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Alfa Laval in brief

Alfa Laval is a leading global provider


of specialized products and engi-
neered solutions.
Our equipment, systems and
services are dedicated to helping
customers to optimize the perform-
ance of their processes. Time and
time again.
We help our customers to heat,
cool, separate and transport prod-
ucts such as oil, water, chemicals,
beverages, foodstuff, starch and
pharmaceuticals.
Our worldwide organization works
closely with customers in almost
Compabloc - compact performance
100 countries to help them stay ahead.

Compabloc - the new laser welded heat exchanger series


How to contact Alfa Laval

Contact details for all countries are


continually updated on our website.
Please visit www.alfalaval.com to
access the information direct.

PPM00033EN 0804
Compabloc plate heat
Compabloc exchanger installed for
liquid-to-liquid heat
recovery in a chemical
The Compabloc welded plate heat exchanger from Alfa Laval is just reaching plant in Scandinavia
peak performance when many other conventional heat exchangers start to run
out of steam. With no gaskets between the plates, Compabloc is perfect for
operation in chemically aggressive environments and for handling high-tempera-
ture fluids.

The heart of the matter focus on efficient mechanical cleaning, adjacent passes by a pressed baffle, Range • AISI 316L • alloy C276
The heart of Compabloc is a stack of the L series to meet the particular which forces the fluid to turn between CP (TIG welded, medium pressure, • alloy B-2
corrugated heat-transfer plates in requirements associated with high- the plate pack and the panel. This cleanable mechanically): CP15 & CP20 • titanium • tantalum
stainless steel or exotic materials, pressure applications, and the X pattern enables cleaning by backflushing. CPL (laser welded, high pressure, • titanium-palladium
welded alternately to form channels. combining high pressure and mechani- Baffles are inserted inside the plate pack cleanable chemically): CPL30, CPL50 & • incoloy™ 825 • 254 SMO
Compabloc is available in seven differ- cal cleanability. as shown in the two figures on the next CPL75 • hastelloy™ C2000 • 904L (UB6)
ent plate family models: CP15, CP20, page. The baffles are dimensioned to CPK (laser welded, medium pressure,
CP30, CP40, CP50, CP75 and CP120 All patterns have been optimized with withstand full vacuum and can be cleanable mechanically): CPK40, Made to order
with heat transfer areas ranging from regards to structural strength and flow rearranged to fit a change in duty. CPK50 & CPK75 Compabloc is manufactured as stand-
0.7 to 840m2 (7 to 8985 ft2) per unit. mechanics, making the Compabloc CPX (laser welded, high pressure, ard in accordance with international
Each model is modularized with a stan- more resistant to pressure peaks and The two media flow in cross-flow Body cleanable mechanically): CPX120 pressure vessel codes such as ASME
dard number of plates to fit any duty. cycling. This boosts the reliability and in alternately welded channels The Compabloc frame consists of four HCP (laser welded, hygienic design and (with or without U stamp) or ADM (code
safety of the unit as well as providing corner girders, top and bottom heads manufacture): HCP15, HCP20, HCP30 used for PED and CE Marking).
Welds that meet your challenges better heat transfer performance. arrangement within each pass (see fig- and four side panels with nozzle con- & HCP40
Compabloc models CP15 and CP20 ure at right) while the overall flow nections. These components are bolted CPM (laser welded, 2 section condens-
are TIG welded whereas the larger Flow paths arrangement is counter-current for a together and can be quickly taken apart er with 2 different cooling media):
models CP30 to CP120 are laser The two media flow in alternately weld- multi-pass unit (see sectional view for inspection, service or cleaning. CPM15, CPM20 & CPM30
welded. The advantage of laser welding ed channels between the corrugated below). When required, the unit can be
is that the weld is thinner and more plates. They flow in a cross-flow designed with overall co-current opera- Panels and nozzles to fit More in less space
accurate, and the heat input is tion. Each pass is separated from the The panels and nozzles can be unlined Compabloc is very compact. All the
substantially reduced. This results in a or lined using the same materials as heat transfer area is packed into a Cross-section of a baffle arrangement
Upper head
unit with less stress, which makes it the plate pack. The nozzle size is vari- smaller footprint than that required for illustrating flow distribution
less sensitive to fatigue and cycling. able and can be selected independently comparable heat exchangers. For
Panel
In other words, laser welding improves Heat transfer for each side. The nozzle size is example, a Compabloc with 330m2
plate pack
reliability, extends the working life, and determined by: (3 530 ft2) heat transfer area needs only
enables Compabloc installation in harsh • the frame width (i.e. plate size). 1m2 (11 ft2) of floor space.
environments. Another advantage is the • the frame height (i.e. number of plates). Baffle
shorter and more flexible delivery time. • the number of plates per pass Extended performance limits
(i. e. pass height). Compabloc extends design pressure
In addition to the advantage of using from full vacuum (FV) up to 42 barg Baffle
high tech laser welding the plates are Compabloc’s variable nozzle sizes and (600 psig) depending on the model,
configured in such a way that the joint flexible pass arrangements make it suit- and standard design temperatures up
between the plates allows butt welding able for liquid-to-liquid duties with dissim- to 350º C and down to -29ºC (ASME Baffle
Baffle Girder
thus eliminating the crevices that are a ilar flow rates. In condensation duties the design) or alternatively -40º C (PED
feature of other welded plate exchangers vapour inlet may need a large nozzle design), with the possibility of special
using manual TIG welding, and that are Gasket while the condensate requires only a design down to -100º C (-148º F).
highly susceptible to crevice corrosion. small one.
Lower Take your pick of plate materials
head
Plate pattern Between the panel and the column lining Compabloc is available in virtually any
Support
The laser-welded range of Compablocs is a gasket that seals off the exterior. This material that can be pressed and
A series of baffles force the media to reverse
is available with three plate patterns – gasket can be made of graphite, or ptfe welded, including: flow direction and create a multi-pass flow
Sectional view of Compabloc
the K series, designed with a special or other typical flange gasket materials. • AISI 304L • alloy C22 pattern

