Worth the energy - Alfa Laval

Worth the energy
Compact heat exchangers for the petrochemical industry from Alfa Laval

It takes less energy than you think
As sure as the rising sun, energy means a lot to your business.
For years, Alfa Laval has been leading the way in efficient heat transfer.
The recovery and re-use of costly energy, whether purchased or generated
during process operations, can have an enormous impact on your results.
And with increasing attention on greenhouse gas emissions, heat recovery
will no doubt continue to be a key issue.
That’s why many businesses are adopting compact heat exchangers.
The investment can mean huge improvements – increased heat recovery,
less waste and reduced emissions, just to name a few.
When the time is right – for example, you need to expand operations,
improve your environmental profile, decrease maintenance or increase
capacity – you should talk to us. The advantages will simply brighten your day.
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What’s on hand is worth most
With the combination of high turbulence and counter-current flow, Alfa Laval
compact heat exchangers maximize heat recovery.
The concept is simple. Liquids or vapours flow through channels between
corrugated plates, creating a high degree of turbulence in the media. This
results in better heat transfer between the media. A counter-current flow
enables crossing temperature programs, where the cold fluid can be heated
to temperatures very close to those of the hot fluid. The closer the
temperature approach between two fluids, the more heat is recovered.
Energy saved and energy re-used. To get the most from your operations,
you recycle valuable energy for a wide range of uses rather than producing or
buying more. It’s worth it to you. It’s also worth it for the environment, since it
means you reduce fuel consumption and emissions.
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Compabloc
AlfaDisc
AlfaNova
Gasketed
and semi-welded
Spiral
Packinox
All-welded yet fully accessible, the
Compabloc offers the possibility to
handle tough duties involving high
pressures and temperatures as well as
aggressive media – without
compromising fast and easy cleaning
and inspection. Flexible connection
sizes and placements allow dissimilar
flows, and combine with the short plate
construction to make the Compabloc
an excellent choice for condensing and
reboiling duties.
The all-welded AlfaDisc is ideal for
duties involving high pressures and
temperatures, as well as for steam
applications. Its cylindrical shape makes
the unit capable of withstanding very
high pressures, and the accordion-like
plate pack makes it less sensitive to
thermal expansion. Futhermore, with its
flexible connection sizes, the AlfaDisc is
an excellent choice for duties involving
dissimilar flows.
The fusion bonded AlfaNova consists of
100 % stainless steel. Alfa Nova’s
patented bonding technique makes it
possible to take on industrial applica tions
that require higher temperature extremes
and high pressures. Its construction
makes it suitable not only for liquid/liquid
applications, but also for use as a gas
heater, gas cooler or reboiler.
Alfa Laval’s gasketed heat exchangers
meet basic operational needs. A full
portfolio with a wide range of shapes
and sizes makes it possible to tailor a
solution for each given duty, and the
design can be adjusted to fit new
conditions simply by removing or adding
plates to the plate pack. Furthermore,
the ease of dismantling and cleaning
makes them highly serviceable. The
semi-welded concept is designed to
handle aggressive media on one side.
The ultimate problem solver, the spiral
heat exchanger has a single-channel
arrangement that makes it self-cleaning
and uniquely able to handle highly
fouling fluids. Easy accessibility for
maintenance reduces its operating
costs and increases plant uptime even
further. The unit’s flexible design also
makes it an outstanding condenser that
utilizes the lowest possible pressure
drop. Moreover, the spiral condenser
can be top-mounted, which reduces the
installation costs involved.
The Packinox all-welded
heat exchanger features a
unique design for thermal
and hydraulic efficiency at
high temperatures and
high pressure, all within a
compact large-capacity unit. The result
is highly efficient heat recovery with an
extremely low pressure drop. Because
the Packinox can withstand extreme
temperatures at high pressure, it is
suited for a variety of duties, for example
in methanol and aromatics production.
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Bright ideas whose time has come
Alfa Laval’s compact heat exchangers are used for a wide variety of duties in
plants and industries around the world. Today, there are over 50,000 in use –
not just as utility equipment, but as process equipment as well.
