Plate and Frame Heat Exchangers, technology
Quality Heat Exchangers 1
Overview FUNKE is your specialist for the development and fabrication of heat exchangers with a heat transfer area from 0,04 m² of up to 2500 m². FUNKE heat-exchangers are used in applications where heating, cooling, ventilation or air-conditioning is required. FUNKE calculates, designs and fabricates the most common types of heat exchangers and as such offers superior expertise between a variety of solutions.
Shell-and-Tube Heat Exchangers
Oil-Air Coolers
Brazed Plate Heat Exchangers
Plate-and-Frame Heat Exchangers
2
Overview FUNKE Products apply to: HEATING COOLING
VAPORIZING CONDENSING of Liquids and Gases
3
Fields of Application Mechanical engineering Compressors Chemistry Food/Pharmaceutics Petrochemistry Paper Industry Hydraulic systems Lubricating oil systems Shipbuilding Heating/Ventilation/Air-conditioning Power plants 4
Overview •
Shell-and-Tube Heat exchangers with pressure ratings of up to 600 bar, 600°C and a diameter of 2 mt.
•
Plate and Frame heat exchangers with Heattransfer areas of 2500m², flowrates of 4,500m³/h and 34 mW (120°C to 30°C, 10°C to 100°C,dp 4bar, 4100m³)
•
Brazed Heat Exchangers upto 4“ connections
•
Aluminium Oil/Air Coolers with a front area of 1,5 m² and 15 hp Motors. 5
Overview FUNKE products are applied in most critical processes:
Double Oil-Cooler at John Crane Ltd. Double Oil-Cooler for Brazilian Oil-Rig
Hydraulic Oil Cooler for the Liebherr Concrete-Mixer Truck
Double Oil-Cooler for Baric Pumps Ltd
Methanol Cooler for DOW Chemicals (ANGUS) 6
Overview
Process Water Cooling at Masterfoods
Double oil cooler at a Siemens Power Plant
Power Plant of 5x12 MW at Volkswagen
FUNKE Heat-Exchangers are installed where it matters 7
Our 3 productlines all contribute considerably to our revenue:
10%
SIP S&T PHE 56%
34%
8
The quality and reliability of our products and performance results in a steady growth.
1999
2009
FUNKE Germany Employees Turnover (Mio. €)
Subsidiaries with Employees International Sales Partners
Employees in the Group
125
260
14
50
0
9
0
170
12
41
ca. 140
ca. 500
9
Growing of Headquarters 1974
1990
2006
2008
10
The FUNKE-Group on the global key-markets in 2009
Supported by a global net of approx. 30 sales and manufacturing partners.
11
A selection of our customers
12
Core Competence Design and calculation strictly adapted to the customers' requirements: Process engineering, thermodynamics, stress analyses, vibration analyses.
13
Core Competencies World-wide standards / design codes: •EU-97/23/EG (Pressure vessels) •AD-data sheet (D) •TEMA (International) •ASME, U-Stamp (USA) •API (American Petr.Industry (USA) •British Standard (GB) •Stoomwezen (NL) •Swedish Pressure Vessel Code •TTK (FIN) •Australian Standard 1210 •OEWBV (A)
•Codes SNCT (F) •ARAB (B) •Raccolta (I) •ABS (USA) •ISCIR (Rumänien) •USSR-Register of Shipping •GOST (GUS) •Lloyd`s Register •Bureau Veritas •Det Norske Veritas •Germanischer Lloyd
14
Core Competencies We have supplied in accordance with the following customer specific specifications: Engineering companies:
Oil companies:
- Badger - C.J.Brown - Fluor-Daniel - Edeleanu - Fluor - Linde - Lummus - Lurgi - R.M. Parsson - Petronas - Davy Powergas - SNAM Progetti
- Agip BP Esso Exxon Shell - Statoil
- Technimont - Technip - Uhde - Foster Wheeler
-
15
Funke is holder of following certificates - AD – Merkblatt HP 0 acc. DIN EN 729-2 - ASME U – Code – Stamp - Bureau Veritas (BV) - Det Norske Veritas (DNV) - DIN EN ISO 9001:2000, BS EN ISO 9001:2000 - Germanischer Lloyd (GL) - GOST (Russia) - TÜV Nord, CE 0045 - RTN (Russia) - SELO (China- Stamp, SQL)
16
Quality is recognized world-wide
certifications
17
Core Competencies Design, manufacturing and supply to world-wide Standards - American Petroleum Institute (API Standard) - ATEX RL 94/9/EG - BASF Standards - Bayer Standard - Heatexchanger Institut (HEI) Standard - Linde Standard - NACE Standard - Shell Dep’s - Krupp – Uhde Standards
18
