Process Technology - SGL Group
DIABON
®
Shell & Tube Heat Exchangers
Process Technology
Broad Base. Best Solutions.
C
Carbon is Future. SGL Group – The Carbon Company.
Process Technology The Business Unit Process Technology is a premium technology provider for chemical and related industry process systems, equipment and after sales services. Our focus are high-tech materials for demanding chemical applications. With smart and sustainable solutions for an increasing number of industry we give proof of our strong innovation culture. Broad Base
Carbon has unique properties. It is indispensable in the production of steel, aluminum and solar energy systems. Carbon increases the performance of wind turbines and reduces the weight of airplanes, cars and sports equipment.
Carbon substitutes other materials and contributes to a reduction in CO2 emissions.
SGL Group is one of the leading manufacturers of carbonbased products and has the broadest product and technology portfolio, a global sales network and state-of-the-art production sites in Europe, North America and Asia.
Our range of materials: E graphite E SiC E PTFE E reactive metals E steel Our range of services: E process design E engineering E project management E production and assembly E commissioning E after sales services. With 9 manufacturing sites in 8 countries and a continually growing worldwide sales and service network, we are always close to our customers.
Reliability. Efficiency. Sustainability.
Powered by our Broad Base of competencies, products and services, we offer Best Solutions to our customers. For the Business Unit Process Technology, those solutions are characterized by reliability, efficiency and sustainability. Best Solutions E
Reliability
In a business that strongly depends on reliability we never compromise on quality and safety. Our products deliver dependable results; our services are fast and competent. The long-standing loyalty of our customers proves that we keep our promises – on-time, on-spec, on-budget.
E
Efficiency
Tailor made, innovative solutions and an integrated approach on chemistry, materials, technology and design, ensure outstanding efficiency and improved customer value: higher yields, lower operating cost, lower service and maintenance cost, longer service intervals and less downtimes, and the extended product lifetime sum up to significant lower total cost of ownership and to a higher return on investment for our customers.
E
Sustainability
In all industries that deal with resource- and energy- consuming processes sustainability is of crucial importance. Based on innovative solutions, more than 60 % of our sales contribute to the saving of resources and energy and to the reduction of greenhouse gases.
Contents DIABON Shell and Tube Heat Exchangers
4
Carbon Fiber-Reinforced DIABON Components
9
Technical Information
6
Multi-Tube Bundle Heat Exchangers
10
Design Options
7
Quality Management and After Sales Service
14
Properties and Applications
8
Process Technology – Our Products
15 3
DIABON® Shell and Tube Heat Exchangers at a Glance
Advantages of our shell and tube heat exchangers in DIABON process equipment graphite 씰
High efficiency
씰
Large heat exchange areas possible (over 2,000 m2)
씰
Price advantage for medium and large heat exchange areas
씰
High heat transfer capacity
씰
Abrasive wear protection minimizes erosion
씰
Low pressure drops
씰
All seals are external for ease of inspection
씰
Ease of repair
씰
Excellent drainage of condensate in steam applications
씰
Complete drainage of product and service side
씰
Wide range of material combinations for shell and header (FRP, rubber-lined steel, enamel, steel/PTFE) On this basis, DIABON shell and tube heat exchangers are used as heaters, coolers, condensers and falling-film evaporators and absorbers, especially in the treatment of:
4
씰
Hydrochloric acid
씰
Sulfuric acid
씰
Hydrofluoric acid
씰
Phosphoric acid
씰
Chlorinated hydrocarbons
씰
Organic and inorganic media
씰
Waste acids
씰
Combustion gases
DIABON® tube bundle
Corrosion resistance The basic materials for our shell and tube heat exchangers, DIABON NS1 and DIABON NS2 process equipment graphite, are resistant to virtually all organic and inorganic media. For heat exchange between two corrosive media, we supply special designs
Pressures and
on request with a suitable anti-
temperatures
corrosion lining or coating of the
A maximum permissible material
steel shell (rubber, PTFE, enamel,
temperature of 200 °C has been
etc.)
certified for DIABON NS1 and NS2 tubes by the South German
O-ring seal
Technical Supervisory Board
Our long experience has shown
(TÜV). Moreover, strength certifi-
that O-ring seals offer substantial
cation up to G32-0-200 (32
advantages over stuffing box
N/mm2 with 0 ‰ strength de-
packings:
crease up to 200 °C) can be given for the tubes. The standard design
Extremely low coefficients
allows for optional pressures of up
of friction
to 6 bar gauge for both service
씰
Low sealing forces required
and product sides. Special designs
씰
Universal resistance of
for higher pressures up to 16 bar
O-ring seals
gauge on the service side and up
씰
Ease of adjustment
to 12 bar gauge on the product
씰
Ease of replacement
side can be supplied on request.