We offer the world’s most extensive selection of compact heat exchangers,
including gasketed and semi-welded as well as gasket-free, such as all-welded
and fusion bonded solutions. The design is infinitely flexible. A number of
configurations and materials can be combined to handle a range of
temperatures, pressures and aggressive media.
Our heat exchangers are highly competitive in terms of capital, installation,
operating and service costs. They are lighter in weight, take up little space and
can be installed in previously unthinkable places. With our solutions,
maintenance is a small issue.
From design, production and installation to parts and service, we draw
from know-how, experience and a global pool of skilled engineers to ensure
your operations run brilliantly.
Others have seen the light
Many companies are already using compact heat exchangers in their operations – and
with rising energy costs and environmental concerns, many more are in the process of
considering this technology.
Here are a few reasons why:
– Optimum heat recovery from each and every process, using less cooling and
heating medium.
– Increased capacity using less area.
– Savings in capital investment and installation due to compact size and lighter weight.
– Lower operating costs with higher heat transfer efficiency.
– Less fouling due to better flow patterns and greater turbulence, resulting in less
maintenance and increased uptime.
– Improved process control due to lower hold-up volume.
– Reduction of fuel consumption and greenhouse gas emissions, lessening the
effect on the environment.
While shell-and-tubes have reached their efficiency peak, compact heat
exchangers continue to rise and shine.
Product details
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Shining examples
Since the1960s, we have delivered solutions to over 100 countries combining
global resources with local support. With the world’s most extensive range,
Alfa Laval knows heat exchangers inside and out. Our parts and service
organization is staffed by experienced service engineers, ready to assist you
with performance evaluation, troubleshooting and field service. Ultimately, our
solutions are optimized to your needs. You’ll expend less energy and get all the
more for your operations.
Of course, the best source of information and inspiration is our customers.
Here are just a few examples from many glowing installations. See how our
compact heat exchangers can provide environmentally responsible solutions
with efficient heat transfer and minimum energy consumption for low overall
cost and maximum reliability.
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CO 2
reduced
Dow Wolff Cellulosics, Belgium
Two Compabloc compact heat
exchangers from Alfa Laval were
installed for different duties in one of the
solvent recovery columns. The first unit
replaced a worn-out shell-and-tube
reboiler and provided a substantial
capacity increase. Calculations show
that the second Compabloc, installed to
heat the process feed to the column,
will provide significant annual energy
savings and CO 2
reductions.
Space
saving
Rhodia, Brazil
The Compabloc thermosiphon reboiler
concept was the only recovery solution
that would work for Rhodia, to meet
environmental restrictions as well as
space constraints. Compabloc not only
has a considerably smaller footprint
than shell-and-tubes but also brings a
number of operational benefits. The
start-up process is quicker with lower
hold-up volume. It reacts more rapidly
to changes in control parameters.
Service requirements are minimal.
Facts
Example (see disclaimer* on p. 27)
Energy savings/year
500 kW
Fuel savings/year
480 ton
Fuel cost savings/year
100 kEUR
CO 2
-emission savings/year 1 250 ton
CO 2
-emission cost savings/year 20 kEUR
Annual cost savings
120 kEUR
Capital cost savings
Reduction of effective surface area >50%
Space savings 80%
Reduced installation cost
Operating cost savings
Reduced start-up time
Improved process control
Reduced downtime
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Energy
savings
Balaji Amines, BAL, India
Specialty chemicals and aliphatic
amines producer BAL installed eight
Compabloc compact heat exchangers
for heat recovery duties in 2002. This
alone laid the foundation for savings of
around USD 690,000 per year. Today
Balaji has 48 Compablocs and
Managing Director Prathap Reddy is
impressed with the role the Compablocs
have played in reducing energy costs.
He also appreciates process know-how
and professional service BAL gets from
Alfa Laval in Pune. Other Alfa Laval heat
exchangers installed at BAL include
spiral, semi-welded and gasketed types.
