Shell & Tube Condenser
Heat Exchangers
1. Product Overview
Shell and Tube Condenser
The shell and tube condenser is one of the most widely used types of heat exchanger in the chemical, pharmaceutical and food industries. It consists of a shell, a tube bundle (tube sheets, tubes and baffles), channel heads, inlet and outlet nozzles, and saddle supports. The cooling medium — cooling water, chilled brine or similar — flows on the tube side or the shell side, while vapor enters from the other side and condenses on the tube or shell wall, releasing its latent heat to the cooling medium to complete the condensation and cooling process.
Widely applicable to: reflux condensation in reactors, solvent recovery condensation, distillation column overhead condensation, vapor condensation in evaporation systems, process cooling and heating, etc.
2. Working Principle
Equipment features: broad applicability across a wide range of duties, suitability for relatively high pressures, a simple and reliable structure, multiple material options for corrosive media, and heat exchange areas customized to order.
Vapor enters the condenser from the inlet nozzle and flows through the shell side (or tube side). The cooling medium flows through the tube side (or shell side) in the opposite or cross-flow direction. When the vapor contacts the cooler tube wall surface, it releases latent heat and condenses into a liquid film on the wall, which then flows down by gravity and is discharged from the condensate outlet. Baffles installed on the shell side guide the shell-side flow path, increase flow velocity, improve heat transfer efficiency, and support the tube bundle. The counter-current or cross-flow arrangement between the two fluids maximizes the temperature difference for effective heat transfer.
3. System Classification
| Type | Features | Application |
|---|---|---|
| Fixed tube sheet type | Simple structure, lowest cost, tube bundle not removable | Shell side fluid clean or non-corrosive, no need to clean tube exterior, small temperature difference |
| Floating head type | One tube sheet fixed, the other end can float freely, tube bundle removable | Shell side fluid dirty or corrosive, requires cleaning of tube exterior, large temperature difference |
| U-tube type | Tube bundle in U-shape, only one tube sheet, no thermal expansion issues | Suitable for large temperature differences, fewer tubes, limited cleaning of tube interior |
| Packed gland type | Shell side connected to the channel head through a packing gland, tube bundle removable | Shell side pressure not too high, requires periodic packing replacement |
| By Flow Arrangement | Features | Application |
|---|---|---|
| Shell side condensation | Vapor on shell side, coolant in tubes | Most common, easy to connect to reactor overhead |
| Tube side condensation | Vapor in tubes, coolant on shell side | Higher pressure vapor condensation, easy tube side cleaning |
4. Detailed Technical Parameters
4.1 Common Materials and Applicable Conditions
| Material | Grade | Applicable Media | Remarks |
|---|---|---|---|
| Carbon steel | Q235B/Q345R | Non-corrosive cooling water, non-corrosive process fluid | Low cost, short service life with corrosive media |
| 304 stainless steel | 0Cr18Ni9 | Weakly corrosive media, general chemical process | Standard configuration, good value for money |
| 316L stainless steel | 00Cr17Ni14Mo2 | Chloride-containing media, acetic acid, pharmaceutical | Recommended first choice, excellent corrosion resistance |
