Tailored 320m² Anodic Protection Sulfuric Acid Cooler CD-AP-320 Shell Tube Type 304L 316L Construction

The Carpe Diem CD-AP-320 Anodic Protection Sulfuric Acid Cooler represents a tailored engineering solution for mid-to-large capacity sulfuric acid production facilities that demand both high thermal performance and flexible integration capabilities. Featuring a spacious 320m² heat exchange area, this shell and tube exchanger is purpose-designed to cool 97% concentrated sulfuric acid from 81°C to 47°C while handling a substantial flow rate of 450,000 Kg/h. The unit combines a 304L stainless steel shell with a 316L stainless steel tube bundle composed of precision-drawn tubes measuring Φ19 × 2.0 × 6200mm. What sets the CD-AP-320 apart is our tailored engineering approach: rather than forcing customers to adapt their plant layout to a fixed cooler design, we configure each unit to match existing nozzle locations, support steel positions, and instrumentation port requirements. The anodic protection system parameters are custom-tuned to the specific acid concentration, temperature profile, and flow velocity of each installation. This tailored methodology eliminates the need for costly piping modifications, reduces installation time, and ensures that the cooler integrates as a direct drop-in replacement during plant turnarounds or capacity expansion projects. Our engineering team works collaboratively with client process and mechanical engineers throughout the design phase, providing detailed 3D models, stress analysis reports, and performance guarantees tailored to each unique operating scenario.

• Client-Specific Engineering Configuration: Every CD-AP-320 is designed around the client's specific piping and instrumentation diagram, plant layout drawing, and process data sheet. Nozzle sizes, flange ratings, face-to-face dimensions, support saddle locations, and lifting lug positions are all configured to order, ensuring zero field modifications during installation. This tailored approach has been proven to reduce total installed cost by up to 30% compared to adapting standardized coolers.
• Robust Anodic Protection with Custom Tuning: The electrochemical protection system is precisely calibrated to the acid concentration (97% H&sb2;SO&sb4;) and operating temperature range of each specific installation. The control algorithm setpoints, current density limits, and alarm thresholds are configured during factory acceptance testing using process-specific parameters, ensuring optimal protection from the moment of commissioning.
• High-Capacity 320m² Thermal Design: The generous heat exchange area combined with optimized tube pitch and baffle spacing delivers superior cooling performance with comfortable margin for fouling accumulation. The 450,000 Kg/h flow capacity makes this model ideal for single-train acid plants producing 800 to 1,200 metric tons per day.
• Dual-Grade Stainless Steel Construction: The 304L shell provides reliable corrosion resistance for the shell-side acid environment, while the 316L tube bundle with its molybdenum content offers enhanced resistance to the higher-temperature tube-side conditions where the risk of intergranular corrosion and pitting is elevated. This material pairing optimizes both performance and capital cost.
• Advanced Tube-to-Tubesheet Sealing: Each of the hundreds of tube ends is first strength-welded to the tubesheet face using an automated orbital welding process, then hydraulically expanded into the tubesheet ligament for a dual-barrier seal. This proven technique eliminates the risk of crevice corrosion at the tube-to-tubesheet interface, which is a common failure mode in sulfuric acid service.
• Adaptable Baffle Configuration: The shell-side baffle arrangement can be configured as single-segmental, double-segmental, or rod-type depending on the allowable pressure drop and flow-induced vibration considerations. Our thermal design engineers select the optimal baffle type and spacing based on detailed hydraulic analysis of each specific application.
• Complete Turnkey Documentation: Each tailored CD-AP-320 delivery includes a full engineering data package with fabrication drawings, material test certificates, welding procedure qualification records, NDT reports, hydrostatic test certificates, anodic protection system FAT reports, and the ASME U Stamp Manufacturer's Data Report. Installation, operating, and maintenance manuals are provided in both English and the client's preferred language.

The CD-AP-320 Anodic Protection Sulfuric Acid Cooler is ideally deployed in mid-to-large capacity sulfuric acid plants operating in the 800 to 1,200 metric tons per day range, where its 320m² heat exchange area and 450,000 Kg/h flow capacity provide the optimal balance of performance and footprint. Common installations include the primary acid cooler serving the intermediate absorption tower in double-contact double-absorption process plants, product acid coolers in sulfur-burning facilities, and acid circulation coolers in copper and nickel smelter off-gas treatment systems. The tailored engineering approach makes this model especially suitable for plant modernization and debottlenecking projects, where existing foundation locations and connected piping impose strict dimensional constraints. The CD-AP-320 has also been successfully applied in titanium dioxide pigment plants using the sulfate process, where the cooler handles the intermediate-concentration sulfuric acid streams generated during ilmenite digestion and hydrolysis stages. Chemical grade sulfuric acid production facilities benefiting from precise temperature control for product quality consistency represent another key application area.

Quality assurance for the CD-AP-320 begins with incoming material inspection and verification against EN 10204 Type 3.1 certified mill test reports. All pressure boundary materials undergo positive material identification using portable X-ray fluorescence analysis to confirm alloy composition before fabrication. Welding is executed by ASME Section IX qualified welders using approved WPS documents, with all Category A and B pressure-retaining welds receiving 100% radiographic examination per ASME Section V. Completed units undergo shell-side and tube-side hydrostatic pressure testing at 1.5 times the respective design pressures with a minimum hold time of 30 minutes, followed by a pneumatic leak test using helium as the tracer gas. The anodic protection system receives a complete functional test in our factory, including reference electrode calibration, current output verification across all anode circuits, and alarm system function checks. For shipment, the CD-AP-320 is secured to a welded steel transport cradle with bolted blind flanges protecting all nozzle openings. Threaded connections receive plastic protective caps, and instrument ports are fitted with temporary plugs. The anodic protection control panel and spare reference electrodes are packed in a separate IP65-rated shipping container. A complete quality dossier including all material certificates, NDT film interpretation reports, hydrostatic and leak test certificates, dimensional inspection records, surface finish reports, and the ASME U Stamp data report is delivered with each unit. Installation supervision and commissioning support by our field service engineers are available as optional services and are strongly recommended for first-time anodic protection system operators.