Improved
performance
Sinopec, China
For Sinopec’s gas separation unit in the
ethylene oxide plant, an optimal solution
for the critical heat exchanger positions
is extremely important to system
capacity and efficiency. Compabloc was
the most practical answer, over
shell-and-tubes, to achieve energy
savings with counter-current flow and
handling of crossing temperatures, in a
minimum area. The turbulent flow in the
compact heat exchangers has resulted
in exceptional heat transfer efficiency
and trouble-free operation.
Facts
Facts (see disclaimer** on p. 27)
Energy savings/year 2 470 kW
Fuel savings/year
7 700 ton
CO 2
emission savings/year 23 900 ton
Fuel cost savings/year 690 kUSD
Capital cost savings
Space savings
Smaller footprint
Reduction of effective surface area
Operating cost savings
Reduced costs for maintenance
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Energy
saving
UNIPAR, Brazil
To integrate heat processes more
effectively in their cumene plant, saving
energy and thereby reducing operating
costs, UNIPAR installed one single
Compabloc heat exchanger on the
benzene distillation column as an
integrated reboiler. To heat the reboiler,
cumene vapour from another distillation
column further downstream is used.
This enables significant savings by
reducing steam consumption.
Improved
performance
BASF, Germany
At BASF’s amine plant, the re-use of
ammonia stripped off a distillation tower
is vital for the economics of the plant.
Compabloc combines condensing
and sub-cooling in a unique way, which
results in a lower outlet temperature
on the process side and boosts the
capacity of the distillation tower.
Savings in capital investment costs with
Compabloc also enabled the use of
corrosion-resistant plate materials for
trouble-free operations.
Facts
Facts (see disclaimer*** on p. 27)
Energy savings/year 3400 kW
Fuel savings/year
5300 ton
CO 2
emission savings/year 13800 ton
Fuel cost savings/year 1200 kUSD
Capital cost savings
Weight reduction 30 %
Space savings 70 %
Smaller footprint
Operating cost savings
Improved distillation capacity
2-in-one solution
No corrosion
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Improved
heat recovery
Petrochemical company, Asia
Compabloc heat exchangers have
enabled a petrochemical company in
Asia to increase capacity for the
production of benzene and toluene,
while at the same time improving heat
recovery levels. Overall, the choice was
an easy one compared to shell-andtube
solutions – highly competitive
capital and installation costs, more
capacity using less space than the
original installation. Long service
intervals and easy service access, and
namely, high heat recovery resulting in
lower emissions.
Improved
performance
Lanxess, Germany
Of 110 units, AlfaNova and Compabloc
heat exchangers are used in nearly 75 %
of the positions at Lanxess’ plant for the
production of phenol-based colorants.
Because space is limited, a key
determinant in the decision to use
Alfa Laval exchangers is the flexible and
compact design. What’s more, Lanxess
expends less on installation, avoids
problems with corrosion and leakage
and gains considerably on performance
and efficiency.
Facts
Facts (see disclaimer**** on p. 27)
Energy savings/year
2100 kW
Fuel savings/year
2 028 ton
Fuel cost savings/year
446 kUSD
CO 2
-emission savings/year 5280 ton
CO 2
-emission cost savings/year 104 kUSD
Annual cost savings
550 kUSD
Capital cost savings
Reduced installation costs
Space savings
Operating cost savings
No corrosion or leakage
Reduced downtime
Reduced cost for maintenance
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Reliable
operation
Hualian Sunshine, China
The manufacturer of polymer-grade
terephthalic acid, Hualian Sunshine uses
a spiral heat exchanger made of titanium
for heat recovery in the filtrate treatment
and catalyst recovery unit. Because the
filtrates have a high solids content, the
process is prone to blockages. However,
when flushed with acetic acid each
month, the spiral heat exchanger
operates continuously with no need for
mechanical cleaning – saving on
downtime and maintenance.
Space
saving
Braskem, Brazil
When Braskem revamped its ethylene
plant, size was a determining factor. Now,
with Compabloc operating in parallel
with shell-and-tubes, the advantages of
compact heat exchangers are unmistakable.
