BORSIG

PROCESS HEAT EXCHANGER

SYNLOOP
SYNLOOP WASTE
WASTE HEAT
HEAT BOILER
BOILER
IN
IN AMMONIA
AMMONIA PLANTS
PLANTS

A Member of KNM Group Berhad

The Company

BORSIG Process Heat ExchangerGmbH (a member of

the BORSIG Group, Berlin/Germany that is owned by the
global process technology player KNM Group Berhad,
Kuala Lumpur/Malaysia) is a worldwide leading manufacturer of pressure vessels, heat exchangers and other
systems for special industrial applications.
Our products Waste Heat Recovery Systems, Quench
Coolers and Scraped Surface Exchangers stand for
high quality, competence and reliability.
BORSIG Process Heat Exchanger GmbH is able to produce according to all applicable codes and standards and
is certified according to e.g. DINEN ISO 9001:2000,
SCC, ASME U, U2 and S, SQL PR China, Environmental
Management System DINENISO 14001, EMAS II, etc..

Process gas waste heat boiler

Long time experience, state-of-the-art technology, highly

qualified employees as well as innovative engineering
enables us to find the perfect solution for our customers.
Other products of the BORSIG Group:
Membrane technology, compressors, blowers, boiler
and power plant technology and industrial and power
plant services.
For more information please visit www.borsig.de.

Tunnelflow quench coolers

Process gas waste heat recovery system

Synloop Waste Heat Boilers

in Ammonia Plants

More clients decide in favor of BORSIG Process Heat

Exchangers HOT/COLD tubesheet design for synloop
waste heat boilers for their waste heat recovery systems
in ammonia plants, as they are aware of the following
advantages:
= Unique patented HOT/COLD BORSIG tubesheet
design
= Use of ferritic tubes
= Hydraulic expansion of tubes through thickness of
tubesheet
= Internal gasinlet chamber
= Tubesheet temperature is below temperature,
where nitriding starts
= No stress corrosion cracking
= No crevice corrosion
= No welding overlay of gasinlet channel against
hydrogen attack and nitriding
BORSIG Process Heat Exchanger GmbH offers an individual solution for your waste heat recovery system in
your ammonia synthesis loop.

1: Ferritic tubes are used, which are not sensitive to stress

corrosion cracking, contrary to incoloy tubes
2: Unique patented HOT/COLD tube arrangement which results
in tubesheet temperatures below from where nitriding starts
3: Hydraulically expanded tubes avoid crevice corrosion
4: Hot incoming gas is guided through internal gas chamber
directly to tube inlet ends, no special protection of combined
gasinlet/outlet chamber against nitriding and hydrogen
embrittlement is necessary

Waste heat boiler for a formaldehyde plant

Ammonia plant with synloop WHB, reformed gas WHB,

steam superheater and steam drum

BORSIGS Process Heat Exchanger

Unique Patented HOT/COLD Tubesheet Design

U-tubes with hot and cold ends are alternately arranged. The hot shank is surrounded by cold
shanks.
Advantage of this design is that the tubesheet and the hot end tube wall temperature inside
the tubesheet can be kept below 380C to avoid nitriding and to use ferritic tubes.
As a result the inlet ends of the tubes inside the tubesheet as well as the whole tubesheet
itself are at gas outlet temperature.
The U-tubes are arranged in such way that each inlet is located adjacent to an outlet end. Inlet
end ferrules protude approx. 50 mm from the thick tubesheet into the channel and are fitted to
a dummy tubesheet, which is connected to an internal gas chamber of incoloy for the hot incoming gas.

Principle sketch of HOT/COLD tubesheet design

Combined gasinlet/outlet chamber for HOT/COLD tubesheet design

Conventional Tube Arrangement Compared to

HOT/COLD Tube Arrangement
The diagram below indicates the temperature distribution across the tubesheet thickness. With conventional
tube arrangement the tubesheet temperature will be
above the temperature, where nitriding starts.
But BORSIGs Process Heat Exchanger unique
HOT/COLD tube arrangement achives an even temperature distribution across tubesheet thickness, which is
below nitriding temperature. This HOT/COLD tube
arrangment is the best technical solution.

