Custom Engineered Anodic Protection Sulfuric Acid Cooler CD-AP-180 180m² for Concentrated Acid Cooling

The Carpe Diem CD-AP-180 Anodic Protection Sulfuric Acid Cooler represents our commitment to delivering custom engineered cooling solutions tailored to the unique process requirements of medium-scale sulfuric acid production facilities. Designed with a 180m² heat exchange area and engineered to handle 95.5% concentrated sulfuric acid, this shell and tube cooler reduces acid temperature from 75°C inlet to 43°C outlet at a flow rate of 200,000 Kg/h. Unlike standardized off-the-shelf products, every CD-AP-180 can be configured with customized nozzle orientations, flange connection types, mounting bracket positions, and anodic protection system parameters to match existing plant piping layouts and process control interfaces. The construction combines a 304L stainless steel shell with 316L stainless steel tubes measuring Φ19 × 2.0 × 6000mm, providing an optimal balance of corrosion resistance, thermal conductivity, and cost-efficiency for medium-concentration sulfuric acid service. Whether your plant requires atypical nozzle positioning to fit into a constrained equipment bay or specialized instrumentation ports for integration with a distributed control system, our engineering team works directly with your process engineers to deliver a cooler that functions as a seamless extension of your existing acid circulation system.

• Fully Customizable Engineering Design: Each CD-AP-180 unit is configured to order with flexible options for nozzle orientation (top, bottom, side entry), flange standards (ANSI, DIN, JIS, or GB), support saddle positioning, and lifting lug placement. Our application engineers review your plant layout drawings, piping isometrics, and process data sheets to ensure perfect physical integration with your existing infrastructure.
• Reliable Anodic Protection System: The integrated electrochemical protection circuit is tuned to the specific acid concentration and temperature range of your process, with platinum-clad titanium anodes positioned at multiple locations along the shell length to ensure complete coverage of all acid-wetted internal surfaces. The system continuously monitors the corrosion potential and adjusts the protection current automatically.
• Optimized Tube Bundle Configuration: The 180m² heat exchange surface is achieved through a carefully engineered tube layout using Φ19 × 2.0mm tubes arranged in a triangular pitch pattern. This configuration provides an excellent balance between heat transfer coefficient and shell-side pressure drop while maintaining sufficient tube pitch for effective mechanical cleaning access.
• Medium-Scale Process Flexibility: Rated for 200,000 Kg/h acid throughput, the CD-AP-180 is the ideal size for medium-capacity sulfuric acid plants, copper smelter acid systems, and spent acid recovery units. The design can be adapted for parallel operation when future capacity expansion is planned.
• Dual Material Corrosion Defense: The 304L shell provides excellent resistance to sulfuric acid at moderate temperatures, while the 316L tube bundle with molybdenum alloying delivers superior pitting resistance in the higher-temperature tube-side environment where localized corrosion risks are greatest. All tube-to-tubesheet joints are strength-welded and hydraulically expanded for absolute leak integrity.
• Rapid Project Turnaround: Despite the custom engineering approach, our standardized design platform and pre-qualified component library enable delivery within 60 workdays from order confirmation. All customization is achieved through configuration rather than ground-up design, ensuring both flexibility and speed.
• Comprehensive Engineering Support Package: Every CD-AP-180 delivery includes detailed 3D general arrangement drawings, nozzle load tables, foundation loading data, wiring schematics for the anodic protection system, and complete process performance guarantees. Our engineers are available for on-site commissioning supervision upon request.

The CD-AP-180 Anodic Protection Sulfuric Acid Cooler is engineered for medium-capacity sulfuric acid production plants including sulfur-burning contact process units, metallurgical off-gas acid plants, and spent sulfuric acid regeneration facilities. Its 180m² heat exchange area and 200,000 Kg/h flow capacity make it the preferred choice for single-train plants producing 300 to 600 metric tons per day of sulfuric acid. The unit performs exceptionally well as the inter-pass cooler between absorption tower stages and as the final product acid cooler before storage. The customizable nozzle arrangement is particularly valuable for brownfield retrofit projects where existing piping configurations impose geometric constraints that standard coolers cannot accommodate. In copper smelter and zinc roaster gas cleaning systems, the CD-AP-180 reliably handles acid streams containing trace impurities that would rapidly degrade unprotected carbon steel or cast iron exchangers.

Every CD-AP-180 cooler is manufactured under our ISO 9001 certified quality management system and fabricated in accordance with ASME Section VIII Division 1 code requirements. Materials are traceable to certified mill test reports with full chemical and mechanical property documentation. Fabrication welding is performed by qualified welders using approved welding procedure specifications, with all pressure-retaining welds receiving 100% radiographic or ultrasonic examination. Post-fabrication, each unit undergoes hydrostatic pressure testing at 1.5 times design pressure on both shell and tube circuits, followed by a helium mass spectrometer leak test with a maximum allowable leak rate of 1×10&supminus;&sup6; Pa·m³/s. The anodic protection system is fully commissioned in our factory with simulated load testing across the complete operating range. For transportation, the assembled cooler is mounted on a structural steel shipping frame with bolted flange covers protecting all nozzle connections. The anodic protection control panel, cables, and reference electrodes are packed in a separate moisture-resistant plywood case. A comprehensive documentation package including material certificates, NDT reports, pressure test records, anodic protection system calibration data, dimensional inspection reports, and the ASME U Stamp Manufacturer's Data Report accompanies each shipment.