Spiral Heat Exchanger

Spiral Heat Exchanger (SHE), may refer to a helical (coiled) tube configuration,more generally, the term refers to a pair of flat surfaces that are coiled to form the two channels in a counter-flow arrangement. Each of the two channels has one long curved path. A pair of fluid ports are connected tangentially to the outer arms of the spiral, and axial ports are common, but optional.

The main advantage of the SHE is its highly efficient use of space. This attribute is often leveraged and partially reallocated to gain other improvements in performance, according to well known tradeoffs in heat exchanger design. (A notable tradeoff is capital cost vs operating cost.) A compact SHE may be used to have a smaller footprint and thus lower all-around capital costs, or an over-sized SHE may be used to have less pressure drop, less pumping energy, higher thermal efficiency, and lower energy costs.

Construction

The distance between the sheets in the spiral channels are maintained by using spacer studs that were welded prior to rolling. Once the main spiral pack has been rolled, alternate top and bottom edges are welded and each end closed by a gasketed flat or conical cover bolted to the body. This ensures no mixing of the two fluids will occur. If a leakage happens, it will be from the periphery cover to the atmosphere, or to a passage containing the same fluid.

Applications

The SHE is good for applications such as pasteurization, digester heating, heat recovery, pre-heating (see: recuperator), and effluent cooling. For sludge treatment, SHEs are generally smaller than other types of heat exchanger.

Self cleaning

SHEs are often used in the heating of fluids which contain solids and thus have a tendency to foul the inside of the heat exchanger. The low pressure drop gives the SHE its ability to handle fouling easier. The SHE uses a “self cleaning” mechanism, whereby fouled surfaces cause a localized increase in fluid velocity, thus increasing the drag (or fluid friction) on the fouled surface, thus helping to dislodge the blockage and keep the heat exchanger clean. The internal walls that make up the heat transfer surface are often rather thick, which makes the SHE very robust, and able to last a long time in demanding environments. They are also easily cleaned, opening out like an oven where any build up of foulant can be removed by pressure washing.

Flow Arrangements

There are three main types of flows in a spiral heat exchanger:

1.Countercurrent Flow: Both fluids flow in opposite directions, and are used for liquid-liquid, condensing and gas cooling applications. Units are usually mounted vertically when condensing vapour and mounted horizontally when handling high concentrations of solids.

2.Spiral Flow/Cross Flow: One fluid is in spiral flow and the other in a cross flow. Spiral flow passages are welded at each side for this type of spiral heat exchanger. This type of flow is suitable for handling low density gases which passes through the cross flow, avoiding pressure loss. It can be used for liquid-liquid applications if one liquid has a considerably greater flow rate than the other.

3.Distributed Vapour/Spiral flow: This design is a condenser, and is usually mounted vertically. It is designed to cater for the sub-cooling of both condensate and non-condensables. The coolant moves in a spiral and leaves via the top. Hot gases that enter leave as condensate via the bottom outlet.