씰
Long service life
씰
Low servicing cost
씰
Shell and tube heat exchanger with DIABON® NS1 tubes
Terms of reference Training
To be able to offer the same standards of quality
Servicing of our DIABON shell
anywhere in the world, our shell and tube heat
and tube heat exchangers is sim-
exchangers are designed to meet the following in-
ple and can be carried out on site
ternational standards:
by your own personnel. On re-
AD specification
Germany
quest, we put your technical per-
APAVE
France
sonnel through our training cour-
ASME
USA
ses. This enables repairs and
BS
United Kingdom
overhauls to be carried out even
Chinese Requirements
China
more quickly and economically.
ISPESL
Italy
In addition, our specialists are
JIS
Japan
always at your service – whatever
Stoomwezen
Holland
your problem. We also supply
SVTI
Switzerland
spare parts quickly and easily.
UDT
Poland 5
Technical Information DIABON® Shell and Tube Heat Exchangers DIABON shell and tube heat exchangers are constructed from the following components: 씰
Two tube sheets with or without carbon fiber reinforcement – one fixed and the other floating, relative to the shell
씰
Baffle cages with DIABON baffles
씰
Headers made from DIABON NS1/ NS2 graphite or other materials. Depending on the application, the header in contact with the floating tube sheet is braced against the tube sheet by a dual clamping tie rod system
씰
Shell made from steel, with anti-corrosion lining on request, or from other materials
씰
Partition plates in the headers allow several passes through the tube bundle, when required in the
DIABON® tube sheet with wear sleeves
process
Technical specification
Tubes
Material
Others
6
d1 [mm]
d2 [mm]
t [mm]
Tube type 0
15
26
33
Tube type 1
22
32
39
Tube type 2
25
37
44
Tube type 3
37
50
57
Tube length
1 bis 9 meter (standard)
Tube bundles and headers
DIABON NS1 / NS2 / HF1 / HF2
Shell and flanges
DIN standard steel, P 265 GH
Acceptance inspection
CE, TÜV and other authorized test institutes
Design pressure
-1 / 6 bar gauge (standard)
Design temperature
180 °C (standard)
Options for Various Designs
Top header with laterial nozzle and removable top cover
Falling-film DIABON® header
Cooled DIABON® header for high gas inlet temperatures
Standard steel shell
Steel shell with steam inlet distributor
Steel shell with conical steam inlet nozzle
Conical steel bottom header with corrosion-resistant lining
Extended DIABON® bottom header for separating gases and liquids
Steel shell with 360° steam distributor
7
Properties and Applications of DIABON® Graphite Brands
Micrograph of DIABON® NS1
Micrograph of DIABON® NS2
DIABON® NS1
DIABON® NS2
Properties
Properties
Standard material for a wide
Graphite material for superior
range of applications in chemi-
demands. This graphite brand
cal technology, environmental
is distinguished by its lower pore
protection and similar industries.
volume combined with reduced
DIABON NS1 is an impervious,
pore size and greater mechani-
synthetic resin-impregnated pro-
cal strength. The maximum per-
cess equipment graphite with a
missible material temperature is
highly homogeneous material
200 °C.
structure. This results in excellent corrosion resistance and thermal
Applications
stability. The maximum permissi-
DIABON NS2 is suitable for
ble material temperature under
heat exchanger tube sheets and
permanent load is 200 °C.
tubes, if these are subjected to elevated mechanical stress
Applications
and/or extremely corrosive
Standard material for the pro-
media and solvents.
duction of heat exchangers and for all pressure- and temperaturestressed components.
8
Carbon Fiber-Reinforced Components for Increased Safety In developing the carbon fiber reinforcement of components (DIABON HF), SGL Group has found a way to increase the operational reliability of DIABON graphite components appreciably and expand their range of application under high-stress conditions. The fiber reinforcement is used for tube sheets, headers and column sections and especially for tubes.
