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Spiral Heat Exchanger

What Is a Spiral Heat Exchanger?

A spiral heat exchanger (SHE) is a highly efficient, compact type of heat exchanger designed with two concentric spiral channels that enable effective heat transfer between two process fluids. Unlike traditional shell-and-tube or plate heat exchangers, the spiral design provides a single, continuous flow path, making it exceptionally suitable for handling viscous, fouling, slurry-based, or particle-laden fluids. This unique geometry enhances thermal performance, reduces maintenance, and ensures long-term reliability in demanding industrial environments.

Engineered for maximum heat recovery in limited space, spiral heat exchangers are widely used in chemical processing, wastewater treatment, petrochemical plants, food processing, pulp and paper mills, and other applications requiring robust heat transfer with minimal downtime.

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How Do Spiral Heat Exchangers Work?

A spiral heat exchanger works by guiding two process fluids through separate, concentric spiral channels, allowing them to exchange heat efficiently across a metallic wall. This innovative flow arrangement ensures high thermal performance, minimal fouling, and consistent operation even with viscous or particle-rich fluids.

  1. Separate Spiral Flow Channels
    The heat exchanger is constructed from two long metal plates wound around a central core to create two distinct spiral channels.Each fluid—hot and cold—enters through its own inlet, ensuring there is no mixing between them. The channels are welded alternately so each fluid remains confined to its dedicated pathway.
  2. Counter-Current Flow for Maximum Efficiency
    Most spiral heat exchangers operate in a counter-current flow configuration, which is the most thermally efficient arrangement.

    • Hot fluid: Often enters at the center and flows outward.
    • Cold fluid: Enters at the outer edge and moves inward.
    This opposite flow direction maintains the highest temperature difference along the entire channel length, significantly improving the heat transfer rate and overall thermal efficiency.
  3. Heat Transfer Through Spiral Plates
    As the fluids move through their spiral paths, heat is transferred:

    • From the hot fluid → through the metal spiral plate → to the cold fluid
    • The long continuous flow paths enhance contact time and heat exchange surface area
    This results in rapid temperature equalization, even when processing heavy or high-viscosity media.
  4. Turbulent Flow Created by Curved Channels
    The spiral shape forces the fluids into turbulent flow, even at lower velocities. This turbulence provides key benefits:

    • Higher heat transfer coefficients
    • Improved energy efficiency
    • Better thermal uniformity
    • Reduced risk of stagnant zones
    The curvature naturally disrupts laminar flow, producing stronger mixing and better heat exchange compared to straight-channel heat exchangers.
  5. Self-Cleaning Effect (Anti-Fouling)
    One of the biggest advantages of spiral heat exchangers is their self-cleaning action, created by:

    • Uniform channel width
    • High shear forces
    • Scrubbing action of turbulent flow
    Deposits, sludge, and particulates are swept out of the channel, preventing blockages and significantly reducing cleaning frequency. This makes spiral heat exchangers especially suitable for:

    • Slurry
    • Wastewater
    • Pulp and fiber
    • Viscous chemical streams
  6. Pressure-Optimized Design
    The single-pass channel design maintains a consistent fluid velocity, resulting in:

    • Lower pressure drop
    • Stable flow conditions
    • Better handling of solids and fibrous materials
    The welded construction also eliminates internal gaskets, making the exchanger suitable for high-temperature and high-pressure duties

Types of Spiral Heat Exchangers

By Flow Configuration

  1. Counterflow Spiral Heat Exchanger
    In counterflow designs, the two fluids move in opposite directions through a single spiral channel. This arrangement maximizes the temperature difference between the hot and cold fluids throughout the exchanger, resulting in high thermal efficiency and optimal heat recovery. Counterflow configurations are ideal for viscous or fouling fluids because they maintain consistent velocity and reduce the risk of deposits.
  2. Parallel-Flow Spiral Heat Exchanger
    Parallel-flow spiral heat exchangers allow both fluids to move in the same direction through separate spiral channels. This setup creates a smoother temperature gradient across the heat exchanger, making it suitable for sensitive process fluids that cannot tolerate rapid temperature changes.
  3. Crossflow Spiral Heat Exchanger
    Crossflow designs allow fluids to move in a cross-wise direction, sometimes combining counter-current and cross-current flow paths within the same unit. This configuration is particularly useful in specialized applications where phase changes or complex thermal duties are involved.

