1. Technical Principle and Working Process

A serpentine tube high heater works by utilizing steam or flue gas waste heat to increase boiler feedwater temperature, thereby enhancing the efficiency of the thermal cycle.

1.1 Operating Process

1. Steam Side:

   • High-pressure steam (e.g., extraction steam from a turbine or industrial waste heat steam) serves as the heat source.
   • Steam enters the heater, exchanges heat with feedwater, and then condenses into water. Some of this condensate is discharged to the drain system, while the rest is recovered.

2. Feedwater Side:

   • Lower-temperature feedwater from low-pressure heaters enters the high-pressure heater.
   • As it flows through the serpentine tube bundle, it undergoes convective and conductive heat transfer with the high-temperature steam.

   • The heated high-temperature feedwater is then supplied to the boiler, reducing fuel consumption and improving thermal efficiency.

   
   

   

2. Structural Features

The serpentine tube high heater differs from traditional shell-and-tube heaters by utilizing a serpentine tube bundle design, which enhances heat transfer efficiency and adapts better to high-temperature and high-pressure conditions.

2.1 Key Components

2.2 Structural Advantages

• High Heat Transfer Efficiency: The serpentine tube design increases flow disturbance, enhancing heat transfer.
• Compact Design: Takes up less space than traditional shell-and-tube heaters, making it suitable for restricted installation areas.
• High-Temperature and High-Pressure Resistance: Made from alloy steel or stainless steel, capable of withstanding extreme conditions.
• Reduced Thermal Stress: The serpentine structure mitigates thermal expansion stress, minimizing fatigue damage.

3. Design Parameters

Designing a serpentine tube high-pressure heater requires careful consideration of various parameters to ensure suitability for different operational conditions.

3.1 Key Technical Parameters

4. Design Standards

The design, manufacturing, and inspection of serpentine tube high heaters must comply with international and industry standards to ensure safety and reliability.

4.1 Major Standards

• GB/T 151-2014 Shell-and-Tube Heat Exchangers
• ASME Boiler & Pressure Vessel Code (BPVC)
• DL/T 439-2020 Technical Conditions for Power Plant Boiler Feedwater Heaters
• JB/T 10326-2002 Serpentine Tube Heat Exchangers for Power Plant Boilers
• API 661 Petrochemical Air-Cooled and Heat Exchange Equipment

5. Application Industries

Serpentine tube high heaters are widely used in power generation, petrochemical, metallurgical, and chemical industries, where they recover waste heat to improve energy efficiency.

5.1 Typical Applications

• Thermal Power Plants: Preheats boiler feedwater, reducing coal consumption and improving efficiency.
• Petrochemical Industry: Enhances heat recovery in steam systems, reducing energy costs.
• Metallurgical Industry: Recovers high-temperature waste gas heat, improving process energy efficiency.

6. Case Studies

6.1 Power Plant Application

A 500MW thermal power plant retrofit replaced traditional high heaters with serpentine tube high heaters, achieving:

• 30°C increase in boiler feedwater temperature, reducing coal consumption by 2%.
• Heat transfer efficiency boosted to 90%, minimizing heat loss.
• 20% reduction in equipment footprint, optimizing boiler room space utilization.

6.2 Petrochemical Application

A refinery adopted serpentine tube high heaters to recover steam waste heat:

• 15% increase in heat exchange rate, reducing steam consumption.
• Extended equipment lifespan, mitigating thermal stress damage.

7. Future Trends

With increasing focus on energy conservation and emissions reduction, serpentine tube high heaters will see growing adoption in supercritical boilers, gas turbine waste heat recovery, and new energy systems.

7.1 Key Development Trends

1. Intelligent Monitoring: Integration with IoT for remote diagnostics and operational optimization.
2. Advanced Materials: Enhanced high-temperature corrosion-resistant alloys to improve durability.
3. Modular Design: Simplified installation, lower maintenance costs, and improved adaptability.

8. Conclusion

The serpentine tube high-pressure heater has become a key heat exchange device in modern boiler and waste heat recovery systems due to its high efficiency, energy-saving benefits, compact design, and strong resistance to high-temperature and high-pressure conditions. It is widely applied in thermal power, petrochemical, and metallurgical industries, contributing to improved energy utilization and reduced operational costs.

If you need more detailed technical specifications, design solutions, or specific case studies, let me know, and I can provide additional information!