Views: 0 Author: Site Editor Publish Time: 2026-10-08 Origin: Site
A plug header air cooled heat exchanger — also called a plug type air cooler or plug header fin fan cooler — is an air-cooled exchanger whose finned-tube bundle terminates in welded rectangular box headers fitted with a removable threaded plug opposite every tube end. In the chemical industry that construction solves two problems at once: it allows each tube to be inspected, mechanically cleaned or plugged individually without opening the whole header, and the welded box resists the pressures and aggressive fluids typical of reactors, solvent recovery and acid-gas service. CSTHEATEXCHANGER manufactures plug header air coolers for chemical plants with tube materials from carbon steel to stainless, duplex-class and nickel alloys, fin and coating options for corrosive atmospheres, and fans with explosion-proof motors, built to the process datasheet and site drawing.
Chemical-industry condition | Plug header response |
|---|---|
Fouling streams — polymers, salts, tars that coat tube bores | Remove the plug opposite each tube and rod, brush or hydro-lance the tube from the header face; no bundle removal |
Corrosive fluids — acids, chlorides, amines, solvents | Welded box header in the same alloy as the tubes; no large gasketed cover plate exposed to the fluid |
Elevated design pressure in reactor loops and compressor circuits | Rectangular welded header with plugged holes is inherently stronger than a bolted cover plate at the same wall thickness |
Leak containment and zero-tolerance for cross-contamination | Individual tube plugging: a failed tube is isolated in minutes; the cooler returns to service at reduced duty |
Hazardous-area classification | Explosion-proof fan motors; non-sparking fan blades on request |
Corrosive plant atmosphere (acid mist, chloride) | Coated aluminium fins or alternative fin alloys; galvanized or coated structure |
Element | CSTHEATEXCHANGER construction |
|---|---|
Tubes | Carbon steel, 304/316 stainless, higher-alloy stainless or nickel alloy to the process datasheet; seamless |
Fins | Aluminium, fin type selected by tube-wall temperature; stainless fins or coated fins (epoxy, E-coating, hydrophobic) for aggressive atmospheres |
Headers | Plug type: welded rectangular box in tube-compatible material, threaded shoulder plug with gasket opposite each tube, pass partitions, nozzles to project flange standard |
Tube-to-header joint | Expanded or expanded-and-welded per fluid and pressure |
Fans | Axial, forced or induced draft; explosion-proof motors; belt or direct drive; auto-variable pitch or VFD on request |
Structure | Hot-dip galvanized or painted carbon steel plenum, fan ring, columns, walkways |
Testing | Hydrostatic test per design code; dimensional check against the approved drawing |
Our Air Fin Fan Cooler product line states the principle: size, tube number and size, fin spacing and material, and fan type and size are all adjustable to the application — the plug header is simply the header style that chemical plants ask for most.
Material compatibility first. We ask for the full stream composition including trace chlorides and acids — the header and plugs must match the tubes.
Pass arrangement for viscous or two-phase streams. Fewer passes with more tubes per pass keeps pressure drop within the process allowance.
Fin-side protection. Chemical plant air often carries corrosive vapour; coated fins extend bundle life.
Winterisation. Where products can freeze or become viscous, we supply recirculation plenums, louvres and steam coils.
Access. Header faces are oriented so plugs can be reached from the walkway during a short outage.
Process fluid, composition, flow, inlet/outlet temperatures, allowable pressure drop
Design pressure and temperature, design code, hazardous-area class
Site design ambient, altitude, plant atmosphere (acid, chloride)
Plot space, forced or induced draft preference, noise limit
Existing drawings for replacement bundles
A plug header has one threaded plug opposite each tube; a cover plate header has a single bolted plate exposing all tubes. Plug headers suit higher pressures and corrosive fluids; cover plates suit low pressure and very heavy fouling.
Yes — remove the plugs at both ends, insert tapered plugs in the tube, refit the header plugs. The cooler runs on at slightly reduced capacity until the next outage.
Carbon steel, 304/316 and higher stainless grades, and nickel alloys, with header and plug material matched to the tubes.
Yes; we fit explosion-proof motors and specify non-sparking components to the area classification.
Yes. Send the existing header drawing and nozzle positions; we build the new plug header bundle to drop into the existing structure.
Send CSTHEATEXCHANGER the process datasheet and site conditions. We will size the plug header air cooled heat exchanger, select materials and fans, and return drawings for approval before manufacture.
Email: info@cstheatexchanger.com
International business: +86 0519 8878 2189
Website: https://www.cstheatexchanger.com/
CSTHEATEXCHANGER — plug type fin fan coolers for the chemical industry: every tube reachable, every alloy available.