By Design and Application

  1. Type 1 – Liquid/Liquid Heat Exchanger
    Type 1 is used for liquid-to-liquid applications, especially with fluids prone to fouling. The self-cleaning spiral channels make it ideal for wastewater, pulp, and chemical processes, ensuring minimal maintenance and consistent performance.
  2. Type 2 – Vaporizing and Condensing Applications
    Type 2 is designed for vaporization and condensation processes, where one fluid flows spirally while the other moves crosswise. This combination improves phase-change efficiency and reduces pressure drop, making it suitable for steam, refrigerants, and chemical vapors.
  3. Type 3 – Liquid/Liquid Fouling Resistant
    Type 3 is similar to Type 1 but optimized for higher fouling conditions. It can also operate as a steam heater, making it versatile for heavy-duty industrial applications.
  4. Type 4 – Condensing Spiral Heat Exchanger
    Type 4 is primarily used for condensing applications. It delivers stable performance under continuous operation, making it suitable for vacuum condensers, process vapors, and heat recovery systems.

By Construction

  1. Spiral Plate Heat Exchanger (SPHE)
    Spiral plate heat exchangers are formed by rolling two flat metal plates into concentric spirals, creating continuous channels for efficient heat transfer. The design reduces fouling, supports viscous fluids, and allows for easy cleaning.
  2. Spiral Tube Heat Exchanger (STHE)
    Spiral tube heat exchangers consist of tubes coiled in a spiral pattern. This construction is preferred for high-pressure and high-temperature applications and provides enhanced mechanical strength.
  3. Spiral-Wound Heat Exchanger
    In spiral-wound designs, hot fluid streams pass through tubes wound around a central mandrel, while the secondary fluid flows counter-currently in the shell side. This configuration is widely used in refrigeration, petrochemical, and hydrocarbon processing, offering excellent thermal performance with compact dimensions.

Applications of Spiral Heat Exchanger

Applications by Industry

  1. Chemical and Petrochemical Industry- In chemical and petrochemical plants, spiral heat exchangers are used for heating and cooling reactive chemicals, distillation, evaporation, and recovering waste heat. Their robust design and high thermal efficiency make them ideal for processes where fouling or viscous fluids are common.
  2. Pulp and Paper Industry- Spiral heat exchangers efficiently handle sluggish materials like pulp and fluids with high solid content. Their self-cleaning spiral channels prevent clogging, ensuring reliable performance in continuous industrial operations.
  3. Food and Beverage Industry- These exchangers are widely used for processing dairy products, oils, fats, and other viscous food materials, providing precise temperature control while minimizing fouling and contamination risks.
  4. Pharmaceuticals and Biotechnology- Spiral heat exchangers are crucial in processes requiring exact temperature management, such as supercritical CO2 extraction, fermentation, and sensitive biochemical reactions, ensuring product quality and safety.
  5. Energy Production- In energy plants, they are employed for geothermal systems and waste heat recovery, enhancing energy efficiency and reducing operational costs.
  6. Mining and Steel Industry- These exchangers handle a variety of abrasive, viscous, and high-temperature process streams, providing reliable heat transfer in demanding industrial conditions.

Applications by Fluid Type

  1. Fouling and Viscous Fluids- The single-pass design and self-cleaning effect allow spiral heat exchangers to process fluids that tend to build up on heat transfer surfaces, maintaining efficiency and reducing maintenance.
  2. Slurries and Solids- Spiral heat exchangers can manage high-solids content liquids, such as sludge or wastewater, without clogging, thanks to their wide and continuous spiral channels.
  3. Corrosive Media- Constructed from corrosion-resistant materials, these exchangers safely handle corrosive hot and cold fluids simultaneously, making them suitable for chemical and industrial applications.
  4. Gases and Vapors- Spiral heat exchangers are ideal for condensation applications, such as chemical distillation or vapor recovery, providing precise control over phase-change processes.

What is the Function of a Spiral Heat Exchanger?

The primary function of a spiral heat exchanger is to transfer heat efficiently between two process fluids, even under challenging conditions involving viscous, fouling, or particle-laden liquids. Its innovative design incorporates two concentric spiral channels, enabling the fluids to flow in a counter-current direction. This arrangement maximizes the temperature difference between the hot and cold streams, ensuring high thermal efficiency while maintaining consistent flow and heat transfer.

