316L Stainless Steel Anodic Protection Acid Cooler CD-AP-215 215m2 Exchange Area

The Carpe Diem CD-AP-215 Anodic Protection Acid Cooler represents a high-capacity industrial solution engineered specifically for the demanding requirements of large-scale sulfuric acid production and oleum processing facilities. Constructed with a robust 304L stainless steel shell and a comprehensive 316L stainless steel tube bundle, this 215 square meter shell and tube heat exchanger is purpose-built to handle extreme oleum concentrations up to 104.5 percent while maintaining exceptional thermal performance. The anodic protection system actively controls the electrochemical potential across all acid-wetted internal surfaces, ensuring that the protective passive oxide layer remains intact even under the severely dehydrating conditions created by oleum at elevated temperatures. With the capacity to cool 395,000 kilograms of acid per hour from an inlet temperature of 82 degrees Celsius down to a controlled outlet temperature of 55 degrees Celsius, the CD-AP-215 delivers relentless reliability for continuous operation in high-throughput acid production lines. The substantial 9,355 kilogram construction weight and shell diameter of 800 millimeters reflect the industrial-grade engineering invested in every weld, tube sheet, and support structure. This model incorporates advanced flow distribution baffles within the shell side to eliminate dead zones and ensure uniform heat transfer across the entire 215 square meter exchange surface.

• Oleum-Grade Material Compatibility: The 316L stainless steel tube bundle is specifically selected for its superior resistance to the highly dehydrating characteristics of oleum at concentrations up to 104.5 percent. The elevated molybdenum content in 316L effectively resists both general corrosion and localized pitting attack that can occur at the elevated acid temperatures and concentrations encountered in oleum processing circuits.
• Advanced Anodic Protection Circuitry: The multi-channel anodic protection system monitors and controls the electrochemical potential at multiple sensing points distributed throughout the heat exchanger. This redundant monitoring architecture ensures that every square meter of acid-wetted surface maintains its protective passive state, with automatic alarm and shutdown interlocks triggered if any monitored zone deviates from the safe potential range.
• High-Capacity Tube Bundle Design: Featuring 215 square meters of effective heat exchange area delivered through a precisely arranged tube matrix using Φ19×2.0×6000 mm 316L tubes, this design achieves the thermal duty required for 395,000 kilograms per hour acid flow while maintaining manageable pressure drops on both the acid and cooling water sides. The tube pitch and baffle spacing are optimized through computational fluid dynamics analysis.
• Thermal Stress Accommodation: The CD-AP-215 incorporates a floating head design at the tube bundle outlet end, allowing the tube bundle to expand and contract freely in response to the thermal gradient between the hot acid inlet and cooled acid outlet. This design feature eliminates tube sheet warping and tube joint stress that would otherwise accumulate in fixed tube sheet exchangers operating across this temperature range.
• Industrial-Grade Structural Integrity: Weighing 9,355 kilograms with a shell diameter of 800 millimeters, the CD-AP-215 is engineered for decades of continuous service. All pressure-retaining welds undergo full volumetric examination, and the complete assembly is post-weld heat treated to relieve fabrication stresses and ensure dimensional stability throughout the equipment lifecycle.
• Comprehensive Process Control Integration: Standard instrumentation connections include thermowell ports at acid inlet and outlet, pressure transmitter taps on both process and utility sides, and dedicated anode reference electrode ports. The unit is designed for seamless integration with distributed control systems (DCS) and plant-wide safety instrumented systems (SIS).

The CD-AP-215 is purpose-designed for high-capacity acid cooling in large-scale sulfuric acid production plants with daily outputs exceeding 2,000 metric tons, oleum manufacturing and processing facilities, and integrated fertilizer complexes where intermediate acid cooling is critical to process stability. The 215 square meter exchange area and 104.5 percent oleum compatibility make this model the preferred choice for absorption circuit cooling in double-contact double-absorption (DCDA) sulfuric acid plants where oleum is produced as an intermediate product. Additionally, the CD-AP-215 serves effectively in spent acid regeneration plants within petroleum refineries, where high-temperature acid streams require reliable cooling prior to recirculation or neutralization. The robust construction and comprehensive anodic protection system enable deployment in remote mining sites where acid plant availability directly determines metal production output and unscheduled downtime carries significant financial consequences.

Each CD-AP-215 cooler is shipped in naked packing with a heavy-duty protective steel frame engineered to support the 9,355 kilogram unit weight during road, rail, and sea transportation. All flange faces receive protective covers with desiccant, and the anodic protection electrode ports are fitted with temporary protective plugs to prevent contamination. Our quality assurance regime for this model includes 100 percent radiographic testing of all pressure boundary welds, positive material identification on every stainless steel plate and tube used in construction, helium leak testing of all tube-to-tube sheet expanded joints, and full hydrostatic pressure testing at 1.5 times design pressure for a minimum holding period of 120 minutes. Documentation delivered with each unit comprises material test certificates (EN 10204 Type 3.1), weld maps with NDE reports, pressure test certificates, surface finish inspection reports, and detailed anodic protection system commissioning and maintenance manuals. Carpe Diem provides a standard 24-month warranty on all CD-AP-215 coolers and offers optional extended warranty coverage with annual on-site inspection visits by certified corrosion engineers.