Advanced Anodic Protection Cooling System CD-AP-200 200m2 Cooler for 93 Percent

The Carpe Diem CD-AP-200 Advanced Anodic Protection Cooling System is a high-performance shell and tube heat exchanger engineered for demanding 93 percent concentrated sulfuric acid cooling applications in chemical processing, fertilizer manufacturing, and hydrometallurgical operations. This robust 7,800 kilogram unit delivers 200 square meters of effective heat exchange surface through a carefully optimized 304L stainless steel shell housing a 316L stainless steel tube bundle featuring heavier-wall Φ25×2.5×6000 mm tubes that provide enhanced structural rigidity and extended service life in high-temperature acid service. The anodic protection system represents the core technological advantage of this cooler, actively maintaining a stable passive electrochemical film across all internal acid-wetted surfaces and effectively eliminating the corrosion mechanisms that would otherwise rapidly degrade unprotected stainless steel in 93 percent sulfuric acid at elevated temperatures. With a substantial design capacity of 250,000 kilograms of acid per hour and a commanding temperature reduction from 90 degrees Celsius inlet down to 45 degrees Celsius outlet, the CD-AP-200 delivers the high thermal duty required for absorption and drying tower acid circuits in medium to large-scale sulfuric acid production plants. The 750 millimeter shell diameter and 7,200 millimeter overall length strike an optimal balance between thermal performance and plant layout integration, while the selection of thicker-wall tubes provides additional safety margin for plants operating with variable acid quality or occasional process upsets.

• Concentrated Sulfuric Acid Cooling Expertise: The CD-AP-200 is specifically designed and optimized for 93 percent sulfuric acid cooling, the most common concentration encountered in drying tower acid circuits across the sulfuric acid industry. Every material selection, tube specification, and electrochemical parameter has been refined through extensive operating experience to deliver maximum reliability and thermal performance at this specific acid concentration.
• Enhanced Tube Wall Thickness: The Φ25×2.5×6000 mm tube specification provides a 25 percent thicker wall compared to standard 2.0 mm tubes, delivering superior resistance to erosion-corrosion at the high flow velocities encountered in acid circulation loops and providing extended corrosion allowance that significantly extends equipment service life beyond standard product offerings.
• Wide Temperature Range Capability: With an inlet temperature capacity of 90 degrees Celsius and an outlet target of 45 degrees Celsius, the CD-AP-200 provides a 45-degree temperature reduction in a single pass. This substantial temperature differential is achieved through the optimized counter flow arrangement and generous 200 square meter heat exchange area, eliminating the need for multi-stage cooling arrangements in most standard sulfuric acid plant configurations.
• Precision Anodic Protection Control: The microprocessor-based anodic protection controller continuously samples the electrochemical potential at multiple reference electrode locations distributed throughout the exchanger. The controller automatically adjusts the protection current output to maintain all surfaces within the optimal passive potential range, with user-configurable alarm setpoints for high and low potential conditions and automatic protection shutdown upon detection of process abnormalities.
• Heavy-Duty Tube Rolled Joints: Each 316L tube is mechanically expanded into the tube sheet using precision torque-controlled rolling equipment, creating a gas-tight seal that withstands the full range of operating pressures and temperatures without degradation. The expanded joint design eliminates the residual stresses and metallurgical discontinuities that create preferential corrosion sites in welded tube-to-tube sheet joints operating in concentrated acid service.
• Robust Process Integration Features: Factory-installed instrumentation ports include temperature measurement wells at all four process connections, pressure sensing taps with block-and-bleed isolation valves, corrosion coupon access fittings for periodic corrosion rate verification, and dedicated reference electrode mounting bosses that simplify field replacement of anodic protection system components without requiring heat exchanger disassembly.

The CD-AP-200 is specifically optimized for the drying tower acid cooling circuit in sulfuric acid production plants with daily capacities between 1,500 and 2,500 metric tons, where 93 percent acid is continuously circulated to remove moisture from the incoming combustion air stream and must be cooled before returning to the drying tower for effective moisture absorption. The unit is equally effective as the primary acid cooler in single-contact single-absorption plants and as the drying tower cooler in double-contact double-absorption facilities. Beyond core sulfuric acid production, the CD-AP-200 provides reliable acid cooling in copper SX-EW (solvent extraction electrowinning) operations where temperature-controlled acid ensures optimal copper extraction kinetics and electrolyte quality, in nickel laterite high-pressure acid leaching (HPAL) plants where acid temperature directly influences leaching efficiency, and in titanium dioxide pigment production via the sulfate process where consistent acid cooling stabilizes the hydrolysis reaction and determines final pigment particle size distribution. The 200 square meter cooling area and robust 93 percent acid compatibility also make the CD-AP-200 suitable for spent acid cooling applications in methyl methacrylate (MMA) production, nitration processes, and sulfonation reactions where concentrated sulfuric acid is used as a process catalyst or reaction medium and must be continuously cooled for temperature control and acid quality preservation.

Each CD-AP-200 cooler is shipped in naked packing with a heavy-duty structural steel transport and lifting frame rated for the full 7,800 kilogram load during both vertical lifting and horizontal transportation. All process connection flanges are protected with full-face bolted covers incorporating desiccant breather cartridges, and the complete shell exterior receives a high-build epoxy intermediate coating protected by temporary transport wrapping. Our rigorous quality assurance program for this model includes 100 percent radiographic testing of shell longitudinal and circumferential seams, ultrasonic thickness verification of all tube sheet plates, helium leak detection on every tube-to-tube sheet expanded joint, hydrostatic pressure testing at 1.5 times design pressure with a minimum two-hour hold period, and complete anodic protection system functional testing with electrochemical potential mapping data recorded and archived for each individual unit produced. The documentation package supplied with each exchanger includes full material certification to EN 10204 Type 3.1, certified weld procedure specifications and welder qualification records, complete NDE reports with film interpretation records, hydrostatic test charts with certified gauge calibration certificates, surface preparation and coating inspection reports, and detailed operation and maintenance manuals for both the heat exchanger and the anodic protection system. Carpe Diem provides comprehensive 24-month warranty coverage and offers optional service agreements including annual on-site inspection by certified corrosion specialists, remote monitoring system installation, and priority spare parts availability for anodic protection system components.