Compabloc is resistant to
fouling, with no corrosion or risk of
leakage and longer maintenance intervals.
Installation was less compli cated
than with shell-and-tubes. Importantly,
Compabloc is helping to improve
efficiency at increasing production levels.
Facts
Facts (see disclaimer***** on p. 27)
Energy savings/year 850 kW
Fuel savings/year
1200 ton
CO 2
emission savings/year 4000 ton
Fuel cost savings/year >55 kEUR
Capital cost savings
Lower cost for compact solution
Lower cost for foundation
Less time needed for installation
Operating cost savings
Reduced downtime
Reduced costs for maintenance
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Double
safety
SBPC chemicals plant, China
Shanghai BASF Polyurethane Co., Ltd.
(SBPC), has installed a double-wall plate
heat exchanger from Alfa Laval for
cooling MDI from the process plant
before it is put into storage tanks. The
double-wall design of the PHE
eliminates risk of intermixing between
the cooling water and the product that
can result in the formation of solids that
may clog other equipment downstream.
According to Mr. Walter van Gysel, MDI
Technology Manager, at SBPC, the
double-wall PHE has performed beyond
expectations.
Fast
service
BASF, Belgium
Experiencing start-up problems with
new AlfaVap heat exchangers at its
Antwerp Caprolactam plant, BASF
called Alfa Laval. When BASF opened
the units on Alfa Laval’s instructions,
they saw crystallization due to a
problem with the wetting rate. BASF
project leader Sven Fastré relates: “Alfa
Laval came, and we put our heads
together and worked around the clock
to solve the problem. We were up and
running again within four days!”
Facts
Capital cost savings
Space savings
Reduction of effective surface area
Operating cost savings
Reduced costs for maintenance
Reduced downtime
Facts
Capital cost savings
Space savings
Heat recovery
Operating cost savings
Reduced start-up time
Reduced downtime
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… and more still
Belgium
Taminco selected three Compabloc for its
production site for Methylamine and
derivates in Ghent, Belgium where 39
such units are now installed. The heat
exchangers will be used in the production
of choline chloride.
When BASF, Antwerp chose two AlfaVap
700’s, one AlfaCond 800 and a M15B,
this was the second order for plate heat
exchangers for an evaporation system in
their caprolactam process.
China
Sinopec chooses Alfa Laval Packinox heat
exchangers for its Zhenhai (ZRCC)
aromatics plant. The equipment is running
in the catalytic processing sections in the
manufacturing of mixed Xylenes.
When Yisheng Dahau Petrochemical Co
decided on constructing the first large
central cooling system for the
petrochemical industry in China, they
chose 18 M30 from Alfa Laval.
Alfa Laval received three orders in China
for EO/EG projects of three different
licenses. The orders were for Compabloc,
plate and spiral heat exchangers.
Czech Republic
When UNIPETROL RPA at Litvinov in the
Czech Republic decided to increase the
capacity of its benzene plant, a total of 13
Compabloc heat exchangers were chosen
as coolers, condensers and reboilers in
the aromatic complex.
Germany
Linde AG chose Compabloc as reboilers
for producing steam from process water
as part of the BASF ethylene cracker
expansion project
BASF selected four Compabloc units for
various usages in their new phosgene
plant in Schwartzheide.
Hungary
With three Compabloc heat exchangers
already installed in their MDI plant in
Kazinbarcika, Borsodchem ordered four
more to work as crude MDI coolers.
India
Balaji Amines Ltd., Hyderabad ordered
seven Compabloc and two spiral heat
exchangers for their specialty chemical
plant (production of Gamma Butyro
Lactone). The company has previously
installed more than 35 compact heat
exchangers from Alfa Laval.
Italy
Polimeri Europa chose two Compabloc
heat exchangers as quench water coolers
at their ethylene plant in Brindisi.
Japan
A major petrochemical company in Japan
purchased a total of five Compabloc units
for their Sulfolane aromatics extraction
unit; three of which will be operating as
interchangers, and two as reboilers.
