Compabloc - compact performance

Compabloc - the new laser welded heat exchanger series

arrangement within each pass (see fig-ure at right) while the overall flowarrangement is counter-current for amulti-pass unit (see sectional viewbelow). When required, the unit can bedesigned with overall co-current opera-tion. Each pass is separated from theadjacent passes by a pressed baffle,which forces the fluid to turn betweenthe plate pack and the panel. Thisenables cleaning by backflushing.Baffles are inserted inside the platepack as shown in the two figures onthe next page. The baffles are dimen-sioned to withstand full vacuum andcan be rearranged to fit a change induty.

Panel

Heat transferplate pack

Gasket

Support

Upper head

Baffle Girder

Lower head

The heart of the matterThe heart of Compabloc is a stack ofcorrugated heat-transfer plates in stain-less steel or exotic materials, weldedalternately to form channels.Compabloc is available in six differentmodels: CP15, CP20, CPL30, CPL40,CPL50 and CPL75 with heat transferareas ranging from 0.7 to 320m2

(7 to 3 450 ft2) per unit. Each model ismodularized with a standard number ofplates to fit any duty.

Welds that meet your challengesCompabloc models CP15 and CP20are TIG welded whereas the largermodels CPL30 to CPL75 are laserwelded. The advantage of laser weldingis that the weld is thinner and moreaccurate, and the heat input is substan-tially reduced. This results in a unit withless stress, which makes it less sensi-tive to fatigue and cycling. In otherwords, laser welding improves reliability,extends the working life, and enablesCompabloc installation in harsh environ-ments. Another advantage is the short-er and more flexible delivery time.

Plate patternA new and improved plate pattern, optimized with regards to structuralstrength and flow mechanics, makesCompabloc more resistant to pressurepeaks and cycling, thus increasing thereliability and safety of the unit with bet-ter heat transfer performance.

Flow pathsThe two media flow in alternately weld-ed channels between the corrugatedplates. They flow in a cross-flow

The two media flow in cross-flowin alternately welded channels

Sectional view of Compabloc

CompablocThe Compabloc welded plate heat exchanger from Alfa Laval is just reachingpeak performance when many other conventional heat exchangers start to runout of steam. With no gaskets between the plates, Compabloc is perfect foroperation in chemically aggressive environments and for handling high-tempera-ture fluids.

2 Compabloc

Baffle

Baffle

Baffle

Compabloc plate heatexchanger installed forliquid-to-liquid heat recovery in a chemical plant in Scandinavia

A series of baffles force the media to reverseflow direction and create a multi-pass flowpattern

Cross-section of a baffle arrangementillustrating flow distribution

More in less spaceCompabloc is very compact. All theheat transfer area is packed into asmaller footprint than that required forcomparable heat exchangers. Forexample, a Compabloc with 320m2

(3 450 ft2) heat transfer area needs only1m2 (11 ft2) of floor space.

Extended performance limitsCompabloc extends design pressurefrom full vacuum (FV) up to 35 barg(500psig) depending on the model, andstandard design temperatures up to350ºC and down to -29ºC (ASMEdesign) or alternatively -40ºC (PEDdesign), with the possibility of specialdesign down to -100ºC (-148ºF).

Take your pick of plate materialsCompabloc is available in virtually anymaterial that can be pressed and wel-ded, including:

• AISI 304L • alloy C22• AISI 316L • alloy C276• monel • alloy B-2• titanium • tantalum• titanium-palladium • DIN 1.4335• incoloy™ 825 • 254 SMO• hastelloy™ C2000 • 904L (UB6)

Made to orderCompabloc is manufactured as stan-dard in accordance with internationalpressure vessel codes such as ASME(with or without U stamp) or ADM (codeused for PED and CE Marking).

BodyThe Compabloc frame consists of fourcorner girders, top and bottom headsand four side panels with nozzle con-nections. These components are boltedtogether and can be quickly taken apartfor inspection, service or cleaning.

Panels and nozzles to fitThe panels and nozzles can be unlinedor lined using the same materials as theplate pack. The nozzle size is variableand can be selected independently foreach side. The nozzle size is deter-mined by:• the frame width (i.e. plate size).• the frame height (i.e. number of plates).• the number of plates per pass (i. e.

pass height).

Compabloc’s variable nozzle sizes andflexible pass arrangements make it suit-able for liquid-to-liquid duties with dis-similar flow rates. In condensationduties the vapour inlet may need alarge nozzle while the condensaterequires only a small one.

Between the panel and the column lin-ing is a gasket that seals off the exteri-or. This gasket can be made of graphite,Klingersil®, Goretex® or other typicalflange gasket materials.

Compabloc 3

Flow configurations for different dutiesCompabloc can be designed with bothsingle-pass or multi-pass flow configu-rations. For condensation and liquid-to-liquid duties without temperature cross,the single-pass configuration is suitablewith its total cross-flow.

For duties with temperature cross andclose temperature approaches, a multi-pass configuration is suitable. Eachpass is in cross-flow, but the overallflow pattern within the heat exchangeris counter-current.