Funke supplies to customized specifications - Aerzener Maschinenfabrik (D) - Andritz AG (D / A) - Atlas Copco Energas GmbH (D) - Burckhardt Compression (CH) - Caloric Anlagenbau (D) - Chemieanlagenbau Cemnitz (D) - Coperion Werner & Pfleiderer (D) - Coperion Waeschle (D) - Cryostar France S.A. (F) - Dresser Rand GmbH (D) - Gardner Denver Nash (D) - Hermetic Pumpen GmbH (D) - Hydac Technology GmbH (D) - Ingersoll Rand (I) 19
Funke supplies to customized specifications II - Leobersdorfer Maschinenfabrik (A) - Linde AG (D) - Lefa GmbH (D) - MAN Turbo (D / CH) - Neuman & Esser (D) - OMV (A) - Peter Brotherhood, Ltd (GB) - Siemens AG (D) - Thomassen Compress. Syst. (NL) - Uhde Inventa Fischer (D) - Voith Turbo (D) - Voith Paper (D) - Zeppelin GmbH (D) 20
And specifications of engineering companies ABB Lummus Global B. V. ADNOC (Abu Dhabi National Oil Company) * Aker Kvaerner Inc.* Air Liquide Engineering * Air Products Armstron Engineering BASF * BASELL Bayer * Bechtel Corporation Borealis * BP * Celanese Ltd. * Conoco Phillips * Daewoo Engineering Company Davy Process Technology Limited * Dow Chemicals Company * ENPPI (Engineering Petroleum & Process Industries)* Eastman Chemical Company Edeleanu * Exxon Mobil Research and Engineering Company * Flour * Foster Wheeler Energy Limited * Hyundai Engineering Co., Ltd. Hitachi Ltd. Jacobs Engineering Group Inc.* Kellogg Brown & Roots, Inc. Linde AG * Lurgi AG
Mitsubishi Chemical Corperation Mitsui Engineering & Shipbuilding Co., Ltd. MOBIL OIL * OMV * PARS * Parsons Infrastructure and Technology Group Inc. PETROBRAS Petroleo Brasileiro S. A. * Petronas Malaysia * Reliance Engineering Associates (P) Limited Repsol S. A.* SABIC * Samsung Engineering Co., Ltd. Sasol * SAUDI ARAMCO (Saudi Arabian Oil Co.) Sazeh * SembCorp Engineers & Contstructors Pte Ltd. Siemens AG * Simon Carves Sinopec Engineering Incorperation Snamprogetti S. p. A. Stone & Webster Inc. Technicas Reunidas S. A. Terbodin B.V., Consultants & Engineers Technimont S.p.A. * Technip * Total * TOYO Engineering Corporation * Uhde GmbH *
(*registrated as supplier with document or delivered) 21
Calculation with HTRI-Software
22
Manufacturing equipment at Gronau Machinery and Plants:
- laser-plasma cutting equipment - machine tools CNC and conventional - large automatic presses (max.15.000 tons) - vacuum soldering installation - shot blasting equipment - pickling bath - paint shop - rolling equipment for tubesheets
Testing procedure:
- equipment for hydraulic tests - with automatic pressurising up to 200 bar - manual pressurising up to 600 bar - radiographic test - magnetic particle test - ultrasonic test - spectroscopic analysis - high tension test - penetration test - helium test - layer thickness test
23
Shell-and-Tube Heat Exchangers
24
Shell-and-Tube Heat Exchangers
Used materials
carbon steel, stainless steel, titanium, aluminium alloys, copper, copper-nickel, brass, plated steel (more on request)
Linings
plastic coatings rubber linings metallic linings
Performance Transfer Surface Shell Diameter Operating Temperature Operating Pressure
Max. dimensions
1 KW - 30 MW 0,11 m2 - 2000 m2 60 mm - 2000 mm -20°C - 500°C max. 600 bar diameter: length: weight:
2000 mm 10 m 20 t 25
Shell-and-Tube Heat Exchangers
Standard units
Customized solutions
TDW, BCF, CCF, SSCF, CCFA
CP, A 100, C 100…C 500, WRA 200
Preselected geometries enable:
Strict application of customers requirements:
- Short delivery times - Attractive price performance ratio - Guaranty of years of approved series
- Company specifications - Standards of engineering companies - International design standards
26
Customised solution – C300 (BEU) with operating pressure 200bar
27
Customised solution – C300 with operating pressure 200bar
28
Shell-and-Tube Heat Exchangers – fabrication examples
29
Shell-and-Tube Heat Exchangers – fabrication examples
30
Tube to tube sheet (two layers) welding by hand
31
Plate Heat Exchangers
32
Plate-and-Frame Heat Exchangers, introduction FUNKE heat transfer plates were developed to create high heat transfer coefficients. This results in a superior economical and technical adaption to the respective application requirements.