Alfa Laval got an order for eleven spiral
heat exchangers from the Japanese
contractor Mitsubishi Heavy Industries.
The heat exchangers will be used as
coolers in a propylene plant.
Russia
Alfa Laval received an order for two
Compabloc heat exchangers for the
Russian VCM plant Sayansk Himlaplast,
to serve as coolers in the dichloroethane
cracking process.
Saudi Arabia
Samsung Engineering in Korea selected
16 plate heat exchangers and three
Compabloc for the ethylene glycol
production plant in Eastern Petrochemical
Company SHARQ (SABIC), Saudi Arabia.
Libra Techcon Ltd in Mumbai placed two
orders for 39 compact heat exchangers
for acetaldehyde and pentaerythritol
production in Saudi Arabia with Alfa Laval.
Singapore
SembCorp Utilities Pte Ltd selected three
T50 plate heat exchangers to serve as a
central cooling system for Lucite’s 120kta
methyl methacrylate (MMA) plant at
Jurong Island.
Slovakia
Slovnaft chose Compabloc to function as
a dilution steam generator at the
company’s ethylene plant in Bratislava.
Taiwan
Formosa Chemicals and Fibre Company in
Taiwan ordered 16 semi-welded plate heat
exchangers and 15 Compabloc for their
polycarbonate production.
USA
BASF chose to install three additional
Compabloc to cool quench water at an
ethylene plant in Port Arthur, Texas,
making it five such units in all at the
position.
Disclaimer*:
Price on natural gas:
200 EUR/ton
Heat of combustion of natural gas: 48 MJ/kg
CO 2
-emission cost: 22 EUR/ton 1)
CO 2
-emissions:
2,6 ton/ton natural gas
Operation time:
350 days/year
Boiler efficiency: 65%
Disclaimer**:
Price on coal:
90 USD/ton
Heat on combustion of coal:
15 MJ/kg
CO 2
-emissions:
3,3 ton/ton coal
Operation time:
350 days/year
Boiler efficiency: 65%
Disclaimer***:
Price on natural gas:
225 USD/ton
Heat of combustion of natural gas: 48 MJ/kg
CO 2
-emissions:
2,6 ton/ton natural gas
Operation time:
350 days/year
Boiler efficiency: 40%
Disclaimer****:
Price on natural gas:
220 USD/ton
Heat of combustion of natural gas: 48 MJ/kg
CO 2
-emission cost: 20 USD/ton 1)
CO 2
-emissions:
2,6 ton/ton natural gas
Operation time:
350 days/year
Boiler efficiency: 65%
Disclaimer*****:
Price on coal:
45 EUR/ton
Heat on combustion of coal:
34 MJ/kg
CO 2
-emissions:
3,3 ton/ton coal
Operation time:
350 days/year
Boiler efficiency: 65%
1) Countries with restrictions on (to decrease)
CO 2
-emissions, so called Annex 1-countries.
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Ready for more enlightenment?
More information about compact heat exchangers and the benefits they
offer is already at your fingertips. The website below contains in-depth
case stories, detailed product information and application overviews, as
well as a valuable calculation tool. With its help, you can determine your
own potential fuel savings and reduction in CO 2 emissions.
www.alfalaval.com/energy
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Alfa Laval in brief
Alfa Laval is a leading global provider of specialized products
and engineering solutions.
Our equipment, systems and services are dedicated to
helping customers to optimize the performance of their
processes. Time and time again.
We help our customers to heat, cool, separate and
transport products such as oil, water, chemicals, beverages,
foodstuffs, starch and pharmaceuticals.
Our worldwide organization works closely with customers
in almost 100 countries to help them stay ahead.
How to contact Alfa Laval
Contact details for all countries are continually updated on
our web site. Please visit www.alfalaval.com to access the
information.
Alfa Laval is a trademark registered and owned by Alfa Laval Corporate AB. PPI00271 EN 0901
www.alfalaval.com/energy