FEM models of HOT/COLD tube arrangement

Comparison of different synloop waste heat boiler designs

Tubesheet temperature across tubesheet thickness based on FEM-analysis

Diaphram gasket

Bredtschneider
sealing cover

Welded on
hemispherical
head with manhole

Gas inlet channel of a synloop WHB

Standard high pressure sealing covers for combined

gasinlet/outlet channel for synloop WHBs and
BFW-preheaters

Manufacturing of a synloop WHB

Synloop WHB furnished as kettle type

Temperature profile of evaporation and

BFW-preheating section

Synloop Waste Heat Boiler with

Integrated Boiler Feed Water Preheating Zone

The BFW is entering the BFW section close to the bottom of the tubesheet and is passing through it in counterflow to the converter effluent, is heated up close to
saturation temperature and is entering the evaporation
section. Then the steam/water mixture is flowing
upwards through the cone and chimney. Above the
upper end of the chimney an impingement plate is
arranged to force droplets and water to flow down
through the inside waterjacket. The steam leaves the
synloop boiler by passing a demister. The down-flowing
water is guided through an annular space to the tubesheet. At tubesheet the water flows radially to the centerpart and flows upwards by generating steam.
The arrangement of BFW-section, waterjacket and cone
with chimney ensures that up-flowing water/steam mixture and downflowing water are separated. This circulation
is a natural circulation and the tubesheet is flushed by
cooling radial incoming down-flowing water. Therefore
no pool boiling areas in the center of the tubesheet are
present.
To reduce investment costs, BORSIG Process Heat
Exchanger GmbH is prepared to offer a design of a synloop waste heat boiler with integrated BFW-preheating
section.

Sketch of synloop waste heat boiler with integrated boiler

feed water preheating zone

Principle sketch of synloop waste heat boiler with integrated BFW-preheating section

Tube bundle of HOT/COLD design

Synloop Steam Superheater

Tube bundle of steam superheater

Tube to tubesheet welding

Synloop WHB ready for delivery

Steam superheater ready for delivery

Typical Layouts and

Arrangements
for Synloop WHBs

Synloop WHB with integrated steam drum

1 - Synloop WHB horizontal design

2 - Synloop WHB designed as reboiler

Arrangement of reformed and synthesis gas waste heat boilers

with one common steam drum:

Synloop WHB with steam drum designed as compact unit

1
2
3
4
5
6
7

Reformed gas WHB

HP steam superheater
Steam drum
Shift WHB
Shift BFW preheater
Synloop WHB
Synloop BFW preheater

Engineering and
After Sales Services

BORSIG Process Heat Exchanger GmbH has complete

inhouse engineering facilities. Thermal layout and special heat transfer calculations are performed and checked
with inhouse developed computer programs. For
complex problems the gas flow and the heat transfer are
calculated by three dimensional finite element programs
(computational fluid dynamics).
Calculations of pressure vessels and heat exchangers
are performed according to all worldwide established
codes like AD, TRD, ASME, BS, Raccolta VSR, Codap,
Stoomweezen, IBR, JS, Australian Standard and others.
Critical components are subject to additional strength
calculations by using the finite element analysis.
Flexibility, rooting, foundation loads and forces and interconnecting piping are calculated by computer programs.

Lifting of a synloop WHB on site

Synloop WHB on site

BORSIG Process Heat Exchanger supplies also the service of complete replacement jobs. BORSIG Process
Heat Exchanger supervisors are specialized on replacement performances covering the detailed engineering,
elaborating the shortest time frame, determining the logistic replacement sequence, mobilization of local personnel and complete supervision from shutdown to start-up
of plant.

Positioning of a synloop WHB on site

Manufacturing and
Quality Assurance

BORSIG Process Heat Exchanger GmbH with its manufacturing methods, workshop facilities and equipment
complies fully with the latest state-of-the-art. The hightech welding technology is our core competence:
-

Laser controlled narrow gap SAW welding system,

robot welding technology for GMAW welding for high
pressure vessels,
TIG-hot wire welding, also on ball valve surfaces,
mechanical tube to tubesheet welding,
qualified manufacturing of all steel and nickel-based
alloys.

Quality assurance and control activities are independent

of the manufacturing process or product lines and guarantee that machined and handled materials, components, assemblies, products and service operations are
executed in accordance with all specified requirements.
Quality assurance surveils adherence to national and
international specifications, statutory and contract provisions as well as the directives, standards and regulations stipulated by BORSIG.

Automatic SAW nozzle to shell welding

BORSIG Process Heat Exchanger certification comprise

DINEN ISO 9001:2000, SCC, ASME U, U2 and S, SQL
PR China, Environmental Management System DINEN
ISO 14001, EMAS II, etc..
In 2003 BORSIG Process Heat Exchanger GmbH has
introduced the Integrally Management System (IMS)
comprising of quality, works safety and environmental
management systems.

Automatic
tube to tubesheet
welding
Synloop WHB furnished as kettle type

Assembling of a synloop WHB

BORSIG ProcessHeat Exchanger GmbH

Egellsstrasse 21
D-13507 Berlin/Germany
Phone +49 (0) 30 / 4301-01
E-mail synloop@pro.borsig.de

Fax
+49 (0) 30 / 4301-2447
http://www.borsig.de