Single-pass and multi-pass plate heat exchangers - heat exchange surfaces/plate
0,04 – 3,00 m²
- max. design pressure
25 bar
- max. design temperature
195° C
Also available as safety plate heat exchangers
33
Plate and Frame Heat Exchangers, introduction Standard features Our plates are provided with double gaskets at the inlet and outlet which prevent mixing of the two media. If designed as safety heat exchanger, double plates are provided with a special sealing system
Plate material standard: stainless steel 1.4301/AISI 304 1.4401/AISI 316 (L) optionally: 1.4539, 254 SMO, titanium, NI200
Gasket materials NBR (nitrile-rubber), EPDM (ethylene-propylene-rubber) Viton (fluorine-rubber) -other materials on request.
34
Plate and Frame Heat Exchangers, introduction
35
Plate and Frame Heat Exchangers, technology
1.
fixed plate
2.
pressure plate
3.
support
4.
carying beam
5.
guiding bar
6.
carrier roller
7.
tightening bolt
8.
fixing screws
9.
rubber liner
10. gaskets 11. heat transfer plates
36
Plate and Frame Heat Exchangers, technology
Single-pass
Two-pass Three-pass Position of single-pass und multi-pass connections 37
Plate and Frame Heat Exchangers, technology
FUNKE-Offset-Wave
standard Sinus-Wave
The Funke specific „Off-set“ wave and conventional wave 38
Plate and Frame Heat Exchangers, technology Semi welded PHE – FPG series Advantages: - compact, low weight - easy maintenance - minor fouling - rapid and cost effective assembly - high heat transfer rate - high corrosion resistance
39
Final PHE-assembly
40
Funke Instrumentation for PHE
• • • • • •
5 Presses for plate manufacturing 10,000 m², assembly and warehouse In situ hydronic testing Automated frame blast and paint line High speed multihead CNC Qualified approved welding
41
Plate Heat Exchangers Embossing of quality plates with 6000 tons clamping force Production unit for the new developed plate program, comprising 14 sizes and four different corrugations, enabling nine special flow gaps.
42
Plate Heat Exchangers Fully automated press line with a clamping force of 15000 tons
43
Production hall for large PHE units with 5 cranes and automated sand blasting line.
Sand Blasting Line
44
Fully automated coating and curing line
coating
complete line curing
45
Plate Heat Exchangers Final assembly hall small and medium sized units
46
Large versus small
47
Brazed Plate Heat Exchangers
48
Brazed Plate Heat Exchangers – Type GPLK
49
Brazed Plate Heat Exchangers – Type GPLK - Design
GPLK are made of corrugated stainless steel plates. The plates are assembled in a 180° angle to each other. Depending on the requirements of the application, the plates are vacuum brazed using either copper or nickel (NPLK). This results in separate flow gaps with counter-flow of the media involved in the heat exchange (standard
50
Application conditions Operating pressure and operating temperature •
The BPHE GPLK is designed for a working pressure up to 30 bar / 435 psi at max. 200°C / 392 °F.
•
In special designs, GPLK can work with up to 45 bar / 653 psi at 150°C / 302°F.
•
The NPLK (nickel brazed) can be operated at 10 bar / 145 psi at 150°C / 302°F.
