Shell & Tube Heat Exchangers

heat exchanger shell tube

As technologies of the various process industries advance, they tend to use larger, more sophisticated heat exchangers with improved performance.
The combination of technical advances in the fields of welding, heat treatment, and non-destructive testing – with highly flexible manufacturing capabilities – allows Kelvion to fully meet clients’ requirements, at the same time offering optimised solutions.
Kelvion has the in-house capability to design and manufacture shell-and-tube heat exchangers for the petrochemical, mining and power generation industries.


Renzmann Double Tube Safety Heat Exchangers (DTSHX)

Unlike tube bundles of single-wall design, double-tube bundles are provided with two tube sheets at each end. If a tube wall shows a leak, the product flows through fine ducts arranged between the double tubes into the leakage collection space and triggers a check command.

However, the 2nd remaining undamaged tube keeps the product separated from the second fluid. The plant operator may continue to run the heat exchanger until the next scheduled maintenance, thus avoiding cost-intensive shutdown times. Depending on the application, our double-tube safety heat exchangers can be designed and manufactured in any desired shell, header and sealing variant. Different material combinations are available for the inner and outer tubes. Double tube heat exchangers can thus be used for a wide variety of applications. Appropriate materials permit many different fluids to be cooled, heated, condensed or evaporated. Double-tube safety heat exchangers are suitable for operating pressures ranging from vacuum to 300 bar high pressure applications and for temperatures ranging from -150°C to more than 350°C.


air dryer

Air Dryer Customized for every application

Air Dryer is available in different material designs: galvanized steel, stainless steel, copper, and smooth pipe. These product variations allow us to offer solutions that best fit to our customer’s applications.

Heavy industrial loadings or high temperatures make no difference to air dryers made of galvanized steel. They are manufactured completely from steel to form a welded unit. The elliptical finned tubes are hot-dip galvanized. Frame and headers are protected against corrosion by zinc-dust primer and an epoxy aluminum finishing paint. It goes without saying that the complete heat exchanger unit is also available as a version galvanized in a dipping bath. Air dryer made of stainless steel are the specialists meeting the highest hygiene standards or for applications involving aggressive media. The seamless joint between tube and fin produced using a laser enables longer service life without performance losses: you benefit from state-of-the-art manufacturing technology with laser finned tubes by us. The heat exchanging surface consists of elliptical or round stainless steel finned tubes. Plain-tube heat exchangers made by us are the first choice when high performance is called for despite heavy air pollution. The heat exchanging surface consists of round galvanized plain steel tubes. This variant stands out for its long on-stream times and easy cleaning. Cross-flow heat exchange, stainless steel versions or galvanized steel – our engineers will find a solution for your application.

Benefits of the elliptic finned tube:

  • Aerodynamically favourable core tube with roughly three to ten times less hydraulic friction as compared with a round tube
  • Low pressure loss and minimum soiling
  • High thermal transmittance resulting in small heat exchanger surface
  • Low noise level
  • Good corrosion protection due to hot-dip galvanizing in a dipped bath and at the same time an optimum metal joint between core tube and fin
  • Compact design leading to good use of a given volume
  • Maximum service life


air dryer economizers

Variants for every demand

Air preheater is heat exchangers for heating and evaporation, for cooling and condensing and for heat recovery. Many decades of experience in designing and manufacturing have made us a leading supplier of heat exchangers for cooling and heating of gaseous and liquid media. The wide range of available plain and finned tube systems is certainly an important aspect of our market success.

Finned-tube heat exchangers can be made from numerous materials: steel, stainless steel, copper/aluminium, aluminium and other special materials. Plain-tube heat exchangers are used mostly where a fluid present around the tubes is so polluted that finned tubes can no longer be used. Plain tubes can be configured in different ways either next to one another or serially. Steel and stainless steel versions as well as a hairpin design are also possible.

Benefits of the elliptic finned tube:

  • Aerodynamically favourable core tube with roughly three to ten times less hydraulic friction as compared with a round tube
  • Low pressure loss and minimum soiling
  • High thermal transmittance resulting in small heat exchanger surface
  • Low noise level
  • Good corrosion protection due to hot-dip galvanizing in a dipped bath and at the same time an optimum metal joint between core tube and fin
  • Compact design leading to good use of a given volume
  • Maximum service life


Kemmerling Type Shell-and-Tube Heat Exchangers

The type of materials is determined while taking into account the media used and pressures applied, as well as corrosion protection requirements.

Operating pressures

For the series production of FKV, GK heat exchangers, operating pressures of 16 bar are applied, however, 200-250 bar versions can also be manufactured.

Operating temperatures

As regards operating temperatures, 3 groups are distinguished:

  1. up to 100°C – Perbunan type seals
  2. up to 200°C – Viton type seals
  3. for higher temperatures – special seals adjusted to specific working conditions
  • Series FKV-T

The FKV submersible cooler has been specially developed for the use in oil tanks and fitted with finned U-shaped tubes. Such type coolers are used when the oil from the hydraulic circuit must be returned to the oil tank upon cooling. To save space, the cooler is inserted into the oil tank and tightly bolted through an annular flange, where service pipes are arranged.

  • Series FKV-D

The “D” series is characterized by a stable structure with the tube bundle fitted with two tube-sheets  plates, one of them slidably mounted in the sealing ring. In this way, thermal expansions are accepted without any damage. The whole exchanger is installed in a shell and closed with covers. With the cover unbolted, the tube bundle can be removed and the inside and outside of the exchanger can be easily cleaned. If cleaning of the outside is unnecessary and the length compensation is not required as based on the thermal data, a welding design can be chosen (with a non-removable tube bundle – NZ).

