Process gas coolers

One of the important elements of gas main lines is a cooling system of the transported gas, which helps to increase its reliability and reduce operating costs. As gas temperature decreases, the capacity of the main gas pipelines increases.

Cooling of gases is based on application of cooling systems (tubular heat exchangers) which decrease the temperature of hot dusty gases without supply of external air to into the cooled gas stream.

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System operation is based on convection process -  heat transfer from heated gases to refrigerant. Gas (in the majority of cases -atmospheric air) or liquid (most commonly water or oil) can serve as refrigerant. Heat exchange occurs on the walls of the heat exchanger’s tubes.

Application of this system also allows usage of the cooler as the first stage of dust elimination. Cooled gas containslarge dust fractions that are caught at this stage.

The dust that is contained in process gas tends to adhere to tubes surfaces. To prevent this, a chain cleaning system is used – it helps to avoid formation of dust layers on the surface of the cooling tubes.

The direction of the cooled gas flow is from top to bottom, the refrigerant moves perpendicular to it. Such a system contributes to the loss of dust in the collecting cone, separated in the chamber of the heat exchanger. For heat exchangers using cooling gas, the latter is injected into the heat exchanger tubes by means of axial or centrifugal fans. For heat exchangers using liquid, the pressure of the supply network is used.

Process gas cooling systems can be:

  • with a removable or non-removable tube bundle;
  • finned tubes, tubes with low or plate-like fins;
  • internal or extruded finning;
  • single-stage and multistage;
  • with a moisture separator built into the tube bundle or casing.

Standard materials:

Heat exchanger tubes: carbon and stainless steel, aluminum, copper, titanium and their alloys. 

Fins: carbon and stainless steel, aluminum, copper, titanium and their alloys.

Casing: carbon and stainless steel.

Tube sheet: carbon and stainless steel, copper, titanium and their alloys.

Advantages of this system:

  • no increase in volumetric gas discharge;
  • a customer can use the recovered heat (heated agent is clean, since it does not directly contact with dusty process gases);
  • preliminary dust elimination of cooled gases;
  • automatic cleaning of heat exchanger tubes from deposited dust;
  • preventing corrosion of the heat exchanger elements by using recirculation of cooling air (avoiding temperature drop below the dew point);
  • avoiding temperature drop below the acid dew point by adding sorbents to the flows of the cooled gas fed to the heat exchanger;
  • possibility of creating multi-stage heat exchangers. In this case materials of each stage are selected depending on the steady-state temperatures;
  • possibility of creating special systems using flue gases, cooled in a bag filter and pre-filtered for re-cooling of contaminated gases
Pressure up to 400 bar (tube side), up to 70 bar (shell side)
Temperature up to 600 °C
Dimensions with no particular limits
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