Iron and steel

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Application, Process Flow, and Material Selection of KDP Plate Heat Exchangers in the Steel Industry

The steel industry is characterized by high energy consumption, high temperatures, and high pollution. Plate heat exchangers (PHEs) play a critical role in various steel production processes due to their high heat transfer efficiency, temperature resistance, and corrosion resistance. Below is a detailed analysis of their specific applications, process flows, and material selection in the steel industry.

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Specific Applications of KDP PHEs in the Steel Industry

Blast Furnace Cooling System

Application:

Cooling high-temperature components (e.g., furnace walls, tuyeres) to prevent overheating.

Recovering waste heat from cooling water for air preheating or power generation.

Process Flow:

Blast furnace cooling water (80–120°C) exchanges heat with low-temperature softened water (30–50°C) in the PHE.

After heat exchange, the cooling water temperature drops to 60–80°C and recirculates, while preheated softened water is reused.

Material Selection:

Plates: 316L stainless steel (chloride-resistant) or titanium (highly corrosive water).

Gaskets: EPDM (≤150°C) or FKM (high-temperature conditions).

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Case Study: A steel plant recovered waste heat from blast furnace cooling water using PHEs, saving 5,000 tons of coal annually.

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BOF/EAF Waste Heat Recovery

Application:

Recovering waste heat from high-temperature flue gas (800–1200°C) in basic oxygen furnaces (BOF) or electric arc furnaces (EAF) for power generation or combustion air preheating.

Process Flow:

Flue gas is first cooled to 400–600°C in a radiation heat exchanger, then further cooled in a PHE.

The PHE transfers heat to water or thermal oil to generate steam for power generation.

Material Selection:

Plates: Nickel-based alloys (e.g., Inconel 625, resistant to high-temperature oxidation).

Gaskets: PTFE-encapsulated (high-temperature and corrosion-resistant).

Case Study: A BOF flue gas heat recovery system using PHEs generated 20 million kWh of electricity annually.

Plate Material Selection for Steel Industry PHEs

Steel industry conditions (high temperature, corrosion, abrasion) demand careful plate selection:

ConditionRecommended PlateReason
High-temperature flue gas (>500°C)Nickel alloy (Inconel 625)Resists oxidation and sulfur corrosion.
High-chloride water (cooling towers)Titanium (Ti) or 254SMOTitanium resists seawater/chlorides; 254SMO offers cost efficiency.
Coke oven gas (H₂S)Titanium or Hastelloy C-276Titanium resists H₂S; C-276 suits highly acidic environments.
Rolling mill emulsions316L stainless steelEconomical and resistant to emulsion corrosion.
General cooling water304 stainless steelCost-effective for clean water systems.

Advantages of KDP PHEs in the Steel Industry (vs. Shell-and-Tube Heat Exchangers)

AdvantagePerformanceCase Study
High Heat Transfer3–5x higher heat transfer coefficient than shell-and-tube, reducing energy use.Blast furnace cooling system saved 20% energy
Compact Design1/3 the size of shell-and-tube units, ideal for space-constrained steel plants.Rolling mill retrofit saved 40% space.
Corrosion ResistanceTitanium/nickel alloys withstand harsh steel industry media.Coking plant PHE lifespan extended to 15 years.
Easy MaintenanceDetachable for cleaning, suitable for high-fouling conditions.Sinter plant PHEs cleaned quarterly without clogging.
High Economic ROIRapid waste heat recovery with payback periods <3 years.BOF waste heat project earned $500K/year.

Common Challenges & Solutions

High-Temperature Flue Gas Degrades Gaskets

Solution:

Use PTFE-encapsulated gaskets (resistant to 260°C).

Install radiation heat exchangers upstream to lower gas temperature.

Dust/Particulate Clogging

Solution:

Select wide-gap plate designs (e.g., free-flow PHEs).

Install self-cleaning filters.

Corrosive Media (H₂S, Cl⁻)

Solution:

Choose titanium or Hastelloy plates.

Use FKM gaskets (chemical-resistant).

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Summary

Value of PHEs in the Steel Industry

Energy Savings

Efficient recovery of waste heat from blast furnaces, BOFs, and rolling mills.

Cost Reduction:

Lowers cooling water consumption and operational energy use.

Environmental Benefits:

Reduces CO₂ emissions, supporting green steel production.

Selection Guidelines

Prioritize PHEs for:

Waste heat recovery (flue gas, cooling water).

Space-limited retrofits.

Choose Shell-and-Tube for:

Ultra-high temperature (>600°C) or pressure (>40 bar) applications.

With proper material selection (e.g., titanium for corrosion resistance, nickel alloys for high temperatures) and optimized design, PHEs deliver high efficiency, long service life, and low maintenance in the steel industry, making them indispensable for modern, sustainable steel plants.

Our Core Strengths

In the petrochemical industry, equipment needs to withstand high temperature, high pressure, corrosion, scaling and other multiple tests. We are the preferred supplier of heat exchanger solutions for harsh working conditions due to the following core advantages:

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Customized design

Optimized heat transfer solutions according to petroleum/chemical process requirements

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Diversified products

Full range of plate heat exchangers, condensers, evaporators, etc.

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High reliability

Strict quality control, adapt to high temperature, high pressure and corrosive environment.

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Full life cycle service

From selection to maintenance, to ensure long-term stable operation.

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