•
In special designs, NPLK can be operated at up to 30 bar / 435 psi at 150°C / 302°F.
Material:
For the plates stainless steel AINSI 316 / 1.4401 is used.
Performance:
2.0 to 6 000 kW / 6824 Btu to 20.5 MBtu 51
Applications
For universal applications with media of low viscosity GPLK has a well balanced ratio of high heat transfer rates with low pressure losses. The thermodynamic optimized corrugation of the embossed plates allows for high turbulent flow even at low volumetric flow rates. This allows for efficient use of the heat exchange area available and leads to a perfectly optimized heat transfer. The high turbulent flow also results in an efficient self-cleaning effect, which greatly reduces maintenance and time-out. GPLK have a compact design and are used for high pressures and temperatures. 52
Applications Typical applications for brazed plate heat exchangers GPLK are heating, cooling, condensing • System separation • Heat extraction and heat recovery in domestic and process technology • Refrigeration engineering • Mechanical engineering • Oil cooling • Hot water/Process water • Heating engineering (solar thermal systems, central heating, floor heating) • Evaporation / Condensing in cooling systems • Air drying • Hydraulic oil cooling • Cooling of machines and motors • Mold machine temperature control • Economizing 53
Media Copper brazed plate heat exchangers GPLK are mainly used for media such as • Oil and oil containing fluids • Glycol mixtures • Alcohols • Refrigerants • Gas/Air • Water • many more (according to media properties and its viscosity)
54
Information Copper brazed plate heat exchangers GPLK should not be used for the following media: • Seawater • Ammonia • Deionates • Silicone oils • high chloride media For applications with • Ammonia • Deionates • Silicone oils the nickel brazed plate heat exchangers NPLK are recommended. 55
56
Brazed PHE´s – type TPL With special turbo-plates in the flow gaps, especially developed for the requirements in plant and mechanical engineering .
Application • Hydraulic- and Motor-oil-Cooling • Air cooling • universally applicable with diverse media
57
Plattenwärmeaustauscher Brazed PHE´s – type TPL Technical Data heat transfer surface / plate operating pressure operating temperature Material plates solder
0,035 – 0,286 m² max. 30 bar max. -100 °C bis +200 °C
1.4401 / AISI 316 copper 99,9 %
Small design sizes are possible due to high heat transfer rates at higher viscosities. This compact design means it needs lesss space compared to conventional brazed PHE. This system only is available from FUNKE!
58
Vacuumovens (brazed PHEs)
59
SIP – Standard Industry Products
60
Oil/Air Cooling Units
Electrical Oil Pre-heaters
61
Oil/Air Cooling Units – Standards 13 sizes with cooling capacity up to 2,5 kw/K Application Cooling of oil, emulsions and fluids (of low flammability) with air – especially for plant- and mechanical engineering as well as for mobile hydraulic systems.
Technical Data frontal area of core max. operating pressure operating temperatures oil/emulsion
0,05 – 1,50 m² 16 bar 120 / 90°C
max.
Fan drive Three-phase motor, direct-current motor, or hydraulic motor; power related controlled
62
Oil/Air Cooling Units – Standards New series Okan III Innovative construction raises customer‘s benefit Thermodynamically optimised: - oil/air-lamellae - oil in- and outlet channels
- depth of cooler block reduced to 64 mm - optimised, selfsupporting fan bonnet 63
Oil/Air Cooling Units – Standards The new series Okan III – Less Euro per kW cooling capacity! Up to 18% more cooling capacity! (with the same inflow area as before) Therefore especially suited for mobile hydraulics and compact mechanical engineering Fa. Putzmeister, concrete mix facility
Fa. Raster Zeulenroda, producer of presses
Fa. Liebherr, concrete mixer
64
Applications for mechanical engineering and mobile hydraulics
65
Electrical Oil Pre-heaters
Available in 11 sizes for use in- and outdoors
Application Heating of oil, emulsions and fluids (of low flammability) using electric current. Especially for machines and plants outdoors.
66
Electrical Oil Pre-heaters
Technical Data Heat transfer rate max. operating pressure < 6kW / > 9kW max. final temperature
3 -100 kW 25 / 16 bar 80°C
Design/Material Heating element: with bent heating rods (like a U-tube bundle) shell: steel, standard thermostat
67
Thank you for your attention!