  • Series FKV-U

Finned tubes of the “U” series are arranged in the “U” shape. This is conducive to acceptance of thermal expansions and enables cost-effective solutions.

  • Series GK

The GK series heat exchangers are suitable for many thermo-kinetic processes. In the case of plain tube heat exchangers, the cooling medium generally flows on the tube side. Media, such as water, oil and gas, can be both heated and cooled. The product programme is based on three standard pipe diameters (8, 12, 16 mm). Materials for the tubes: carbon steel, high-alloy steel, copper, copper-nickels, titanium and others.

External dimensions are identical and only the incorporated tube bundles have different heat exchange surfaces. The entire GK series includes nine different shell diameters and is designed in ten different installation lengths. This provides gradual heat transfer surfaces of 0.2 m2  to 100 m2. Solutions with a removable or welded tube bundle may be applied. In cases of specific requirements, designs with a floating head are available.

Finned tubes

An essential element of the FKV production series is a bundle of finned tubes. The medium with less preferred thermal parameters flows on the shell side (the outer side of the tube bundle) and the medium with more favourable parameters – in the tubes. The geometry of finned tubes largely eliminates adverse conditions of the heat transfer of e.g. oil as compared with water. Thus an extremely flexible operation is possible so that effective velocities and, in consequence, good heat transfer characteristics are attainable even with a small amount of medium.

Good points

– Sturdy, extruded finned geometry (with an option to calculate for dozens of bars).

– High efficiency at a low pressure drop.

– The distances between deflectors depend on the application, which ensures and optimum oil velocity on the shell side.

– Tin-plated ribbed surface (optional) to protect against oil ageing.

– Tubes rolled out or welded in the tube support plate.

Materials: Cu-DHP


                 Cu-DHP/1.4571 and others

A wide range of solutions:

– oil coolers in injection moulding machines, compressors, marine installations,

– water coolers in compressors,

– air coolers in compressors/pumps

– process gas coolers (intercoolers).


st oil cooler

Individual solutions for petrochemical systems

The oil and gas industry is constantly facing new challenges. On the one hand, the global energy demand is steadily increasing, due in particular to growing economies around the world. On the other, exploiting and developing oil and gas reserves has become ever more difficult and risky. More expensive, too. On top of that, energy resources such as unconventional gas or oil shales or oil sand have come to the fore.

Oil and gas developers also have to consider the fact that each reservoir is unique: While the crude oils produced in Venezuela, for example, have a relatively high viscosity, crude oils from Saudi-Arabia are thinner and thus more easily developed. There are two constants, though: Whatever kind of oil and gas you deal with, wherever you do it, you usually deal with corrosive media, high temperatures and pressures, as well as polyphase mixtures. Constant is the uncompromising reliability of Shell & Tube products.

In a business where efficiency, versatility and safety are deciding competitive factors, we are always the right choice. Why?

  • Because each and every Shell & Tube application is tailor-made for you, with robust, low-maintenance designs that are specifically laid out to suit your individual needs.
  • Because optimised resource deployment, intelligently connected material flows makes your Shell & Tube system very efficient.
  • Because every single part is made of the most durable and resistant materials and undergoes meticulous testing before installation.

Because all the knowledge and the experience shared by our engineers worldwide have gone into its design.


Design (thermal and mechanical), basic and detail engineering, procurement, manufacturing, testing, delivery and commissioning of turbine exhaust steam water cooled condensing units.

Condensers manufactured in diverse materials (tubes made of carbon steel, stainless steel, Cu alloys, Ni alloys, Titanium,..; tube sheets can be of the solid type or cladded) according to the quality and nature of the cooling water (Sea water, cooling tower, river water, etc..).

Our standard supply comprises of:

  • Condenser: Circular or rectangular cross-section, axial or vertical steam entry
  • Turbine to condenser steam duct including the necessary expansion joints
  • Vacuum system: Either steam-jet ejectors or liquid ring vacuum pump types
  • Flash tank, drain header and/or vacuum drains lifting system
  • Dump tube and pressure reduction desuperheated system
  • Condensate pumps system: Pumps in vertical or horizontal arrangement; either motor or steam turbine driven; API 610,  ISO5199 or standard manufacturer pumps design
  • Control system: Including level control valves; Level, Pressure and Temperature indicators, transmiters, controllers,..
  • Ball tube cleaning system
  • Interconnecting piping with filter, fittings and valves

All components mentioned above will be mounted and/or prefabricated up to a maximum extent in our workshop in common base frames.


Kelvion Aircooled Systems has collaboration agreements with TEI (USA) and EON (Germany) for the design and manufacture of feedwater heaters. Tubesheet type feedwater heaters are offered. Tube to tubesheet attachments could be by conventional welding, internal bore welding, explosion welding, etc.


coiling coils

For heat recovery:

  • Behind a hot process which generates hot fumes,
  • Behind boiler on the exhaust gas,
  • Behind hot exhaust gas (g. motors),

For heat delivery

  • Air preheating
  • Air heating
  • To cool a process fluid or air

Heat recovery clients:

  • Energy plants: to increase boiler efficiency
  • Steam / hot water productions: to increase efficiency
  • District heating
  • Food and bewerage industries examples
  • Dryer
  • Spray dryer
  • Steel plant: ta decrease exhaust gas temperature

Heat delivery clients:

  • To heat air for Dairy system
  • To heat air for HVAC system
  • To heat air for anti icing system (e.g. gas turbine in let)
  • Hot water <100°C
  • Presurised water >100°C
  • Saturated or superheated steam

Cooling fluid:

  • Air process
  • Air for HVAC
  • Air Inlet for gas turbine to increase GT efficiency
  • Cold water
  • Water + MEG
  • Water + MPG