2 Compabloc Compabloc 3
Made to meet the process conditions Designed with demanding duties in mind
While many heat exchangers on the market today are manufactured to satisfy a When it comes to high thermal performance under difficult process conditions,
broad range of process conditions, Alfa Laval’s Compabloc heat exchangers are the laser welded Compabloc has a distinct advantage over alternative heat
tailor-made to meet the customer’s exact process conditions. This design flexibili- exchangers including shell-and-tube.
ty includes both the flow configurations in the heat exchanger and the installation
mode.

Flow configurations for different duties • the rearrangement of the baffles to fit Compabloc vs. shell-and-tube • Compactness – • Versatility – condensation takes place in the first
Compabloc can be designed with both a new duty should the flow rates or Take a look at a few of the features, takes only a fraction of the floor variable nozzle sizes allow pass; final condensation or sub-cool-
single-pass or multi-pass flow configu- temperature change. advantages and benefits of Compabloc space of a shell-and-tube heat Compabloc to handle large differ- ing of inerts takes place in the second
rations. For condensation and liquid-to- in comparison with the shell-and-tube exchanger. ences between vapour and conden- pass, which also serves as a mist
liquid duties without temperature cross, Three ways to install Compabloc heat exchanger: sate flow rates. eliminator.
the single-pass configuration is suitable Compabloc plate heat exchangers can Condensation & evaporation
with its total cross-flow. be installed in three different positions: • Alternately welded plates – In condensing and evaporating duties, • No need for extra equipment – • Short flow path and flexible con-
permit access for inspection, service, the Compabloc provides additional a two-pass arrangement on the con- nection sizes –
For duties with temperature cross and • Vertical mounting – or cleaning. advantages: densing side permits gas-liquid sepa- make Compabloc a perfect reboiler
close temperature approaches, a multi- normally used for liquid-to-liquid ration in the unit, thereby eliminating and evaporator.
pass configuration is suitable. Each duties, condensation with subcooling • No gaskets between plates – • Large cross-flow area and short the need for a separator. The main
pass is in cross-flow, but the overall and gas cooling duties, particularly allows operating: flow path –
flow pattern within the heat exchanger when floor space is limited. - with aggressive media. fit low-pressure condensing duties
is counter-current. - at higher temperatures and pressures. and allow very low pressure drops. vapour non-condensable
• Horizontal mounting – gases

The configuration of Compabloc has used for condensation duties, reboil- • Corrugated plates –
unique advantages that permit: ing, gas cooling or liquid-to-liquid promote high turbulence which, in turn:
duties, when there are height limitations. - achieves three to five times greater
• a different number of passes on the overall heat transfer coefficients than a condenser
two circuits, thereby enabling large • Suspended mounting – shell-and-tube heat exchanger.
differences in flow rates between the hanging the unit from the ceiling - minimizes fouling, which makes longer
hot side and the cold side. generally used for condensing duties. operating periods possible.

• Close temperature approach –


can handle temperature approaches
Two-pass process condenser condensate
down to 3º C (5.4º F). with gas/liquid seperation

column
vapour/liquid
mixture
12 metres (39 feet)

Vertical Compabloc
for liquid/liquid heat
recovery pre-heater
reboiler
steam
3.4 metres
(11 feet)

Compabloc installed as stripping column Suspended Compabloc vs. shell-and-tube (same duty). Compabloc as pre-heater, condenser and reboiler
Reboiler
liquid condensate
reboiler at an ethyl-acetate plant in Rhodia, mounting for
Brazil condensation duties

4 Compabloc Compabloc 5
From oil & gas to district heating Compact facts about Compabloc
Design temperature:
Design pressure:
up to 350° C (660° F), down to -100° C (-148° F).
up to 42 barg (600 psig) depending on models and full vacuum (FV).
Maximum heat transfer area: 840 m2 (8985 ft2).
The numerous advantages of the Compabloc heat exchanger make it suitable for Maximum liquid flow rate per unit: 6000 m3/h (26250 USgpm).
Lowest achievable temperature difference: 3° C (5.4° F).
use in a wide range of industries and applications. Duty: heat recovery (feed/bottom on stripping/distillation column), cooling, heating,
condensation, partial condensation, reboiling, evaporation and gas cooling.
Performance: low to high thermal length or NTU duty. Handles any corrosive medium.