Properties of graphite tubes with carbon fiber reinforcement 씰
Carbon fiber-reinforced tube sheet
Increased bursting pressure
The tube becomes more resistant to steam hammer and service pressures above the permitted limit, its bursting pressure at room temperature being raised to 130 to 140 % of that of a non-reinforced tube, depending on the tube dimensions. 씰
Resistance of a cracked tube to leakage
Should a longitudinal crack occur in a DIABON HF tube as a result of overstressing, the tube will not allow any major leakage up to a differential pressure of some 2 to 5 bar. In all instances, the reinforcement prevents any spalling from the tube and
DIABON® HF tubes
a consequent escape of product in large quantities. Usually the equipment can continue in operation without interruption until the next planned shutdown.
Comparison of tube properties Unit
DIABON HF1
N/mm2
> 52
> 52
Bursting pressure at 20 °C
bar
110
80
Bursting pressure at 50 °C
bar
120
75
Resistance to pressure surges
relative %
250
100
Leakage pressure2) 5)
bar gauge
2-5
0
Thermal conductivity
W/(K·m)
50 3)
> 60
°C
200
200
Flexural strength, longitudinal
Maximum material temperature4)
1)
DIABON NS1 1) DIABON® tube reinforced with SIGRAFIL® HF fibers 2) on a cracked tube under internal pressure from water 3) effective value, calculated from the tube’s heat transfer capacity 4) depends on service medium 5) pressure up to which no appreciable loss of medium occurs from the cracked tube under brief pressure surges
9
Multi-Tube Bundle Heat Exchangers made from DIABON® Process Equipment Graphite
A new generation of heat exchangers Unlike conventional products, our DIABON multitube bundle heat exchangers feature an exchange surface area distributed over several identical small tube bundles instead of a single large bundle. Separate graphite tube bundles are incorporated in a shell made from carbon steel. One or more of these elements can be integrated in a frame of support plates. The tube bundles are sealed against
DIABON® bundles of a multi-tube bundle heat exchanger
both the steel flanges and headers with O-ring seals made from a high-quality sealing material.
The special design of multi-tube bundle heat exchangers allows single or multiple counter-current flow, or several different applications in a single
The special design features make for a whole
unit, e.g. in
range of advantages:
씰
condensation
Technical
씰
residual gas and condensate sub-cooling
씰
using different cooling media for the purpose
10
High performance combined with small heat exchange area
씰
Savings in heat exchange area of up to 40 %
씰
Modular design
씰
Multi-mode operation in a single unit
씰
Flexibility in use
씰
Connection scheme adjustable to requirements
씰
Stress-free installation of tube bundles
DIABON® multi-tube bundle heat exchangers (2 bundles)
Design advantages 씰
Design ideally matched to graphite material – sliding seal to compensate for thermal expansion – minimal axial and radial movement
씰
씰 씰
씰
Automatic ventilation and emptying possible
Identical and standardized assemblies 씰
Long servicing intervals
씰
Ease of handling
Practical sealing system with reliable O-rings
씰
Ease of servicing
and sealing cords in high-quality materials
씰
Maximum operational reliability
씰
Optional inspection glass allows
(tube bundles, modules, headers, etc.) 씰
Meets cGMP requirements (current Good Manufacturing Practices)
– short tightening distances
process control
Flexible design allowing – co-current-flow operation – multi-mode operations
Cost advantages 씰
Low space requirements due to compact design
Operational advantages 씰
Vertical and horizontal installation
씰
씰
Antifouling properties
씰
씰
Optimum design for CIP procedures
Low capital expenditure Up to 80 % savings on servicing and repairs
(Cleaning in Place)
11
Multi-Tube Bundle Heat Exchangers made from DIABON® Process Equipment Graphite
Another special advantage of this design is that it allows pure counter-current flow. Compared with standard equipment, the temperature differential can be used to full advantage. Moreover, the design can be individually adapted and optimized for each application. The resulting savings in heat exchange area can be as much as 40 %. DIABON® multi-tube bundle heat exchanger (5 bundles)
The equipment design is optimized to allow an ideal inlet flow profile for the cylindrical tube sections. As a result, flow conditions for each tube bundle are identical, without dead spaces or areas exposed to undercurrents and turbulence. This is why our equipment displays excellent antifouling behavior when used for media with an inherent fouling tendency.