The spiral geometry also promotes turbulence within the channels, which reduces fouling and creates a self-cleaning effect, making it ideal for fluids that tend to deposit solids or form sludge. The combination of compact design, high surface area, and single-pass flow ensures the exchanger operates reliably in applications with limited space or difficult process streams.
  1. Efficient Heat Transfer- The counter-current flow and spiral channel design maximize the thermal gradient between the two fluids, providing rapid and uniform heat exchange. This makes spiral heat exchangers highly effective for heating, cooling, condensing, or vaporizing liquids.
  2. Fouling Resistance- The spiral channels generate turbulence that prevents deposits from sticking to the walls. If fouling occurs, the narrowing spiral paths accelerate the fluid velocity, dislodging buildup and maintaining consistent performance with minimal maintenance.
  3. Compact Design- Despite offering a large heat transfer surface area, the spiral configuration is highly compact, making it suitable for industrial setups where space is limited without compromising performance.
  4. Versatility- Spiral heat exchangers handle a wide range of duties, including liquid-to-liquid, vaporization, condensing, and heating, even for tough fluids such as sludges, slurries, emulsions, or viscous oils.
  5. Low Maintenance- The combination of self-cleaning flow, turbulence, and robust construction reduces maintenance requirements, extends operational life, and ensures reliable performance in continuous industrial operations.

Why Choose Spiral Heat Exchanger?

Spiral heat exchangers are preferred in many industries for their high thermal efficiency, compact design, and exceptional ability to handle viscous, fouling, or particle-laden fluids. Their unique spiral configuration not only maximizes heat transfer but also reduces the space required for installation, making them ideal for plants where footprint is limited.
Additionally, the single-pass spiral design promotes turbulence and a self-cleaning effect, lowering maintenance needs and ensuring reliable performance over long-term operation. With their versatility across applications and robust construction, spiral heat exchangers offer a cost-effective solution for demanding industrial processes.

Key Reasons to Choose Spiral Heat Exchangers

  1. High Thermal Efficiency- The counter-current flow within the concentric spiral channels ensures the maximum temperature difference between fluids throughout the exchanger, delivering superior heat transfer compared to conventional designs.
  2. Compact Design- Despite offering a large heat transfer surface, the spiral configuration requires minimal space, making it ideal for industrial setups with footprint limitations.
  3. Fouling Resistance- Each fluid follows a single, curved flow path, generating turbulence that helps prevent sediment buildup. This self-cleaning effect is especially beneficial for handling viscous fluids, slurries, or materials with suspended particles.
  4. Versatility- Spiral heat exchangers can handle a wide variety of challenging fluids, including slurries, sludges, emulsions, and viscous oils, making them suitable for chemical, food processing, pulp and paper, and wastewater applications.
  5. Reduced Maintenance- The design minimizes fouling and plugging, significantly reducing maintenance and cleaning frequency. When maintenance is required, hinged or removable covers provide easy access to the heat transfer surfaces.
  6. Cost-Effectiveness- The combination of high thermal efficiency, low maintenance, and compact installation makes spiral heat exchangers a long-term economical choice, delivering energy savings and lower operational costs.

Benefits of Spiral Heat Exchanger

Spiral heat exchangers provide significant operational and performance advantages that make them highly effective for demanding industrial processes. Their innovative design delivers enhanced heat transfer, reliability, and versatility, making them a preferred choice across multiple industries.
  1. Enhanced Heat Transfer Efficiency- The concentric spiral channels ensure true counter-current flow, which maximizes the temperature gradient between the two fluids. This allows for faster and more consistent heat exchange, improving energy efficiency and process performance.
  2. Superior Fouling Resistance- The spiral flow paths induce turbulence that naturally reduces deposit formation, preventing clogging even with viscous, particle-laden, or fouling-prone fluids. This self-cleaning effect ensures smooth operation over extended periods.
  3. Versatility in Applications- Spiral heat exchangers can handle a wide variety of fluids, including slurries, sludges, emulsions, corrosive media, and high-viscosity liquids. They are suitable for heating, cooling, condensing, and vaporizing duties in industries such as chemical processing, pulp and paper, food and beverage, pharmaceuticals, and energy.
  4. Compact and Space-Saving Design- Despite offering a high heat transfer surface area, spiral heat exchangers occupy minimal space. Their compact size makes them ideal for limited-space installations or retrofitting existing systems.
  5. Low Maintenance and Long Life- The self-cleaning mechanism, combined with durable construction from corrosion-resistant metals, reduces maintenance needs and extends operational life. When cleaning is necessary, hinged covers allow quick access to internal surfaces, minimizing downtime.
  6. Cost-Effective Operation- By combining high efficiency, low maintenance, and compact design, spiral heat exchangers reduce operational costs and energy consumption, making them a long-term economical solution for industrial heat transfer applications

