Alfa Laval – plate technology

It’s all about optimizing

Alfa Laval’s business activities have one sole focus –

providing you as the customer with technologies and

solutions that help you optimize a wide range of your

key industrial processes still further.

Because virtually all forms of industrial processes

involve heating or cooling substances of some kind,

it is only natural that Alfa Laval focuses strongly on

heat transfer technologies and solutions.

Alfa Laval – plate technology 3

Optimizing the use of heat energy

In any form of heating and cooling, onepath to greater profitability is to extractmaximum benefit from all the heatenergy already available within thesystem – rather than producing or buying expensive additional heatenergy.

Heat transfer involves bringing twosubstances at different temperaturesclose to each other, so that one eitherheats or cools the other. This meansthat energy already within the system –which is already paid for – is simplytransferred to another part of theprocess where it can be put to greatesteffect. This saves you money, savesenergy and reduces the overallenvironmental impact of yourproduction processes.

Only the biggest and best companiesin this field have the resources and theknow-how to provide a comprehensiverange of heat exchanger solutions. AlfaLaval is one of those companies, ableto supply the optimal heat transfertechnologies to meet your needs.

Heat transfer technologies – the choiceBroadly speaking, shell-and-tube heatexchangers are the large, traditionalsolution, spiral heat exchangers are thesmaller, simple solution and plate heatexchangers are the compact, modernsolution with significantly better thermalefficiency and by far the greatesttechnology development potential.

At Alfa Laval, we want to provide youwith optimal solutions. Alfa Laval hastherefore focused strongly on plateheat exchanger technology.

Optimizing heat transferPlate heat exchangers are designed tooptimize heat transfer, because thecorrugated plates provide by far thegreatest surface area through whichthe heat can be drawn from one gas orliquid to the other. Despite thissubstantial area for heat transfer, plateheat exchangers are usually relativelycompact. For example, an Alfa LavalCompabloc solution, one of the mostcompact installations currentlyavailable, only takes up about 20% ofthe physical space needed for atraditional installation.The design of the channels alsoensures maximum turbulence as eachfluid passes through. This results inmaximum efficiency in transferring heatfrom one medium to the other.

Plate technology of todayNew designs provide improveduniform distribution and higherdesign pressure capabilities.

Distribution areaLocated at the top and bottom ofthe plate, this area is responsiblefor ensuring fluid is distributeduniformly across the entire widthof the plate, eliminating deadspots. This is more complex onmodern units where inlet andoutlet are aligned vertically foreasier piping. Alfa Laval’s designsprovide complete fluiddistribution across even ourwidest plate.

Entrance neckDesigned for lowpressure drop as wellas low velocities forreliable erosionprevention.

Main heat transfer zoneCritical for creating the highestturbulence consistent withdesired pressure drop.

4 Alfa Laval – plate technology

Support columnInspection cover

Roller assembly

Movable cover Gasket Plate pack Carrying bar

Stud bolt

Frame plate

Frame foot

Protection sheetBearing box

Tightening bolt

Lock washer

Tightening nut

Guide bar

Support foot

Alfa Laval – plate technology 5

Working principleThe basic plate heat exchangerconsists of a series of thin, corrugatedplates that are gasketed or weldedtogether (or any combination of these)depending on the liquids passingthrough and on whether it is practical

to be able to subsequently separatethe plates, for whatever reason.The plates are then compressedtogether in a rigid frame to create anarrangement of parallel flow channels.One fluid travels in the odd numberedchannels, the other in the even.

Corporate Brochure 8

All plate heat exchangers look similarfrom the outside. The differences lieinside, in the details of plate designand the sealing technologies used.

Alfa Laval is the largest manufacturer ofplate heat exchanger solutions in theworld. We use plate heat exchangerdesign and manufacturing processesthat are quite simply in a class of theirown:● single-step pressing of plates –

resulting in greater uniformity, less physical stress, thinner plates and more efficient heat transfer

● patented distribution area design – resulting in maximum use of the heattransfer area, the greatest turbulencein the flow, optimum fluid distribution,higher design pressure capabilities and minimal fouling

● the ability to provide you with a complete range of fully optimized plate heat exchanger designs, sizes and applications that can meet virtually any operational specification.