12
A further advantage of this design is its ease of handling. Since the heat exchanger has only a few components, dismantling is just a short sequence of operations that can be easily performed by the operators themselves. DIABON® multi-tube bundle heat exchanger (3 bundles)
The availability of the equipment can be increased significantly by keeping spare bundles in stock. During heat exchanger cleaning operations, tube bundles can be replaced as required in a minimum of time. This ensures nearly 100 % availability of the equipment and associated plants.
Multi-tube bundle heat exchangers are suitable
Damaged tube bundles can be re-
for a wide range of chemical processes when
paired at any time and even repeat-
used as
edly, thereby minimizing the cost of
씰
Coolers
씰
Heaters
씰
Condensers
씰
Evaporators (forced and natural circulation)
씰
Falling-film evaporators
씰
Integrated equipment for condensing
servicing.
with simultaneous residual gas cleaning (cold trap) 씰
Heating and cooling of pickling lines
13
Quality Management and After Sales Service
After Sales Services – Anytime and Everywhere We take care of our products during the entire operational lifetime. We aim to provide the best customer service anytime and everywhere. Quality Management E
Continuous quality assurance is an integral part of the SGL Group corporate philosophy. Our quality management system is certified in accordance with ISO 9001:2008. In order to guarantee consistently high quality to our customers, we work according to a key performance indicator orientated quality management system.
14
Depending on specifications we are able to meet specific requirements like the Pressure Equipment Directive 97/23/EC Annex III, Module H/H1, AD 2000 Merkblatt N2 as well as ASME “U” Stamp, Section VIII, Part UIG.
E E E
aintenance – genuine spare parts supply, M failure analysis, repair, field service Fast emergency support Start-up assistance Consulting for continuous improvement
Our service specialists as well as our service centers work in a global network to support you best.
Process Technology Our Products
System Solutions E Syntheses E Distillation and concentration E Purification E Dilution E Absorption E Desorption E Thermal destruction and recycling E Reactors and converters E Heat storage E ...
Equipment Solutions E Graphite and SiC heat exchangers – shell & tube, block and plate type E Columns and internals E Vessels E Quenchers E Pumps E Rupture discs E PTFE piping and bellows E PTFE hoses E ...
After Sales Services E Maintenance E Emergency support E Start-up assistance E Consulting E ...
15
Regional Sales & Service Center Central and East Europe
Asia, Oceania
SGL CARBON GmbH Werner-von-Siemens-Strasse 18 86405 Meitingen/Germany Phone +49 8271 83-1564 Fax +49 8271 83-2101 [email protected]
SGL CARBON Far East Ltd. Shanghai 1208, Shanghai Oriental Plaza 31 Wujiang Road/China Phone +86 21 5211 0333 Fax +86 21 5211 0085 [email protected]
South Europe, Middle East, Africa
India
SGL CARBON Technic S.A.S. 18, Avenue Marcel Cachin 38407 Saint Martin d‘Heres/France Phone +33 4 7625 9600 Fax +33 4 7625 6277 [email protected]
SGL CARBON India Pvt. Ltd. Plot No. E-100, MIDC Ranjangaon Village: Karegaon, Taluka: Shirur Dist. Pune - 412 220/India Phone +91 21 386 122-14 [email protected]
Americas SGL CARBON Technic, LLC 21945 Drake Road 44149 Strongsville, Ohio/USA Phone +1 440 572-3600 Fax +1 440 572-9570 [email protected]
® registered trademarks of SGL CARBON SE
11 2014/0 5NÄ Printed in Germany
The data contained herein represent the current state of our product knowledge and are intended to provide general information on our products and their application spectra. In view of the variety and large number of application possibilities, these data should be regarded merely as general information that gives no guarantee of any specific properties and/or suitability of those products for any particular application. Consequently, when ordering a product, please contact us for specific information on the properties required for the application concerned. On request, our technical service will supply a profile of characteristics for your specific application requirements without delay.
Process Technology SGL CARBON GmbH Söhnleinstrasse 8 65201 Wiesbaden/Germany www.sgl-processtechnology.com www.sglgroup.com
®
Shell & Tube Heat Exchangers
Process Technology
Broad Base. Best Solutions.