Technical specifications

Specification Details
Design Type Spiral Plate Heat Exchanger (SPHE), Spiral Tube Heat Exchanger (STHE), Spiral-Wound Heat Exchanger
Flow Arrangement Counter-current, Parallel-flow, Crossflow
Material of Construction Stainless Steel, Carbon Steel, Duplex Stainless Steel, Alloy Steel, Titanium (depending on fluid compatibility)
Channel Width Typically 10–50 mm (depending on application and fouling risk)
Maximum Operating Temperature Up to 400°C (depending on material)
Maximum Operating Pressure Up to 25 bar (higher pressure versions available)
Heat Transfer Area 0.5 m² – 200 m² (customizable based on process requirements)
Connection Types Flanged, Threaded, or Welded Inlets/Outlets
Applicable Fluids Liquids, Slurries, Vapors, Corrosive Media, High Viscosity Fluids
Maintenance Features Hinged/removable covers for cleaning, self-cleaning spiral channels
Typical Industries Chemical, Petrochemical, Food & Beverage, Pulp & Paper, Pharmaceuticals, Energy, Mining & Steel
Standards & Certifications ASME, ISO, PED, API (depending on model and region)

Maintenance Tips for Long-Lasting Performance of Spiral Heat Exchanger

Proper maintenance is essential for ensuring the long-term efficiency, reliability, and safety of spiral heat exchangers. Their unique spiral design requires careful attention to operational practices, cleaning, inspections, and safety measures.
  1. Monitor Performance Indicators- Regularly track key metrics such as temperature differentials, pressure drops, and flow rates. Any sudden rise in pressure drop or decrease in thermal performance can indicate fouling, scaling, or partial blockage. Proactive monitoring allows early detection and prevents costly downtime.
  2. Operate Within Design Specifications- Always run the unit according to its design flow rates and pressure limits. Operating beyond specifications, particularly with viscous fluids or those containing solids, can lead to clogging, inefficient heat transfer, or mechanical stress on the unit.
  3. Prevent Pressure Surges and Air Pockets- During start-up and shutdown, open and close valves slowly to avoid water hammer or pressure surges that could damage internal channels. Ensure proper venting to remove trapped air, as air pockets can significantly reduce heat transfer efficiency.
  4. Implement Fluid Treatment- For systems handling hard water, corrosive chemicals, or scaling fluids, use inhibitors or upstream filtration to protect the spiral channels. Proper fluid treatment helps minimize corrosion, scaling, and fouling, extending the operational life of the heat exchanger.
  5. Cleaning and Inspection Procedures- Fouling is a primary cause of efficiency loss. Cleaning should be performed based on the type of fluid and operating conditions. Cleaning-In-Place (CIP) or back-flushing is often sufficient for regular maintenance, while mechanical cleaning (e.g., high-pressure water jets) may be needed for heavily fouled systems. Periodically conduct non-destructive testing (NDT) such as ultrasonic inspections to detect early signs of corrosion or damage. Regularly check gaskets and seals for wear and replace them during maintenance.
  6. Safety and Shutdown Practices- Always depressurize the unit before opening it to prevent personal injury or equipment damage. For long shutdowns, flush and drain the system completely to prevent corrosion or freezing. When moving the unit, use designated lifting lugs, never the pipe connections or covers, to avoid structural damage.