| 321 stainless steel | 0Cr18Ni11Ti | High temperature conditions, intergranular corrosion resistance | Suitable above 400°C |
| 2205 duplex steel | 00Cr22Ni5Mo3N | Chloride-containing media, high stress environments | Long service life in chloride-containing cooling water |
| Titanium (TA2) | Commercially pure titanium | Strongly corrosive media (hydrochloric acid, wet chlorine) | High cost, selected as needed |
| Graphite | Impregnated graphite | Strong acid media (hydrochloric acid, sulfuric acid) | Special application, fragile |
| Glass-lined | Carbon steel + glass lining | Corrosive gas condensation | Limited to specific conditions |
4.2 Typical Specifications of Shell-and-Tube Condenser
| Heat Exchange Area (m²) | Shell Diameter (mm) | Tube Spec (mm) | Tube Quantity | Tube Length (mm) | Shell Side Pressure (MPa) | Tube Side Pressure (MPa) |
|---|---|---|---|---|---|---|
| 1～5 | 159～325 | Φ25×2.5 | 13～60 | 1000～1500 | 0.1～0.6 | 0.1～0.6 |
| 5～15 | 325～500 | Φ25×2.5 | 60～130 | 1500～2000 | 0.1～0.6 | 0.1～0.6 |
| 15～30 | 500～700 | Φ25×2.5 | 130～250 | 2000～3000 | 0.1～0.6 | 0.1～0.6 |
| 30～60 | 700～900 | Φ25×2.5 | 250～450 | 3000～4000 | 0.1～0.6 | 0.1～0.6 |
| 60～120 | 900～1200 | Φ25×2.5 | 450～800 | 4000～6000 | 0.1～0.6 | 0.1～0.6 |
| 120～200 | 1200～1600 | Φ25×2.5 | 800～1400 | 5000～6000 | 0.1～0.6 | 0.1～0.6 |
Note: The above specifications are common configurations. Actual design depends on process conditions, media properties, pressure requirements, etc. Customization available. Tube specifications also include Φ19×2, Φ38×3, etc.
4.3 Design Conditions and Performance Indicators
| Parameter | Specification |
|---|---|
| Design pressure range | Vacuum ~ 1.6MPa (higher available on request) |
| Design temperature range | -20°C ~ 350°C (material dependent) |
| Heat transfer coefficient (typical) | 200～1200 W/(m²·K) (varies by media and flow pattern) |
| Baffle spacing | 150～600mm (typically 1/5～1/10 of shell diameter) |
| Baffle cut | 15%～45% (typically 20%～25%) |
| Tube pitch | 25mm (triangular) / 32mm (square) for Φ25 tubes |
| Welding process | Argon arc welding, per GB/T 150 requirements for NDT |
| Surface treatment | Internal: pickling passivation (stainless steel); External: anti-rust paint |
| Support type | Saddle support (fixed end + sliding end) |
4.4 Electrical Parameters
| Applicable Region | Voltage | Frequency |
|---|---|---|
| China/Russia/Central Asia | 380V | 50Hz |
| Middle East/Southeast Asia/Africa | 400V / 415V | 50Hz |
| South Korea | 380V | 60Hz |
| Americas (if required) | 440V / 480V | 60Hz |
Note: Standard shell and tube condensers have no electrical requirements. Electrical parameters only apply when equipped with electric tracing or instrumentation. Please specify local voltage and frequency when relevant options are selected.
5. Core Component Selection
| Component | Common Brands | Features & Application |
|---|---|---|
| Gasket | Garlock, Flexitallic, quality domestic | EPDM for general; FKM for high temp/corrosion; PTFE envelope for strong corrosion |
| Instrumentation (optional) | Siemens, E+H, quality local brands | Temperature sensor, pressure gauge for monitoring |
| Expansion joint (optional) | Quality domestic brands | Bellows type, absorbs thermal expansion |
| Safety valve (optional) | Shanghai Valve, Zhonghe Sufa | Set at 1.05～1.1 times design pressure |
| Vent valve / Drain valve | Quality local brands | For venting non-condensable gas and draining condensate |
Customer brand preferences can be specified. For pre-owned equipment, availability depends on inventory.