68
Overview FUNKE is your specialist for the development and fabrication of heat exchangers with a heat transfer area from 0,04 m² of up to 2500 m². FUNKE heat-exchangers are used in applications where heating, cooling, ventilation or air-conditioning is required. FUNKE calculates, designs and fabricates the most common types of heat exchangers and as such offers superior expertise between a variety of solutions.
Shell-and-Tube Heat Exchangers
Oil-Air Coolers
Brazed Plate Heat Exchangers
Plate-and-Frame Heat Exchangers
2
Overview FUNKE Products apply to: HEATING COOLING
VAPORIZING CONDENSING of Liquids and Gases
3
Fields of Application Mechanical engineering Compressors Chemistry Food/Pharmaceutics Petrochemistry Paper Industry Hydraulic systems Lubricating oil systems Shipbuilding Heating/Ventilation/Air-conditioning Power plants 4
Overview •
Shell-and-Tube Heat exchangers with pressure ratings of up to 600 bar, 600°C and a diameter of 2 mt.
•
Plate and Frame heat exchangers with Heattransfer areas of 2500m², flowrates of 4,500m³/h and 34 mW (120°C to 30°C, 10°C to 100°C,dp 4bar, 4100m³)
•
Brazed Heat Exchangers upto 4“ connections
•
Aluminium Oil/Air Coolers with a front area of 1,5 m² and 15 hp Motors. 5
Overview FUNKE products are applied in most critical processes:
Double Oil-Cooler at John Crane Ltd. Double Oil-Cooler for Brazilian Oil-Rig
Hydraulic Oil Cooler for the Liebherr Concrete-Mixer Truck
Double Oil-Cooler for Baric Pumps Ltd
Methanol Cooler for DOW Chemicals (ANGUS) 6
Overview
Process Water Cooling at Masterfoods
Double oil cooler at a Siemens Power Plant
Power Plant of 5x12 MW at Volkswagen
FUNKE Heat-Exchangers are installed where it matters 7
Our 3 productlines all contribute considerably to our revenue:
10%
SIP S&T PHE 56%
34%
8
The quality and reliability of our products and performance results in a steady growth.
1999
2009
FUNKE Germany Employees Turnover (Mio. €)
Subsidiaries with Employees International Sales Partners
Employees in the Group
125
260
14
50
0
9
0
170
12
41
ca. 140
ca. 500
9
Growing of Headquarters 1974
1990
2006
2008
10
The FUNKE-Group on the global key-markets in 2009
Supported by a global net of approx. 30 sales and manufacturing partners.
11
A selection of our customers
12
Core Competence Design and calculation strictly adapted to the customers' requirements: Process engineering, thermodynamics, stress analyses, vibration analyses.
13
Core Competencies World-wide standards / design codes: •EU-97/23/EG (Pressure vessels) •AD-data sheet (D) •TEMA (International) •ASME, U-Stamp (USA) •API (American Petr.Industry (USA) •British Standard (GB) •Stoomwezen (NL) •Swedish Pressure Vessel Code •TTK (FIN) •Australian Standard 1210 •OEWBV (A)
•Codes SNCT (F) •ARAB (B) •Raccolta (I) •ABS (USA) •ISCIR (Rumänien) •USSR-Register of Shipping •GOST (GUS) •Lloyd`s Register •Bureau Veritas •Det Norske Veritas •Germanischer Lloyd
14
Core Competencies We have supplied in accordance with the following customer specific specifications: Engineering companies:
Oil companies:
- Badger - C.J.Brown - Fluor-Daniel - Edeleanu - Fluor - Linde - Lummus - Lurgi - R.M. Parsson - Petronas - Davy Powergas - SNAM Progetti
- Agip BP Esso Exxon Shell - Statoil
- Technimont - Technip - Uhde - Foster Wheeler
-
15
Funke is holder of following certificates - AD – Merkblatt HP 0 acc. DIN EN 729-2 - ASME U – Code – Stamp - Bureau Veritas (BV) - Det Norske Veritas (DNV) - DIN EN ISO 9001:2000, BS EN ISO 9001:2000 - Germanischer Lloyd (GL) - GOST (Russia) - TÜV Nord, CE 0045 - RTN (Russia) - SELO (China- Stamp, SQL)
16
Quality is recognized world-wide
certifications
17
Core Competencies Design, manufacturing and supply to world-wide Standards - American Petroleum Institute (API Standard) - ATEX RL 94/9/EG - BASF Standards - Bayer Standard - Heatexchanger Institut (HEI) Standard - Linde Standard - NACE Standard - Shell Dep’s - Krupp – Uhde Standards
18
