless steel or copper-nickel;

  • Auxiliary nozzles for venting, drainage, and sampling.

• Value: Stable, low-maintenance cooling solutions for continuous operations.

III. Comparative Insights

• Common thread: All applications utilize the shell-and-tube principle, demonstrating its universality.

• Key differences: Application environments drive design choices—such as floating head for fouling fluids, U-tube for high thermal stress, or double tube-sheet for toxic or cryogenic media.

• Overall significance: The shell-and-tube exchanger serves as a platform technology, adaptable across industries by tailoring materials, geometry, and testing protocols.

Conclusion

From pulp and paper to petrochemicals, from power generation to refrigeration and chemical processes, BOOYO’s expertise illustrates how shell-and-tube exchangers meet diverse challenges while delivering safety, efficiency, and reliability. These case studies confirm that shell-and-tube technology is not just a single product, but a versatile engineering foundation for multiple industries.