C
Carbon is Future. SGL Group – The Carbon Company.
Process Technology The Business Unit Process Technology is a premium technology provider for chemical and related industry process systems, equipment and after sales services. Our focus are high-tech materials for demanding chemical applications. With smart and sustainable solutions for an increasing number of industry we give proof of our strong innovation culture. Broad Base
Carbon has unique properties. It is indispensable in the production of steel, aluminum and solar energy systems. Carbon increases the performance of wind turbines and reduces the weight of airplanes, cars and sports equipment.
Carbon substitutes other materials and contributes to a reduction in CO2 emissions.
SGL Group is one of the leading manufacturers of carbonbased products and has the broadest product and technology portfolio, a global sales network and state-of-the-art production sites in Europe, North America and Asia.
Our range of materials: E graphite E SiC E PTFE E reactive metals E steel Our range of services: E process design E engineering E project management E production and assembly E commissioning E after sales services. With 9 manufacturing sites in 8 countries and a continually growing worldwide sales and service network, we are always close to our customers.
Reliability. Efficiency. Sustainability.
Powered by our Broad Base of competencies, products and services, we offer Best Solutions to our customers. For the Business Unit Process Technology, those solutions are characterized by reliability, efficiency and sustainability. Best Solutions E
Reliability
In a business that strongly depends on reliability we never compromise on quality and safety. Our products deliver dependable results; our services are fast and competent. The long-standing loyalty of our customers proves that we keep our promises – on-time, on-spec, on-budget.
E
Efficiency
Tailor made, innovative solutions and an integrated approach on chemistry, materials, technology and design, ensure outstanding efficiency and improved customer value: higher yields, lower operating cost, lower service and maintenance cost, longer service intervals and less downtimes, and the extended product lifetime sum up to significant lower total cost of ownership and to a higher return on investment for our customers.
E
Sustainability
In all industries that deal with resource- and energy- consuming processes sustainability is of crucial importance. Based on innovative solutions, more than 60 % of our sales contribute to the saving of resources and energy and to the reduction of greenhouse gases.
Contents DIABON Shell and Tube Heat Exchangers
4
Carbon Fiber-Reinforced DIABON Components
9
Technical Information
6
Multi-Tube Bundle Heat Exchangers
10
Design Options
7
Quality Management and After Sales Service
14
Properties and Applications
8
Process Technology – Our Products
15 3
DIABON® Shell and Tube Heat Exchangers at a Glance
Advantages of our shell and tube heat exchangers in DIABON process equipment graphite 씰
High efficiency
씰
Large heat exchange areas possible (over 2,000 m2)
씰
Price advantage for medium and large heat exchange areas
씰
High heat transfer capacity
씰
Abrasive wear protection minimizes erosion
씰
Low pressure drops
씰
All seals are external for ease of inspection
씰
Ease of repair
씰
Excellent drainage of condensate in steam applications
씰
Complete drainage of product and service side
씰
Wide range of material combinations for shell and header (FRP, rubber-lined steel, enamel, steel/PTFE) On this basis, DIABON shell and tube heat exchangers are used as heaters, coolers, condensers and falling-film evaporators and absorbers, especially in the treatment of:
4
씰
Hydrochloric acid
씰
Sulfuric acid
씰
Hydrofluoric acid
씰
Phosphoric acid
씰
Chlorinated hydrocarbons
씰
Organic and inorganic media
씰
Waste acids
씰
Combustion gases
DIABON® tube bundle
Corrosion resistance The basic materials for our shell and tube heat exchangers, DIABON NS1 and DIABON NS2 process equipment graphite, are resistant to virtually all organic and inorganic media. For heat exchange between two corrosive media, we supply special designs
Pressures and
on request with a suitable anti-
temperatures
corrosion lining or coating of the
A maximum permissible material
steel shell (rubber, PTFE, enamel,
temperature of 200 °C has been
etc.)
certified for DIABON NS1 and NS2 tubes by the South German
O-ring seal
Technical Supervisory Board
Our long experience has shown
(TÜV). Moreover, strength certifi-
that O-ring seals offer substantial
cation up to G32-0-200 (32
advantages over stuffing box
N/mm2 with 0 ‰ strength de-
packings:
crease up to 200 °C) can be given for the tubes. The standard design
Extremely low coefficients
allows for optional pressures of up
of friction
to 6 bar gauge for both service
씰
Low sealing forces required
and product sides. Special designs
씰
Universal resistance of
for higher pressures up to 16 bar
O-ring seals
gauge on the service side and up
씰
Ease of adjustment
to 12 bar gauge on the product
씰
Ease of replacement
side can be supplied on request.