Funke supplies to customized specifications - Aerzener Maschinenfabrik (D) - Andritz AG (D / A) - Atlas Copco Energas GmbH (D) - Burckhardt Compression (CH) - Caloric Anlagenbau (D) - Chemieanlagenbau Cemnitz (D) - Coperion Werner & Pfleiderer (D) - Coperion Waeschle (D) - Cryostar France S.A. (F) - Dresser Rand GmbH (D) - Gardner Denver Nash (D) - Hermetic Pumpen GmbH (D) - Hydac Technology GmbH (D) - Ingersoll Rand (I) 19
Funke supplies to customized specifications II - Leobersdorfer Maschinenfabrik (A) - Linde AG (D) - Lefa GmbH (D) - MAN Turbo (D / CH) - Neuman & Esser (D) - OMV (A) - Peter Brotherhood, Ltd (GB) - Siemens AG (D) - Thomassen Compress. Syst. (NL) - Uhde Inventa Fischer (D) - Voith Turbo (D) - Voith Paper (D) - Zeppelin GmbH (D) 20
And specifications of engineering companies ABB Lummus Global B. V. ADNOC (Abu Dhabi National Oil Company) * Aker Kvaerner Inc.* Air Liquide Engineering * Air Products Armstron Engineering BASF * BASELL Bayer * Bechtel Corporation Borealis * BP * Celanese Ltd. * Conoco Phillips * Daewoo Engineering Company Davy Process Technology Limited * Dow Chemicals Company * ENPPI (Engineering Petroleum & Process Industries)* Eastman Chemical Company Edeleanu * Exxon Mobil Research and Engineering Company * Flour * Foster Wheeler Energy Limited * Hyundai Engineering Co., Ltd. Hitachi Ltd. Jacobs Engineering Group Inc.* Kellogg Brown & Roots, Inc. Linde AG * Lurgi AG
Mitsubishi Chemical Corperation Mitsui Engineering & Shipbuilding Co., Ltd. MOBIL OIL * OMV * PARS * Parsons Infrastructure and Technology Group Inc. PETROBRAS Petroleo Brasileiro S. A. * Petronas Malaysia * Reliance Engineering Associates (P) Limited Repsol S. A.* SABIC * Samsung Engineering Co., Ltd. Sasol * SAUDI ARAMCO (Saudi Arabian Oil Co.) Sazeh * SembCorp Engineers & Contstructors Pte Ltd. Siemens AG * Simon Carves Sinopec Engineering Incorperation Snamprogetti S. p. A. Stone & Webster Inc. Technicas Reunidas S. A. Terbodin B.V., Consultants & Engineers Technimont S.p.A. * Technip * Total * TOYO Engineering Corporation * Uhde GmbH *
(*registrated as supplier with document or delivered) 21
Calculation with HTRI-Software
22
Manufacturing equipment at Gronau Machinery and Plants:
- laser-plasma cutting equipment - machine tools CNC and conventional - large automatic presses (max.15.000 tons) - vacuum soldering installation - shot blasting equipment - pickling bath - paint shop - rolling equipment for tubesheets
Testing procedure:
- equipment for hydraulic tests - with automatic pressurising up to 200 bar - manual pressurising up to 600 bar - radiographic test - magnetic particle test - ultrasonic test - spectroscopic analysis - high tension test - penetration test - helium test - layer thickness test
23
Shell-and-Tube Heat Exchangers
24
Shell-and-Tube Heat Exchangers
Used materials
carbon steel, stainless steel, titanium, aluminium alloys, copper, copper-nickel, brass, plated steel (more on request)
Linings
plastic coatings rubber linings metallic linings
Performance Transfer Surface Shell Diameter Operating Temperature Operating Pressure
Max. dimensions
1 KW - 30 MW 0,11 m2 - 2000 m2 60 mm - 2000 mm -20°C - 500°C max. 600 bar diameter: length: weight:
2000 mm 10 m 20 t 25
Shell-and-Tube Heat Exchangers
Standard units
Customized solutions
TDW, BCF, CCF, SSCF, CCFA
CP, A 100, C 100…C 500, WRA 200
Preselected geometries enable:
Strict application of customers requirements:
- Short delivery times - Attractive price performance ratio - Guaranty of years of approved series
- Company specifications - Standards of engineering companies - International design standards
26
Customised solution – C300 (BEU) with operating pressure 200bar
27
Customised solution – C300 with operating pressure 200bar
28
Shell-and-Tube Heat Exchangers – fabrication examples
29
Shell-and-Tube Heat Exchangers – fabrication examples
30
Tube to tube sheet (two layers) welding by hand
31
Plate Heat Exchangers
32
Plate-and-Frame Heat Exchangers, introduction FUNKE heat transfer plates were developed to create high heat transfer coefficients. This results in a superior economical and technical adaption to the respective application requirements.