Plate heat exchangers from Alfa Lavalare available:● gasketed or welded together (or any

combination of these) using a vast range of carefully researched gasket materials and adhesives.

● as single–phase containing two liquids or for two-phase applications containing a gas and a liquid, and serving as condensers, evaporators and reboilers.

● for a huge range of different temperatures and pressures, and fluids with differing purity, viscosity and solids/fibre content.

● as two-in-one units because the temperature profile and flow through the unit can be managed exactly as required.

● for a vast range of different applications, ranging from the most aggressive and demanding environments, such as the nuclear power industry and offshore oil and gas installations, to the processing ofdelicate beverages and foodstuffs.

The difference lies on the inside

Glued gasketsShould your operating condition promotegasket swelling, glued gaskets provideincreased reliability, especially for repeatedopenings. Replacement of glued gaskets isnot necessary for servicing. Our oven-curedepoxy affixes the gasket firmly and will notdissolve.

Glue-free gasketsGlue-free gaskets provide fast and easygasket replacement on site.

WeldedCompletely welded plates expandtemperature and pressure limitations to350°C (650°F) and 40 bar 625 psig.

6 Alfa Laval – plate technology

NO SHIFTSIDEWAYS

Plate heat exchanger frame

“No Shift” 5-point metal-to-metal alignment system• Keeps plates aligned easily

during opening and closing• Guarantees first time seal• Improves reliability against

gasket blow-out• Extends gasket life

SS roller assembly to facilitateopening and avoid wear & tear on carrying bar

Carrying bar• SS profile to allow easy

plate movement

5-point alignment system

Bolted construction (no welded parts) allowingfield assembly and future expansion

Connections are available in stainless steel and titanium

Lifting lugs or lifting holes for safe & easy handling

Studded port connection allowing increased pipe loadings

In single-pass units: all connections in frameplate provide maintenance without

disconnection of piping

Maximum design pressure up to 30 bar (450 psig). Design temperature up to

maximum180°C (350°F)minimum -50°C (-58°F).

Recess to secure bolts safely

Thicker frame covers with no reinforcementsmean fewer tightening bolts and easier

opening/closing

In multi-pass units: blind flanges & inspection covers available

Superior bolt closing system

Bolted feet for increased stability and fixing to the floor

Easy-to-open, easy-toclose tightening system• Low torque bearing box

and lock washers allow easy opening and closing

• Simple, one person operation

• No special tools required• Rolled threads eliminate

galling and seizing• Bolted construction (no

welded parts) allows fieldassembly and futureexpansion

Heavy-duty designwithout reinforcement• Applies uniform plate

pressure• Eliminates flexing or

bending of plates• Creates a superior seal• Extends gasket life

Frame standards• ASME, “U” and “UM”

standard

• PED/CE-mark

• pvc ALSTM

Protective shroud meetingOSHA requirement

Diabon Graphite® nonmetallicA composite of fused graphite and fluoroplastic, this unit provides excellentresistance to hydrochloric acid, AlCl3, and other corrosive materials.Unlike traditional graphite, Diabon F® has no porosity or permeability. Itresists cracking and breakage during handling and use.

Semi-welded plateWelded channels for process fluids allow aggressive and difficult fluids to behandled in a plate heat exchanger and expands the pressure range. Thegasket exposure is minimal on the welded side.

Double-wall plateComposed of plates pressed simultaneously and laser welded at the port, thisis designed for applications where additional reliability against intermixing isnecessary to prevent catastrophe. Failure of one plate results in externaldetection without interleakage. The second wall provides a double barrierbetween fluids, meeting local health code regulations.

Wide-gap plateWith 17mm channels free of contact points, this plate is ideal for fluidscontaining fibres or coarse particles. Each channel has been designed toeliminate bridging of solids in the entrance area.