Efficiency Improvement and Retrofitting of Spiral Heat Exchanger

Spiral heat exchangers (SHEs) are highly efficient by design, but their performance can be further enhanced through operational optimization and physical retrofitting methods. Improvements focus on maximizing heat transfer, reducing pressure drop, and resisting fouling, ensuring long-term energy efficiency and process reliability.
  1. Regular Cleaning and Fouling Monitoring- Although spiral heat exchangers have inherent fouling resistance due to their single-pass turbulent flow, deposits can still accumulate over time. Implement condition-based or automated clean-in-place (CIP) systems to monitor fouling levels and clean the exchanger before performance drops. This ensures consistent thermal efficiency and reduced maintenance costs.
  2. Optimize Flow Configuration- For maximum efficiency, maintain a true counter-current flow whenever possible. This maximizes the logarithmic mean temperature difference (LMTD) between hot and cold fluids, significantly improving heat transfer rates. Optimizing flow paths within the existing spiral channels enhances both energy recovery and overall system performance.
  3. Maintain High Turbulence- SHEs benefit from turbulent flow, which increases the heat transfer coefficient and naturally reduces fouling. Operating the system to maintain high Reynolds numbers (typically above 10,000) ensures efficient energy exchange while maintaining self-cleaning effects. Proper pump sizing and flow control are essential to sustain optimal turbulence levels.
  4. Waste Heat Recovery Integration- Spiral heat exchangers are ideal for recovering energy from waste streams, such as boiler blowdown or reactor effluent. Integrating SHEs into the broader process allows reuse of residual heat, lowering energy consumption and improving overall plant efficiency. Combined with digital monitoring, this approach can optimize heat recovery in real-time.
  5. Physical Retrofitting and Material Upgrades- Performance can be further enhanced with physical modifications:

    • Enhanced Surfaces/Turbulators: Wire coils or twisted tapes in spiral tube designs create swirl flow and disrupt boundary layers, increasing heat transfer rates, though careful attention to pressure drop is required.
    • Surface Coatings: Fluoropolymer or corrosion-resistant coatings reduce fouling and extend service life.
    • Material Upgrades: Upgrading components to titanium or specialty alloys improves performance in high-temperature or corrosive environments.
  6. Advanced System Integration and Emerging Technologies- Retrofitting often involves Heat Exchanger Network (HEN) analysis, determining optimal placement of new SHE units in series or parallel to maximize energy recovery. Emerging technologies, such as nanofluids, show promise for enhancing heat transfer rates further. Additionally, IoT-based digital monitoring and AI-driven optimization allow predictive maintenance and continuous efficiency improvement, making SHEs highly adaptable for modern industrial applications.

The Future of Spiral Heat Exchanger

Spiral heat exchangers (SHEs) are already highly efficient and versatile, but ongoing research and technological advances promise even greater performance, sustainability, and applicability across industries. The future of SHEs focuses on material innovation, expanded applications, design optimization, and integration with modern industrial systems.
  1. Material and Manufacturing Innovation- Future developments will emphasize advanced materials and manufacturing techniques to improve durability and performance. Research into high-performance alloys, corrosion-resistant metals, and advanced composite materials aims to extend operational life while maintaining efficiency under extreme temperatures and pressures. Additionally, innovative surface coatings will further reduce fouling and enhance heat transfer. Precision manufacturing techniques, including automated fabrication and additive manufacturing, will allow for more cost-effective and high-quality SHE units.
  2. Expanded Industrial Applications- Spiral heat exchangers are increasingly being applied in renewable energy and sustainable processes. Integration with solar thermal systems, industrial waste heat recovery, and energy-efficient HVAC applications is growing. Their compact size, high thermal efficiency, and fouling resistance make them suitable for complex processes in chemical, petrochemical, oil & gas, and food industries, including handling highly viscous or particle-laden fluids.
  3. Sustainability and Energy Efficiency- The demand for sustainable industrial solutions is driving the adoption of SHEs. Their ability to reduce energy consumption, recover waste heat, and minimize emissions aligns with global sustainability goals. Ongoing research focuses on further improving thermal efficiency, reducing maintenance needs, and enhancing lifecycle energy savings, making SHEs a key technology in environmentally conscious industrial design.
  4. Advanced Design and Optimization- The future of SHEs involves systematic and automated design methodologies to handle their complex geometry and maximize performance. Computational modeling, AI-driven simulations, and parametric design tools will allow engineers to optimize flow configurations, minimize pressure drops, and enhance multi-stream heat transfer. These advancements will enable more precise customization for specialized industrial requirements.
  5. Multi-Stream and High-Performance Capabilities- Next-generation spiral heat exchangers are expected to support multi-stream configurations, allowing multiple fluids to be processed simultaneously with high efficiency. Future SHE designs will also accommodate high-pressure, high-temperature, and highly viscous fluids, expanding their applicability to challenging industrial processes and making them indispensable in modern energy and chemical engineering operations.