Single-pass and multi-pass plate heat exchangers - heat exchange surfaces/plate
0,04 – 3,00 m²
- max. design pressure
25 bar
- max. design temperature
195° C
Also available as safety plate heat exchangers
33
Plate and Frame Heat Exchangers, introduction Standard features Our plates are provided with double gaskets at the inlet and outlet which prevent mixing of the two media. If designed as safety heat exchanger, double plates are provided with a special sealing system
Plate material standard: stainless steel 1.4301/AISI 304 1.4401/AISI 316 (L) optionally: 1.4539, 254 SMO, titanium, NI200
Gasket materials NBR (nitrile-rubber), EPDM (ethylene-propylene-rubber) Viton (fluorine-rubber) -other materials on request.
34
Plate and Frame Heat Exchangers, introduction
35
Plate and Frame Heat Exchangers, technology
1.
fixed plate
2.
pressure plate
3.
support
4.
carying beam
5.
guiding bar
6.
carrier roller
7.
tightening bolt
8.
fixing screws
9.
rubber liner
10. gaskets 11. heat transfer plates
36
Plate and Frame Heat Exchangers, technology
Single-pass
Two-pass Three-pass Position of single-pass und multi-pass connections 37
Plate and Frame Heat Exchangers, technology
FUNKE-Offset-Wave
standard Sinus-Wave
The Funke specific „Off-set“ wave and conventional wave 38
Plate and Frame Heat Exchangers, technology Semi welded PHE – FPG series Advantages: - compact, low weight - easy maintenance - minor fouling - rapid and cost effective assembly - high heat transfer rate - high corrosion resistance
39
Final PHE-assembly
40
Funke Instrumentation for PHE
• • • • • •
5 Presses for plate manufacturing 10,000 m², assembly and warehouse In situ hydronic testing Automated frame blast and paint line High speed multihead CNC Qualified approved welding
41
Plate Heat Exchangers Embossing of quality plates with 6000 tons clamping force Production unit for the new developed plate program, comprising 14 sizes and four different corrugations, enabling nine special flow gaps.
42
Plate Heat Exchangers Fully automated press line with a clamping force of 15000 tons
43
Production hall for large PHE units with 5 cranes and automated sand blasting line.
Sand Blasting Line
44
Fully automated coating and curing line
coating
complete line curing
45
Plate Heat Exchangers Final assembly hall small and medium sized units
46
Large versus small
47
Brazed Plate Heat Exchangers
48
Brazed Plate Heat Exchangers – Type GPLK
49
Brazed Plate Heat Exchangers – Type GPLK - Design
GPLK are made of corrugated stainless steel plates. The plates are assembled in a 180° angle to each other. Depending on the requirements of the application, the plates are vacuum brazed using either copper or nickel (NPLK). This results in separate flow gaps with counter-flow of the media involved in the heat exchange (standard
50
Application conditions Operating pressure and operating temperature •
The BPHE GPLK is designed for a working pressure up to 30 bar / 435 psi at max. 200°C / 392 °F.
•
In special designs, GPLK can work with up to 45 bar / 653 psi at 150°C / 302°F.
•
The NPLK (nickel brazed) can be operated at 10 bar / 145 psi at 150°C / 302°F.