6. Typical Application Fields
Chemical industry: Reactor reflux condensation, solvent recovery, distillation column overhead condensation, evaporation system condensation
Pharmaceutical industry: API synthesis process condensation, solvent recovery, crystallization mother liquor condensation (GMP-compliant materials available)
Food industry: Evaporation and concentration condensation, steam condensation recovery
Petrochemical: Refining process condensation, hydrocarbon vapor condensation
New energy: Lithium battery electrolyte process condensation
Environmental: VOC condensation recovery, waste gas condensation treatment
7. Design Standards and Certifications
| Standard | Description |
|---|---|
| GB/T 150-2011 | Pressure vessels (China) |
| GB/T 151-2014 | Shell and tube heat exchangers (China) |
| NB/T 47003.1-2009 | Steel welded atmospheric vessels (for atmospheric conditions) |
| ISO 9001:2015 | Quality management system |
| TEMA | Tubular Exchanger Manufacturers Association standard (international) |
| ASME VIII | Pressure vessels (available upon request for Americas market) |
| CE | Available upon request for international orders (PED 2014/68/EU) |
| EAC | Available upon request for Russia and Central Asia markets |
| GOST-R | Available upon request for Russian market |
8. Custom Optional Configurations
| Option | Details |
|---|---|
| Heat exchanger type | Fixed tube sheet / Floating head / U-tube / Packed gland |
| Flow arrangement | Shell side condensation / Tube side condensation |
| Tube specifications | Φ19×2 / Φ25×2.5 / Φ38×3 (wall thickness varies with pressure) |
| Tube material | Carbon steel / Stainless steel / Duplex steel / Titanium / Copper |
| Shell material | Carbon steel / Stainless steel / Duplex steel |
| Tube sheet material | Carbon steel + clad / Stainless steel / Titanium clad |
| Baffle type | Segmental baffle / Disc-and-donut baffle / Rod baffle (for low pressure drop) |
| Surface treatment | Internal pickling passivation, external anti-rust paint or sandblasting |
| Insulation | Rock wool / aluminum silicate insulation + stainless steel or color steel cladding |
| Instrumentation | Temperature sensor, pressure gauge, thermometer well |
| Safety accessories | Safety valve, vent valve, drain valve |
| Expansion joint | Bellows expansion joint (for fixed tube sheet type with large temperature difference) |
| Seismic design | Seismic calculation and reinforcement (for earthquake-prone areas) |
9. Warranty Terms
| Equipment Status | Warranty Period | Warranty Scope |
|---|---|---|
| New equipment | 12 months | Shell, tube bundle, tube sheets, heads, nozzles, gaskets |
| Refurbished equipment | 6 months | Shell, tube bundle, tube sheets, heads, nozzles, gaskets |
| Pre-owned equipment (as-is supply) | 3 months | Main functional components |
Final warranty terms are subject to contract. All orders include installation guidance and remote commissioning support.
10. Packaging and Delivery
| Item | Packaging Method |
|---|---|
| Condenser body | Bare packaging with steel band fixation, flange face protection, nozzle caps |
| Spare gaskets | Waterproof sealed packaging in carton |
| Small accessories | Carton or wooden box packaging |
Container capacity estimate (for reference only, subject to actual configuration):
Below 5m² condenser: approximately 2-4 units per 20'GP container
5～15m² condenser: approximately 1-2 units per 20'GP
15～30m² condenser: approximately 1 unit per 40'GP or 1×40'OT
30～60m² condenser: 1×40'OT or bulk vessel
Above 60m² condenser: bulk vessel or flat rack container
Installation service: On-site installation guidance available. Technicians can be dispatched (travel and accommodation expenses borne by buyer).
11. Information Required for Inquiry
To obtain an accurate quotation, please provide the following information:
Process function (reflux condensation / solvent recovery / overhead condensation / cooling)
Condensation medium (vapor name, composition, flow rate or condensation load in kg/h or kW)
Cooling medium type (cooling water / chilled brine / other) and inlet/outlet temperature
Flow arrangement preference: shell side condensation / tube side condensation
Working pressure on both shell side and tube side (positive and negative)
Heat exchange area requirement (if known) or process calculation data
Material requirements for shell, tubes, tube sheet
Heat exchanger type preference (fixed tube sheet / floating head / U-tube)
Whether insulation needed
Whether instrumentation needed (temperature, pressure)
Whether safety valve needed
Local voltage and frequency (if electric tracing or instrumentation required)
Equipment status preference: New / Refurbished / Pre-owned
Budget range and brand preference (if any)
Delivery terms: FOB/CIF/DDP
Destination port or delivery address (for freight calculation)