Welded channel for agressive fluid

Gasketed channel for

cooling medium

Peripheral weld

Plate innovations

8 Alfa Laval – plate technology

Feed

Vapour

Conc

Steam

Cond

Plate condenserCompact design plate condenser replaces traditional large units. Customizedconnections for large volumes of vapour, specific plate pattern, asymmetricplate gap to optimize heat transfer and minimize pressure drop make it suitablefor condensation.

Plate evaporatorCompact and economically efficient, theplate evaporator/condenser replacesconventional large and expensive fallingfilm units. Its deep channels, large portsand laser welding allow vacuum and lowpressure evaporation and condensing forboth aqueous and organic systems.

Alfa Laval – Plate Technology 9

Alfa Laval plate heat exchangersolutions can help you:

Boost performance and capacityAlfa Laval plate heat exchangers areextremely compact. Due to the verysmall footprint, often only about 20% ofthe size of traditional installations, newequipment can be installed even inextremely confined spaces, to boostthe performance and capacity ofexisting plants.

Achieve much greater flexibility andscalabilityAlfa Laval plate heat exchangers are allbased on a design that is inherentlyflexible. The number and specificationsof the plates can simply be increased,reduced or altered as the capacity yourequire varies over time. This meansless capital tied to application-specificequipment.

Ensure smoother operationOperations that use Alfa Laval plateheat exchangers are easier to control,and have much lower start-up volume.Because of the vastly greatercontrolled turbulence in the flow, theyare much less affected by troublesomefouling than traditional solutions. Theyare also subject to less vibration, stressand material fatigue.

Cut down on maintenance, serviceand cleaningAlfa Laval plate heat exchangers canmake a radical difference to yourcompany’s maintenance and serviceschedules, and the down time thesecan involve. These solutions featuresignificantly better flow patterns withmuch greater turbulence than shell-and-tube heat exchangers.

This gives you much greater heattransfer efficiency with the major addedbenefit of less fouling and virtually nocorrosion or erosion. This results infewer, much quicker inspections andrapid cleaning. And the Alfa Lavalsolution means that all cleaning orplate replacement work can be doneon site and within the physical footprintof the unit.

The Alfa Laval pay-off

To achieve maximum profitability in modernprocess industry, it is important that your companycan heat and cool a wide range of substances:

● with great precision● at low overall cost● with maximum reliability● with a minimum of energy consumption● in an environmentally responsible way.

10 Alfa Laval – plate technology

Acquire installations that bring youmajor cost savingsAlfa Laval plate heat exchangers areexceedingly compact in size. Ininstallations that require exotic metals,special alloys and other costlycomponents to deal with aggressivemedia, this means significant savings ininitial purchase costs.

Small size and low weight also meanlow initial installation cost, while highheat transfer efficiency means lowoperating costs throughout the unit’sworking life. And the major reduction inmaintenance requirements comparedwith traditional equipment also cutsservice costs right back.

Ensure minimum environmentalimpactEnvironmental impact is becoming anincreasingly critical concern, and AlfaLaval plate heat exchanger solutionsprovide you with a way of reducing thissignificantly.

By ensuring maximum heat recoveryfrom any and every one of yourindustrial processes, as well as the useof less cooling medium and lessheating medium, Alfa Laval technology

can give a serious boost to the long-term socio-political acceptability of yourindustrial operations.

Create a viable technology upgrade pathShell-and-tube heat exchangers aresolutions that do indeed work, but arefundamentally expensive, heavy andessentially obsolescent.

Alfa Laval plate heat exchangersolutions are equally well proven yetthey are also light in weight andrelatively inexpensive in terms of capitalcost, installation cost, operating costand service cost. And they are capableof virtually unlimited future developmentas regards the kind of industrialprocesses you can use them for.

Alfa Laval is able to supply plate heatexchanger that can deal with acontinually expanding envelope ofpressures and temperatures, as well asliquids with greater viscosity and higherfibre content.