•
In special designs, NPLK can be operated at up to 30 bar / 435 psi at 150°C / 302°F.
Material:
For the plates stainless steel AINSI 316 / 1.4401 is used.
Performance:
2.0 to 6 000 kW / 6824 Btu to 20.5 MBtu 51
Applications
For universal applications with media of low viscosity GPLK has a well balanced ratio of high heat transfer rates with low pressure losses. The thermodynamic optimized corrugation of the embossed plates allows for high turbulent flow even at low volumetric flow rates. This allows for efficient use of the heat exchange area available and leads to a perfectly optimized heat transfer. The high turbulent flow also results in an efficient self-cleaning effect, which greatly reduces maintenance and time-out. GPLK have a compact design and are used for high pressures and temperatures. 52
Applications Typical applications for brazed plate heat exchangers GPLK are heating, cooling, condensing • System separation • Heat extraction and heat recovery in domestic and process technology • Refrigeration engineering • Mechanical engineering • Oil cooling • Hot water/Process water • Heating engineering (solar thermal systems, central heating, floor heating) • Evaporation / Condensing in cooling systems • Air drying • Hydraulic oil cooling • Cooling of machines and motors • Mold machine temperature control • Economizing 53
Media Copper brazed plate heat exchangers GPLK are mainly used for media such as • Oil and oil containing fluids • Glycol mixtures • Alcohols • Refrigerants • Gas/Air • Water • many more (according to media properties and its viscosity)
54
Information Copper brazed plate heat exchangers GPLK should not be used for the following media: • Seawater • Ammonia • Deionates • Silicone oils • high chloride media For applications with • Ammonia • Deionates • Silicone oils the nickel brazed plate heat exchangers NPLK are recommended. 55
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Brazed PHE´s – type TPL With special turbo-plates in the flow gaps, especially developed for the requirements in plant and mechanical engineering .
Application • Hydraulic- and Motor-oil-Cooling • Air cooling • universally applicable with diverse media
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Plattenwärmeaustauscher Brazed PHE´s – type TPL Technical Data heat transfer surface / plate operating pressure operating temperature Material plates solder
0,035 – 0,286 m² max. 30 bar max. -100 °C bis +200 °C
1.4401 / AISI 316 copper 99,9 %
Small design sizes are possible due to high heat transfer rates at higher viscosities. This compact design means it needs lesss space compared to conventional brazed PHE. This system only is available from FUNKE!
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Vacuumovens (brazed PHEs)
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SIP – Standard Industry Products
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Oil/Air Cooling Units
Electrical Oil Pre-heaters
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Oil/Air Cooling Units – Standards 13 sizes with cooling capacity up to 2,5 kw/K Application Cooling of oil, emulsions and fluids (of low flammability) with air – especially for plant- and mechanical engineering as well as for mobile hydraulic systems.
Technical Data frontal area of core max. operating pressure operating temperatures oil/emulsion
0,05 – 1,50 m² 16 bar 120 / 90°C
max.
Fan drive Three-phase motor, direct-current motor, or hydraulic motor; power related controlled
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Oil/Air Cooling Units – Standards New series Okan III Innovative construction raises customer‘s benefit Thermodynamically optimised: - oil/air-lamellae - oil in- and outlet channels
- depth of cooler block reduced to 64 mm - optimised, selfsupporting fan bonnet 63
Oil/Air Cooling Units – Standards The new series Okan III – Less Euro per kW cooling capacity! Up to 18% more cooling capacity! (with the same inflow area as before) Therefore especially suited for mobile hydraulics and compact mechanical engineering Fa. Putzmeister, concrete mix facility
Fa. Raster Zeulenroda, producer of presses
Fa. Liebherr, concrete mixer
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Applications for mechanical engineering and mobile hydraulics
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Electrical Oil Pre-heaters
Available in 11 sizes for use in- and outdoors
Application Heating of oil, emulsions and fluids (of low flammability) using electric current. Especially for machines and plants outdoors.
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Electrical Oil Pre-heaters
Technical Data Heat transfer rate max. operating pressure < 6kW / > 9kW max. final temperature
3 -100 kW 25 / 16 bar 80°C
Design/Material Heating element: with bent heating rods (like a U-tube bundle) shell: steel, standard thermostat
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Thank you for your attention!
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