씰
Long service life
씰
Low servicing cost
씰
Shell and tube heat exchanger with DIABON® NS1 tubes
Terms of reference Training
To be able to offer the same standards of quality
Servicing of our DIABON shell
anywhere in the world, our shell and tube heat
and tube heat exchangers is sim-
exchangers are designed to meet the following in-
ple and can be carried out on site
ternational standards:
by your own personnel. On re-
AD specification
Germany
quest, we put your technical per-
APAVE
France
sonnel through our training cour-
ASME
USA
ses. This enables repairs and
BS
United Kingdom
overhauls to be carried out even
Chinese Requirements
China
more quickly and economically.
ISPESL
Italy
In addition, our specialists are
JIS
Japan
always at your service – whatever
Stoomwezen
Holland
your problem. We also supply
SVTI
Switzerland
spare parts quickly and easily.
UDT
Poland 5
Technical Information DIABON® Shell and Tube Heat Exchangers DIABON shell and tube heat exchangers are constructed from the following components: 씰
Two tube sheets with or without carbon fiber reinforcement – one fixed and the other floating, relative to the shell
씰
Baffle cages with DIABON baffles
씰
Headers made from DIABON NS1/ NS2 graphite or other materials. Depending on the application, the header in contact with the floating tube sheet is braced against the tube sheet by a dual clamping tie rod system
씰
Shell made from steel, with anti-corrosion lining on request, or from other materials
씰
Partition plates in the headers allow several passes through the tube bundle, when required in the
DIABON® tube sheet with wear sleeves
process
Technical specification
Tubes
Material
Others
6
d1 [mm]
d2 [mm]
t [mm]
Tube type 0
15
26
33
Tube type 1
22
32
39
Tube type 2
25
37
44
Tube type 3
37
50
57
Tube length
1 bis 9 meter (standard)
Tube bundles and headers
DIABON NS1 / NS2 / HF1 / HF2
Shell and flanges
DIN standard steel, P 265 GH
Acceptance inspection
CE, TÜV and other authorized test institutes
Design pressure
-1 / 6 bar gauge (standard)
Design temperature
180 °C (standard)
Options for Various Designs
Top header with laterial nozzle and removable top cover
Falling-film DIABON® header
Cooled DIABON® header for high gas inlet temperatures
Standard steel shell
Steel shell with steam inlet distributor
Steel shell with conical steam inlet nozzle
Conical steel bottom header with corrosion-resistant lining
Extended DIABON® bottom header for separating gases and liquids
Steel shell with 360° steam distributor
7
Properties and Applications of DIABON® Graphite Brands
Micrograph of DIABON® NS1
Micrograph of DIABON® NS2
DIABON® NS1
DIABON® NS2
Properties
Properties
Standard material for a wide
Graphite material for superior
range of applications in chemi-
demands. This graphite brand
cal technology, environmental
is distinguished by its lower pore
protection and similar industries.
volume combined with reduced
DIABON NS1 is an impervious,
pore size and greater mechani-
synthetic resin-impregnated pro-
cal strength. The maximum per-
cess equipment graphite with a
missible material temperature is
highly homogeneous material
200 °C.
structure. This results in excellent corrosion resistance and thermal
Applications
stability. The maximum permissi-
DIABON NS2 is suitable for
ble material temperature under
heat exchanger tube sheets and
permanent load is 200 °C.
tubes, if these are subjected to elevated mechanical stress
Applications
and/or extremely corrosive
Standard material for the pro-
media and solvents.
duction of heat exchangers and for all pressure- and temperaturestressed components.
8
Carbon Fiber-Reinforced Components for Increased Safety In developing the carbon fiber reinforcement of components (DIABON HF), SGL Group has found a way to increase the operational reliability of DIABON graphite components appreciably and expand their range of application under high-stress conditions. The fiber reinforcement is used for tube sheets, headers and column sections and especially for tubes.
