High-pressure water-gas shell and tube heat exchangers

These high‑pressure shell and tube water–gas heat exchangers are designed to handle pressures up to 1000 bar, ensuring safe and efficient cooling of hydrogen and other gases under extreme operating conditions.

They are the ideal solution when you need reliable high‑pressure heat exchangers, customized to real process conditions and compliant with major international standards.

High‑pressure water–gas heat exchangers up to 1000 bar

Sesino high‑pressure shell and tube water–gas heat exchangers are developed for applications where gases such as hydrogen or other technical gases must be cooled in a controlled way while maintaining maximum safety. The design allows operation at pressures up to 1000 bar, making these heat exchangers suitable for gas compression plants, storage systems, test benches and advanced process installations.

The use of high‑quality materials and dedicated construction solutions makes it possible to withstand high mechanical and thermal loads, minimizing the risk of deformation and failure over time. Each heat exchanger is sized according to the actual operating parameters (gas flow rate, water flow rate, temperatures, design pressure), in order to ensure optimized thermal performance.

Design in accordance with EN, ASME and PED certification

High‑pressure shell and tube water–gas heat exchangers are designed in accordance with major international technical standards such as EN and ASME. These references ensure that mechanical calculations, wall thicknesses, materials and verification criteria comply with globally recognized standards for pressure equipment.

All heat exchangers are certified according to the European Pressure Equipment Directive (PED), confirming full compliance with the safety and reliability requirements for pressure equipment. This level of certification provides OEMs and end users with additional assurance in terms of quality, traceability and suitability for use in regulated plants.

Advanced mechanical design with FEM analysis

The mechanical design of high‑pressure heat exchangers requires accurate analysis of stresses and deformations that may occur in service, especially in the presence of very high pressures. For this reason, Sesino uses advanced software based on the Finite Element Method (FEM), which makes it possible to simulate the structural behavior of the component under different operating conditions.

These analyses evaluate the effects of pressure, temperature, vibration and load cycles, in order to define the most suitable geometries, thicknesses, reinforcements and supports. The result is a heat exchanger designed with a high safety margin, capable of operating reliably even in critical, high‑risk scenarios.

Thermal design for energy efficiency

In addition to mechanical design, thermal sizing is essential to ensure truly efficient high‑pressure water–gas heat exchangers. The design takes into account heat transfer coefficients, fluid velocities, pressure drops and process conditions, in order to achieve the best balance between thermal duty, footprint and energy consumption of auxiliary circuits.

Proper thermal design keeps gas and water temperatures within the desired ranges, improving process stability and extending the service life of downstream components. This approach is particularly important in hydrogen and high‑value gas applications, where cooling efficiency directly impacts performance, safety and operating costs.

Custom solutions for critical applications

Sesino high‑pressure shell and tube water–gas heat exchangers are developed as custom solutions: each project starts from a detailed discussion with the customer on process parameters and plant constraints. Diameters, lengths, tube bundle configuration, materials and connections can be customized to integrate seamlessly with skids, compression lines or test systems.

This ability to deliver tailor‑made designs, combined with long‑standing experience in heat exchangers and compliance with EN, ASME and PED, makes Sesino a reliable partner for high‑pressure water–gas heat exchangers dedicated to critical, high‑tech applications.