Improving Reliability and Efficiency in High-Load Steel Production

As one of China's largest private steel manufacturers, Shagang Group operates under extremely high production loads with massive annual steel output. In such operating conditions, the performance and reliability of heat exchange equipment play a decisive role in ensuring safe, stable, and efficient production.

Among all heat transfer equipment used in steel plants, the spiral plate heat exchanger is a critical component widely applied in cooling, heat recovery, and process temperature control systems.

What Is a Spiral Plate Heat Exchanger?

A spiral plate heat exchanger is a compact heat transfer device formed by rolling two long metal plates into concentric spiral channels. Hot and cold media flow through separate spiral passages, enabling continuous countercurrent heat exchange.

Key Characteristics of Spiral Plate Heat Exchangers

• High heat transfer efficiency due to true counterflow design

• Compact structure, saving installation space

• Self-scouring flow path, reducing fouling and blockage

• Suitable for high-viscosity, high-solid, and contaminated media, commonly found in steel and coking industries

However, under heavy-duty industrial conditions, traditional spiral plate heat exchangers often suffer from blockage, internal leakage, and rapid efficiency degradation, which limits their long-term reliability.

Long-Standing Challenges in Steel Industry Applications

In high-load steel production environments such as Shagang’s facilities, conventional spiral plate heat exchangers frequently encounter the following issues:

• Frequent fouling and blockage caused by particulate-laden media

• Internal leakage risks at weak welding or sealing points

• Uneven media distribution, leading to short-circuit flow

• Declining heat transfer efficiency over extended operation

• Short service life, resulting in increased downtime and maintenance costs

These challenges have long been considered difficult technical bottlenecks within the industry.

Boyus Technical Innovation for Spiral Plate Heat Exchangers

Leveraging years of engineering experience and continuous technological development, Boyu Heavy Industry carried out a comprehensive structural and manufacturing upgrade for Shagang’s spiral plate heat exchangers.

Advanced Automatic Stud Welding Technology

Boyu introduced automatic stud welding equipment to reinforce critical sealing areas of the spiral plate heat exchanger. Compared with conventional manual welding, this process ensures consistent weld quality, significantly improving structural strength and effectively eliminating internal leakage risks.

Optimized Intermediate Spacer Plate Design

For historically leak-prone zones, Boyu applied a specially designed intermediate spacer plate structure, enhancing mechanical integrity and sealing reliability while maintaining optimal flow geometry.

Optimized Media Distribution System

A custom-designed media distribution device was incorporated to ensure uniform flow across the spiral channels. This design minimizes short-circuiting and dead zones, maximizes effective heat transfer area, and reduces localized erosion and fouling.

Operational Results at Shagang Group

Following the retrofit and optimization, Shagang’s upgraded spiral plate heat exchangers demonstrated outstanding operational performance:

• Significantly extended continuous safe operating time

• Stable and higher heat transfer efficiency

• Reduced maintenance frequency and operating costs

• Improved production stability and throughput

The enhanced heat exchange system directly contributed to improved production efficiency and capacity utilization across the plant.

Conclusion

In modern steel manufacturing, where systems operate under sustained high loads, the reliability of heat exchange equipment is no longer optional—it is essential. Through innovative structural design and advanced manufacturing processes, Boyu has delivered a high-efficiency, leak-free, and long-life spiral plate heat exchanger solution tailored for demanding steel industry applications.

This successful upgrade at Shagang Group provides a proven reference for other steel producers seeking to overcome long-standing heat exchanger performance challenges.