Production Line Introduction for Anodically Protected Sulfuric Acid Coolers (OEM/ODM Available)

Core Production Flow

1. Material Preparation & Forming Raw materials include 316L, 904L, 254SMO, and other high-alloy stainless steels resistant to concentrated sulfuric acid. The line performs CNC cutting, rolling, and stamping to produce shells, tube sheets, heat exchange tubes, and headers, ensuring dimensional accuracy and surface smoothness. For OEM/ODM orders, we can customize material selection according to customer requirements for acid concentration, temperature, and working pressure.
2. Precision Welding & Assembly Automated orbital welding and argon-shielded welding are used for tube-to-tube sheet connections and shell closure. Welds undergo 100% radiographic or ultrasonic testing to eliminate defects. The structure is assembled with strict alignment to guarantee flow uniformity and mechanical stability. ODM solutions support structural optimization based on customer installation space and heat exchange efficiency requirements.
3. Anodic Protection System Integration Cathodes, reference electrodes (Hg/HgSO₄ type), and potential sensors are installed in designated positions. Wiring and sealing are completed to connect with the constant potential rectifier, forming a closed-loop anodic protection (AP) system that maintains passivation in corrosive acid. We provide OEM customization of AP system parameters and can integrate customer-specified components for ODM projects.
4. Pressure Testing & Leak Detection Hydrostatic and pneumatic pressure tests are conducted at 1.25–1.5 times design pressure to verify strength and tightness. Helium leak detection ensures zero leakage in acid and water circuits, critical for safe operation. Testing standards can be customized according to customer industry norms or international standards (e.g., ASME, GB) for OEM/ODM orders.
5. Passivation & AP Commissioning The wetted surfaces are chemically passivated. The AP control system is calibrated to set and stabilize the passive potential, forming a dense, protective oxide film that drastically reduces corrosion rates. Commissioning parameters can be adjusted to match the specific working conditions of customer projects in ODM cooperation.
6. Finishing & Performance Testing External painting, insulation, and labeling are applied. Final testing includes heat exchange efficiency, pressure drop, and long-duration AP monitoring. Only fully qualified units are packaged and delivered. OEM orders support custom labeling, packaging, and compliance with customer brand standards.

Key Advantages of the Production Line

• Corrosion Resistance: The integrated anodic protection system extends service life and reduces iron ion contamination of sulfuric acid.
• High Efficiency: Optimized flow design and precision manufacturing boost heat transfer performance while lowering energy consumption.
• Stable Quality: Full-process digital control and non-destructive testing ensure consistency for heavy-duty industrial use.
• Wide Adaptability: Products suit various concentrations (93%–98%) and temperatures of sulfuric acid, matching drying, absorption, and circulation cooling processes.
• Flexible OEM/ODM Capabilities: We offer one-stop customization from product design, material selection, and structural optimization to branding and packaging, tailoring solutions to meet customer-specific technical requirements, industry standards, and market demands.

OEM/ODM Service Highlights

• Customize product specifications (size, heat exchange area, pressure rating) based on customer drawings or technical parameters;
• Integrate customer-specified components (e.g., control systems, connectors) into the anodic protection and cooling system;
• Provide OEM production with customer brand labeling, packaging, and documentation (user manual, test report);
• Develop ODM solutions for special working conditions (e.g., ultra-high temperature, high-concentration acid, compact installation space);
• Offer technical support and after-sales service for OEM/ODM products to ensure stable operation.

R&D Capabilities

R&D Focus Areas

• Anodic Protection Technology Innovation: Continuously optimize the design of AP systems, including reference electrode performance, constant potential rectifier stability, and passivation process parameters, to enhance corrosion resistance and extend product service life in extreme working conditions (high temperature, high-concentration sulfuric acid).
• Material Research & Application: Collaborate with domestic and foreign material suppliers to test and apply new high-alloy materials, improving product wear resistance, corrosion resistance, and cost-effectiveness while expanding adaptability to different acid concentrations and working environments.
• Structural Optimization: Use 3D modeling and fluid dynamics simulation to optimize the structure of heat exchange tubes, tube sheets, and shells, improving heat transfer efficiency, reducing pressure drop, and adapting to compact installation spaces for ODM projects.
• Intelligent Upgrade: Integrate intelligent monitoring and control technologies into AP systems, developing remote monitoring, fault early warning, and automatic parameter adjustment functions to reduce manual operation and improve operational safety and stability.

R&D Support & Cooperation