Compact facts about Compabloc In case of service…


Applications Hydrocarbon process industry Coke oven plants Design temperature: up to 350°C (660° F), down to -100°C (-148° F). The flexible construction of the
Condensation, heating/cooling, heat • Ammonia liquor scrubber cooling Design pressure: up to 42 barg (600 psig) depending on models and full vacuum (FV). Compabloc makes service a straight-
Oil & gas production recovery and reboiling duties in the pro- • Debenzolized oil cooling Maximum heat transfer area: 840m2 (8985 ft2). forward matter. Cleaning can be done
• Heat recovery in TEG systems (gas duction of: • Benzolized oil heating Maximum liquid flow rate per unit: 6000m /h (26250 USgpm).
3
using 2 different methods. Cleaning by
dehydration) • primaries such as olefins, aromatics, Lowest achievable temperature difference: 3° C (5.4° F). hydroblasting is carried out on site by
• Heat recovery, cooling, condensation aldehydes, acids, ethers, esters, Chlorine alkali plants Duty: heat recovery (feed/bottom on stripping/distillation column), cooling, heating, removing the panels and blasting the
& reboiling in amine systems (gas ketones, and halogens • Chlorine gas cooling (drying) condensation, partial condensation, reboiling, evaporation and gas cooling. inside of the plate pack with a water jet
sweetening, sour service) • intermediates such as acrolein, • Hydrogen gas cooling (drying) Performance: low to high thermal length or NTU duty. Handles any corrosive medium. at pressures of up to 1000 barg.
• Heat recovery, heating and cooling in acrylic acid and acrylates, acryloni-
crude oil dehydration and desalina- trile, adipic acid, alkylbenzenes, ani- Fertilizer production On-site cleaning can also be done by
tion systems line/nitrobenzene, benzenesulphonic • Nitrogen gas cooling circulating cleaning solutions through the
• Condensation in vapour recovery units acid, bispenol A, caprolactam, diiso- • CO2 gas cooling (3-step compressor plate pack. Such chemical cleaning is
• Heat recovery, cooling, condensation cyanates (MDI & TDI), ethylben- interstage cooler - gas drying) highly effective as a result of the unit’s
and reboiling in NGL fractionation zene/styrene, ethylene oxide/glycol, • Ammonia heat recovery and stripping high turbulence and low hold-up volume.
systems hexamethylenediamine (HMDA), column reboiler
maleic anhydride, melamine, phenol, • Nitric acid cooling Chemical cleaning can also be per-
Refineries phosgene, phthalic anhydride, propy- formed by removing the plate pack and
Various condensing & reboiling duties lene oxide/glycol, terephthalic acid Hydrogene peroxide plants immersing it in a chemical bath.
such as: (PTA)/dimethyl terephthalate (DMT), • Heat recovery and cooling of process
• Condensation in atmospheric and vinyl acetate, vinyl chloride, EDC streams
vacuum distillation • polymers including polyethylene,
• Top condensing on fractionators in polypropylene, polystyrene and Ammonium nitrate
FCC, hydrocracking, H2S strippers, etc. styrene co-polymers, formaldehyde • Spent sulphuric acid heat recovery.
• Propane & butane overheads con- resins, polycarbonates, polyols, • Oleum cooling
densing in NGL and alkylation plants polyvinyl acetate, and polyvinyl alcohol
• Reboiling in H2S strippers, sour water • other organic chemicals such as Mining industry
strippers and other columns soaps and detergents, paintings and • Nickel refining solvent extraction
• Steam generation coatings
Vegetable oil & fatty acids
Heat recovery, cooling & heating duties Pharmaceutical industry & specialty • Feed/bottom in deodorization
such as: chemicals
• Cooling of gasoline, kerosene, gas oil, • Special 2-pass condenser with built-in HVAC, district heating, energy,
diesel, pump-around etc gas/liquid separation chamber and utilities, general services
• Cooling & heating of bitumen, VGO mist eliminator for reactor overhead • Hot water production system
(vacuum gas oil) and other heavy and vent condensation • Steam heating
products • Primary and vent condensation with • Heat recovery
• Fractionator feed/bottom heat hygienic design On-site chemical cleaning is performed using
recovery • Solvent recovery the Alfa Laval CIP unit by circulating cleaning
solutions through Compabloc. The solution
• Pre-heating of crude oil • Special 2-pass condenser with 2
is circulated from the lower inlet connection,
• Desalted water/feed water heat cooling medias. through Compabloc and then discharged
recovery from the upper connection to the CIP tank.

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