Properties of graphite tubes with carbon fiber reinforcement 씰
Carbon fiber-reinforced tube sheet
Increased bursting pressure
The tube becomes more resistant to steam hammer and service pressures above the permitted limit, its bursting pressure at room temperature being raised to 130 to 140 % of that of a non-reinforced tube, depending on the tube dimensions. 씰
Resistance of a cracked tube to leakage
Should a longitudinal crack occur in a DIABON HF tube as a result of overstressing, the tube will not allow any major leakage up to a differential pressure of some 2 to 5 bar. In all instances, the reinforcement prevents any spalling from the tube and
DIABON® HF tubes
a consequent escape of product in large quantities. Usually the equipment can continue in operation without interruption until the next planned shutdown.
Comparison of tube properties Unit
DIABON HF1
N/mm2
> 52
> 52
Bursting pressure at 20 °C
bar
110
80
Bursting pressure at 50 °C
bar
120
75
Resistance to pressure surges
relative %
250
100
Leakage pressure2) 5)
bar gauge
2-5
0
Thermal conductivity
W/(K·m)
50 3)
> 60
°C
200
200
Flexural strength, longitudinal
Maximum material temperature4)
1)
DIABON NS1 1) DIABON® tube reinforced with SIGRAFIL® HF fibers 2) on a cracked tube under internal pressure from water 3) effective value, calculated from the tube’s heat transfer capacity 4) depends on service medium 5) pressure up to which no appreciable loss of medium occurs from the cracked tube under brief pressure surges
9
Multi-Tube Bundle Heat Exchangers made from DIABON® Process Equipment Graphite
A new generation of heat exchangers Unlike conventional products, our DIABON multitube bundle heat exchangers feature an exchange surface area distributed over several identical small tube bundles instead of a single large bundle. Separate graphite tube bundles are incorporated in a shell made from carbon steel. One or more of these elements can be integrated in a frame of support plates. The tube bundles are sealed against
DIABON® bundles of a multi-tube bundle heat exchanger
both the steel flanges and headers with O-ring seals made from a high-quality sealing material.
The special design of multi-tube bundle heat exchangers allows single or multiple counter-current flow, or several different applications in a single
The special design features make for a whole
unit, e.g. in
range of advantages:
씰
condensation
Technical
씰
residual gas and condensate sub-cooling
씰
using different cooling media for the purpose
10
High performance combined with small heat exchange area
씰
Savings in heat exchange area of up to 40 %
씰
Modular design
씰
Multi-mode operation in a single unit
씰
Flexibility in use
씰
Connection scheme adjustable to requirements
씰
Stress-free installation of tube bundles
DIABON® multi-tube bundle heat exchangers (2 bundles)
Design advantages 씰
Design ideally matched to graphite material – sliding seal to compensate for thermal expansion – minimal axial and radial movement
씰
씰 씰
씰
Automatic ventilation and emptying possible
Identical and standardized assemblies 씰
Long servicing intervals
씰
Ease of handling
Practical sealing system with reliable O-rings
씰
Ease of servicing
and sealing cords in high-quality materials
씰
Maximum operational reliability
씰
Optional inspection glass allows
(tube bundles, modules, headers, etc.) 씰
Meets cGMP requirements (current Good Manufacturing Practices)
– short tightening distances
process control
Flexible design allowing – co-current-flow operation – multi-mode operations
Cost advantages 씰
Low space requirements due to compact design
Operational advantages 씰
Vertical and horizontal installation
씰
씰
Antifouling properties
씰
씰
Optimum design for CIP procedures
Low capital expenditure Up to 80 % savings on servicing and repairs
(Cleaning in Place)
11
Multi-Tube Bundle Heat Exchangers made from DIABON® Process Equipment Graphite
Another special advantage of this design is that it allows pure counter-current flow. Compared with standard equipment, the temperature differential can be used to full advantage. Moreover, the design can be individually adapted and optimized for each application. The resulting savings in heat exchange area can be as much as 40 %. DIABON® multi-tube bundle heat exchanger (5 bundles)
The equipment design is optimized to allow an ideal inlet flow profile for the cylindrical tube sections. As a result, flow conditions for each tube bundle are identical, without dead spaces or areas exposed to undercurrents and turbulence. This is why our equipment displays excellent antifouling behavior when used for media with an inherent fouling tendency.