Expanding the envelopeAlfa Laval plate heat exchangertechnology also expands the entireenvelope of what you can achieve withyour company’s process technology:● completely new solutions become

possible (combining a condenser and a sub-cooler in one single unit, for example)

● supplementary technologies, such astemperature pinching, can be introduced

● exotic metals can be used at relatively low cost, making it completely feasible to use plate heat exchangers even with volatile and highly corrosive substances

Alfa Laval – plate technology 11

Competitive advantage and bottom-lineprofits are always boosted by makingthe most out of what you’ve got. Butplate heat exchanger solutions fromAlfa Laval also make it possible tobreak new ground. They provide youwith ways of significantly boosting:● the heat transfer capacity at your

disposal, at relatively low cost● your control over the heat transfer

process/temperature profile● your product quality, due to better

control of surface heating/cooling, avoiding harmful overheating

● product quantities due to better condensing

Future objectives in plate heatexchanger technologyAlfa Laval is at the forefront of R&Dwork on plate heat exchangers. Ourpractical experience indicates that theyears to come will feature furtherdevelopment in the following areas:● energy-saving measures● units that can work within even

greater temperature and pressure ranges

● greater focus on Life Cycle Costs (LCC)

● use in even more industrial applications

● multipurpose installations● standardized preventative

maintenance● service that can be conducted within

the physical footprint of the unit

Making the most of it

12 Alfa Laval – plate technology

Precision heat transferCloser approach temperatureTrue counter current flowCapable of handling crossing temperatures80–90% less hold-up volume

Low overall costLow capital investmentReduced installation costsLimited maintenance expenditureMinimal operating costs

Maximum reliabilityLess foulingLess stress, wear and corrosionPrecision engineering/laser welding

Minimum energyconsumptionMaximum heat recoveryLower energy costsSmaller surface area

Environmentallyresponsible solutionMinimum energy consumption for maximum process effectReduced cleaningFewer materials used in constructionLower Life Cycle Costs (LCC)

Alfa Laval – plate technology 13

The full range

AlfaRexWelded plate heat exchangerGasket-free, high temperature, high pressure,compact plate heat exchanger.Laser welded. Two-dimensional welding reduces thermalexpansion fatigue.

Brazed unitsUsing copper for brazing to eliminate gaskets, thesecompact heat exchangers are perfect for small or packagedapplications.

AlfaVap – plate evaporaterTailored for high-capacity evaporation applications with superior abilities tohandle viscous fluids. Features a special plate pattern for stillage evaporation.

One of the key advantages of sourcingyour equipment from Alfa Laval is theexceptional range of products andtechnologies available. Alfa Laval can meetany heat transfer requirement you mighthave, and all installations are backed bythe unparalleled strength of the Alfa LavalNonstop Performance concept.

This ensures:● maximum efficiency of all processes● maximum uptime● minimum maintenance and service costs

14 Alfa Laval – plate technology

Compabloc®Welded plate heat exchanger

Versatile as a liquid-to-liquid exchanger, interchanger, reboiler, condenser,

evaporator, and steam heater.

AlfaCond – plate condenserCompact design plate condenser replaces traditional large units. Customized

connections for large volumes of vapour, specific plate pattern, asymmetric plategap to optimize heat transfer and minimize pressure drop make it suitable for

condensation.

Sanitary solutionsFrontlineTM

Pasteurization and general cooling/heatingof dairy, brewery, beverage and viscous

products.

BaselineCooling and heating of dairy, brewery,

beverage and viscous products andpasteurization in some applications.

Alfa Laval – plate technology 15

Alfa Laval in brief

Alfa Laval is a leading global provider of specialized products and engineered solutions.

Our equipment, systems and services are dedicated to helpingcustomers to optimize the perform-ance of their processes. Time andtime again.

We help our customers to heat, cool, separate and transportproducts such as oil, water, chemi-cals, beverages, foodstuffs, starchand pharmaceuticals.

Our worldwide organization works closely with customers inalmost 100 countries to help themstay ahead.

How to contact Alfa Laval

Up-to-date Alfa Laval contact detailsfor all countries are always availableon our website at www.alfalaval.com

PPM00063EN 0704