engineering for a better world Welded Plate Heat Exchangers 33 GEA Group Aktiengesellschaft High heat transfer ratio Compact design Fully accessible plate pack Easy maintenance
engineering for a better world
Welded Plate Heat Exchangers
33 GEA Group Aktiengesellschaft
High heat transfer ratio
Compact design
Fully accessible plate pack
Easy maintenance
engineering for a better world
Installation examples
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Refineries
Renewable energy
Vegetable oil
Chemical industry
Oil & gas industry
engineering for a better world
Agenda
GEA Group – a strong back
GEA PHE – Energy saving product variety
Energy saving – case studies and advantages
engineering for a better world
Save energy and emissions
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In times of increasing demand for environmental requirements accompanied by
the threat of low margins and strong global competition, energy efficiency
becomes an evident need.
Heat exchanger technology can contribute to achieve this target.
Transfer heat efficiently by using appropriate heat exchanger technology
Maximize performance of heat exchangers
Recover the existing heat by optimzing processes
Reduce maintenance and service costs
engineering for a better world
Reasons for PHE growth
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Process Plant Energy Efficiency
Capable of temperature cross
Various technologies available for different applications
Better and better history
Reduced service & maintenance costs
Small footprint
Short Pay-back time
engineering for a better world
Comparison with Shell & Tube
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Operating limits for different types of Heat Exchangers
gasketed
PHE/LWC
brazed PHE
GEABloc
shell and tube heat exchanger
Design
temperature [°C]
Design pressure [bar]
25
40
-100
-50
-40
180
250
400
GEAFlex
100
900
engineering for a better world
Comparison PHE vs Shell & Tube
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0,0% 10,0% 20,0% 30,0% 40,0% 50,0% 60,0% 70,0% 80,0% 90,0% 100,0%
Fluid content
Heat transfer area
Operating weight
Installation space
Manufacturing costs
Fouling coefficients
Cleaning time
S&T
GPHE
engineering for a better world
Heat Transfer: U-Value vs LMTD
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Example :
ΔT hot side: 20°C (36°F)
ΔT cold side: 20°C (36°F)
Q: 500 kW (1.7 MBTU/h)
Max ΔP = 70 kPa ~10 PSI S&T
PHE
0
200
400
600
800
1000
1200
1400
1600
1,8 3,6 5,4 9 18 36
U-V
alu
e (B
TU/f
t² °
F)
LMTD (°F)
U-Value vs LMTD
U decreases rapidly with decreasing LMTD
engineering for a better world
Reasons for PHE efficiency: Turbulence
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High Turbulence due to corrugation
Turbulence enhances heat transfer
Self-cleaning effect to minimize fouling
High Shear Stress
3 to10 times higher than in S&T
engineering for a better world
Reasons for PHE efficiency: Temperature cross
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Temperature
Cross
Temperature
Approach
T
A
engineering for a better world
Interchanger
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Interchanger Heater Cooler Processing
Feed
Hot process fluid
Recover heat from process
Save energy from heater
Reduce cooling water consumption
Requires heat exchanger capable of temperature cross!
engineering for a better world
Comparison PHE vs Shell & Tube
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Type Shell & Tube HE Plate HE
Heat transfer area 3 x 1 x
Heat transfer ratio
(U or k value) 1 2 to 5
Fluid Volume 5x 1x
Shear stress 5-20 Pa 20-100 Pa
Temp. approach 5°C (9°F) 1°to 2°C (1.8°– 3.6°F)
Temp. cross NO YES
Heat Recovery Low High
Design Pressure high < 450 psig (32 barg)
Design Temperature high 150° to 350°C
Why should you switch from a shell & tube HE to a Plate HE ?
engineering for a better world
Case Study: Interchanger
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Str
ipp
er
Flash
Drum
Ab
so
rbe
r
Lean Amine
exchanger
Lean/rich
interchanger
Overhead
condenser
Reboiler
Acid gas
engineering for a better world
Case Study: Temperature cross
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Amine Regenerator Feed/Effluent Exchanger
Hot Side Cold Side
Fluid type Lean Amine Rich Amine
Temp. In 127,7°C 67,7°C
Temp. Out 93,3°C 107°C
Mass flow 77800 kg/h 80850 kg/h
All. ΔP 35 kPa 35 kPa
Temperature Cross!
engineering for a better world
Case Study: Design results
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S&T option GEABloc choice
2m
5,6m
1,25m
0,8m
engineering for a better world
Case Study: Comparison
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Amine Regenerator Feed/Effluent Exchanger
S&T PHE
No. of HX 2 in series 1
Surface Area 2 x 111m2=222m2 40m2
Pressure drop 22kPa / 17kPa 28kPa / 31kPa
OHTC clean 1180 W/m2K 3200 W/m2K
Shear Stress 14 Pa / 11 Pa 35 Pa / 39 Pa
Weight dry 2 x 3800kg 2230kg
Weight flooded 2 x 5500kg 2500kg
Length 5.6m 1.0m
Height 2 x 1m=2.0m 1.25m
Foot print 5.6m2 1.0m2
Price 90 000€ 35 000 €
Savings
-80%
all. ΔP=35kPa
-70%
+250% / +350%
-70%
-80%
-80%
-60%
engineering for a better world
Vertical Condenser
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Vapor
Condensate
Multiple passes on condensing side
Higher condensate channel velocity
Higher heat transfer coefficient
Smaller heat exchanger size
engineering for a better world
Case Story: Braskem, Brazil
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Polyethylene and Polypropylene plant
Two working heat exhcnagers had to
be replaced during turn-around.
Condenser and sub-cooler were install-
ed on top of column.
One GEABloc replaced two existing
heat exchangers with
Smaller footprint
Less maintenance
Lower CAPEX
engineering for a better world
Case Study: Essar, India
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Heat recovery from heavy naphtha
In original installation Heavy Naphtha was sent to Fin Fan Cooler.
Energy was wasted to air!
Propose welded plate heat exchanger suitable for high pressure
application. Duty is to cool, down heavy naphtha from 188°C to 58°C
using 74 t/h Boiler Feed Water (from 105 to 150°C).
Heat recovery 3.33 GCal/h
Approximate cost estimate : Euro 100,000
Estimated savings : Euro 0.85 Million per yr* (* 1MT MP Steam = euro 20)
Payback period : ca. 2 Month
engineering for a better world
Case Study: Crude Pre-heating Refinery, Russia
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Atm
ospheric C
olu
mn
Gas & Gasoline – 50°C
Kerosene – 190°C
LGO – 270°C
MGO – 310°C
Atm. Residue – 360°C
Crude Oil – 10°C
Pre-heated Crude– 250°C
Atmospheric
furnace
360°C