12
A further advantage of this design is its ease of handling. Since the heat exchanger has only a few components, dismantling is just a short sequence of operations that can be easily performed by the operators themselves. DIABON® multi-tube bundle heat exchanger (3 bundles)
The availability of the equipment can be increased significantly by keeping spare bundles in stock. During heat exchanger cleaning operations, tube bundles can be replaced as required in a minimum of time. This ensures nearly 100 % availability of the equipment and associated plants.
Multi-tube bundle heat exchangers are suitable
Damaged tube bundles can be re-
for a wide range of chemical processes when
paired at any time and even repeat-
used as
edly, thereby minimizing the cost of
씰
Coolers
씰
Heaters
씰
Condensers
씰
Evaporators (forced and natural circulation)
씰
Falling-film evaporators
씰
Integrated equipment for condensing
servicing.
with simultaneous residual gas cleaning (cold trap) 씰
Heating and cooling of pickling lines
13
Quality Management and After Sales Service
After Sales Services – Anytime and Everywhere We take care of our products during the entire operational lifetime. We aim to provide the best customer service anytime and everywhere. Quality Management E
Continuous quality assurance is an integral part of the SGL Group corporate philosophy. Our quality management system is certified in accordance with ISO 9001:2008. In order to guarantee consistently high quality to our customers, we work according to a key performance indicator orientated quality management system.
14
Depending on specifications we are able to meet specific requirements like the Pressure Equipment Directive 97/23/EC Annex III, Module H/H1, AD 2000 Merkblatt N2 as well as ASME “U” Stamp, Section VIII, Part UIG.
E E E
aintenance – genuine spare parts supply, M failure analysis, repair, field service Fast emergency support Start-up assistance Consulting for continuous improvement
Our service specialists as well as our service centers work in a global network to support you best.
Process Technology Our Products
System Solutions E Syntheses E Distillation and concentration E Purification E Dilution E Absorption E Desorption E Thermal destruction and recycling E Reactors and converters E Heat storage E ...
Equipment Solutions E Graphite and SiC heat exchangers – shell & tube, block and plate type E Columns and internals E Vessels E Quenchers E Pumps E Rupture discs E PTFE piping and bellows E PTFE hoses E ...
After Sales Services E Maintenance E Emergency support E Start-up assistance E Consulting E ...
15
Regional Sales & Service Center Central and East Europe
Asia, Oceania
SGL CARBON GmbH Werner-von-Siemens-Strasse 18 86405 Meitingen/Germany Phone +49 8271 83-1564 Fax +49 8271 83-2101 [email protected]
SGL CARBON Far East Ltd. Shanghai 1208, Shanghai Oriental Plaza 31 Wujiang Road/China Phone +86 21 5211 0333 Fax +86 21 5211 0085 [email protected]
South Europe, Middle East, Africa
India
SGL CARBON Technic S.A.S. 18, Avenue Marcel Cachin 38407 Saint Martin d‘Heres/France Phone +33 4 7625 9600 Fax +33 4 7625 6277 [email protected]
SGL CARBON India Pvt. Ltd. Plot No. E-100, MIDC Ranjangaon Village: Karegaon, Taluka: Shirur Dist. Pune - 412 220/India Phone +91 21 386 122-14 [email protected]
Americas SGL CARBON Technic, LLC 21945 Drake Road 44149 Strongsville, Ohio/USA Phone +1 440 572-3600 Fax +1 440 572-9570 [email protected]
® registered trademarks of SGL CARBON SE
11 2014/0 5NÄ Printed in Germany
The data contained herein represent the current state of our product knowledge and are intended to provide general information on our products and their application spectra. In view of the variety and large number of application possibilities, these data should be regarded merely as general information that gives no guarantee of any specific properties and/or suitability of those products for any particular application. Consequently, when ordering a product, please contact us for specific information on the properties required for the application concerned. On request, our technical service will supply a profile of characteristics for your specific application requirements without delay.
Process Technology SGL CARBON GmbH Söhnleinstrasse 8 65201 Wiesbaden/Germany www.sgl-processtechnology.com www.sglgroup.com