Why Choose United Cooling Systems Pvt. Ltd

United Cooling Systems Pvt. Ltd. is a trusted leader in the design, engineering, and manufacturing of high-performance spiral heat exchangers and other industrial heat transfer solutions. With years of industry experience, we specialize in creating customized units tailored to the specific needs of diverse industries, including chemical, petrochemical, food and beverage, pharmaceuticals, and energy production. Our products are built with premium materials, such as stainless steel, duplex alloys, and specialty metals, ensuring durability, corrosion resistance, and long-term reliability, even under challenging high-temperature, high-pressure, or fouling-prone conditions.

At United Cooling Systems, we combine technical expertise with strict quality control and regulatory compliance to deliver reliable, efficient, and energy-saving heat exchangers. Every unit undergoes thorough performance testing and quality verification before shipment, and we provide full after-sales support, including installation guidance, maintenance assistance, and spare parts supply. Our focus on efficiency, low maintenance, and compact design ensures that clients receive cost-effective solutions that maximize operational performance while supporting sustainability and energy conservation goals.

Conclusion

Spiral heat exchangers are a highly efficient, versatile, and reliable solution for industrial heat transfer applications. Their unique spiral design, counter-current flow, and self-cleaning capabilities make them ideal for handling viscous, fouling, or particle-laden fluids while ensuring maximum thermal efficiency in a compact footprint. From chemical processing and food production to energy recovery and pharmaceuticals, spiral heat exchangers provide consistent performance, reduced maintenance, and long-term cost savings.

With ongoing advancements in materials, surface coatings, digital monitoring, and retrofitting techniques, the future of spiral heat exchangers promises even greater energy efficiency, sustainability, and adaptability for complex industrial processes. Choosing United Cooling Systems Pvt. Ltd. ensures access to custom-engineered, high-quality, and fully supported solutions, giving industries a reliable partner for optimizing heat transfer, reducing operational costs, and achieving long-lasting performance

FAQs on Spiral Heat Exchanger

1. What is a spiral heat exchanger?
A spiral heat exchanger is a compact, high-efficiency heat transfer device made with two spiral-shaped channels that allow fluids to flow in a single, continuous path. Its design ensures excellent heat transfer performance, minimal fouling, and easy maintenance, making it ideal for challenging industrial processes.

2. What are the advantages of a spiral heat exchanger?
Key advantages include high thermal efficiency, strong fouling resistance, compact footprint, self-cleaning flow pattern, easy maintenance with removable covers, and the ability to handle viscous, dirty, or slurry-based fluids.

3. What is the working principle of a heat exchanger?
A heat exchanger works by transferring heat between two fluids—either gases or liquids—without allowing them to mix. Heat transfers through a solid surface (plates, tubes, or spiral walls) as one fluid releases heat and the other absorbs it. In spiral heat exchangers, this happens through two continuous spiral channels arranged for efficient heat flow.

4. Who makes spiral heat exchangers?
Spiral heat exchangers are manufactured by several global and regional heat transfer equipment companies. In India, United Cooling Systems Pvt. Ltd. is one of the trusted manufacturers known for producing high-quality spiral heat exchangers designed for demanding industrial applications. Many international heat exchanger companies and specialized fabrication firms also supply spiral designs based on project requirements.

5. What are the disadvantages of spiral heat exchangers?
While highly efficient, spiral heat exchangers have some limitations, including limited allowable pressure compared to shell-and-tube units, higher initial manufacturing cost, and larger cover plates that may need space for removal during maintenance. They are also less suitable for extremely high-pressure applications unless specially designed.

6. How does a spiral heat exchanger work?
It operates by guiding two fluids into separate spiral channels—usually in a counter-current arrangement. The continuous flow path increases heat transfer area and reduces dead zones, while the spiral motion enhances turbulence, improving efficiency and reducing fouling.

7. What industries use spiral heat exchangers?
They are widely used in chemical plants, petrochemical refineries, food processing, pulp & paper industries, wastewater treatment, pharmaceuticals, and energy sectors.