The configuration of Compabloc hasunique advantages that permit:

• a different number of passes on thetwo circuits, thereby enabling largedifferences in flow rates between thehot side and the cold side.

Suspendedmounting forcondensation duties

Vertical Compablocfor liquid/liquid heatrecovery

Compabloc vs. shell-and-tubeTake a look at a few of the features,advantages and benefits of Compablocin comparison with the shell-and-tubeheat exchanger:

• Alternately welded plates –permit access for inspection, service,or cleaning.

• No gaskets between plates –allows operating:- with aggressive media.- at higher temperatures and pressures.

• Corrugated plates –promote high turbulence which, in turn:

- achieves three to five times greateroverall heat transfer coefficients than ashell-and-tube heat exchanger.

- minimizes fouling, which makes longeroperating periods possible.

• Close temperature approach –can handle temperature approachesdown to 3ºC (5.4ºF).

Made to meet the process conditionsWhile many heat exchangers on the market today are manufactured to satisfy abroad range of process conditions, Alfa Laval’s Compabloc heat exchangers aretailor-made to meet the customer’s exact process conditions. This design flexibili-ty includes both the flow configurations in the heat exchanger and the installationmode.

• the rearrangement of the baffles to fita new duty should the flow rates ortemperature change.

Three ways to install CompablocCompabloc plate heat exchangers canbe installed in three different positions:

• Vertical mounting –normally used for liquid-to-liquidduties, condensation with subcoolingand gas cooling duties, particularlywhen floor space is limited.

• Horizontal mounting –used for condensation duties, reboil-ing, gas cooling or liquid-to-liquidduties, when there are height limitations.

• Suspended mounting –hanging the unit from the ceiling generally used for condensing duties.

Compabloc installed as stripping columnreboiler at an ethyl-acetate plant in Rhodia,Brazil

3.4 metres

(11 feet)

12 metres (39 feet)

Compabloc vs. shell-and-tube (same duty).

4 Compabloc

Compabloc as pre-heater, condenser and reboiler

colum

n

condenser

reboilerpre-heater

vapour non-condensablegases

condensate

vapour/liquidmixture

liquid condensate

steam

Reboiler

Two-pass process condenserwith gas/liquid seperation

• Compactness – takes only a fraction of the floorspace of a shell-and-tube heatexchanger.

Condensation & evaporationIn condensing and evaporating duties,the Compabloc provides additionaladvantages:

• Large cross-flow area and shortflow path –fit low-pressure condensing dutiesand allow very low pressure drops.

Designed with demanding duties in mindWhen it comes to high thermal performance under difficult process conditions,the laser welded Compabloc has a distinct advantage over alternative heatexchangers including shell-and-tube.

• Versatility – variable nozzle sizes allowCompabloc to handle large differ-ences between vapour and conden-sate flow rates.

• No need for extra equipment – a two-pass arrangement on the con-densing side permits gas-liquid sepa-ration in the unit, thereby eliminatingthe need for a separator. The main

condensation takes place in the firstpass; final condensation or sub-cool-ing of inerts takes place in the secondpass, which also serves as a misteliminator.

• Short flow path and flexible con-nection sizes –make Compabloc a perfect reboilerand evaporator.

Compabloc 5

Applications

Oil & gas production• Heat recovery in TEG systems (gas

dehydration)• Heat recovery, cooling, condensation

& reboiling in amine systems (gassweetening, sour service)

• Heat recovery, heating and cooling incrude oil dehydration and desalina-tion systems

• Condensation in vapour recovery units• Heat recovery, cooling, condensation

and reboiling in NGL fractionationsystems

RefineriesVarious condensing & reboiling dutiessuch as:• Condensation of naphta in atmos-

pheric distillation• Top condensing on fractionators in

FCC, hydrocracking, H2S strippers, etc.• Propane & butane overheads con-

densing in NGL and alkylation plants• Reboiling in H2S strippers, sour water

strippers and other columns• Steam generation

Heat recovery, cooling & heating dutiessuch as:• Cooling of gasoline, kerosene, gas oil,

diesel, pump-around etc• Cooling & heating of bitumen, VGO

(vacuum gas oil) and other heavyproducts

• Fractionator feed/bottom heat recovery

• Pre-heating of crude oil• Desalted water/feed water heat

recovery

Hydrocarbon process industryCondensation, heating/cooling, heatrecovery and reboiling duties in the pro-duction of:• primaries such as olefins, aromatics,

aldehydes, acids, ethers, esters,ketones, and halogens

• intermediates such as acrolein,acrylic acid and acrylates, acryloni-trile, adipic acid, alkylbenzenes, ani-line/nitrobenzene, benzenesulphonicacid, bispenol A, caprolactam, diiso-cyanates (MDI & TDI),ethylbenzene/styrene, ethyleneoxide/glycol, hexamethylenediamine(HMDA), maleic anhydride,melamine, phenol, phosgene, phthalicanhydride, propylene oxide/glycol,terephthalic acid (PTA)/dimethylterephthalate (DMT), vinyl acetate,vinyl chloride, EDC

• polymers including polyethylene,polypropylene, polystyrene andstyrene co-polymers, formaldehyderesins, polycarbonates, polyols,polyvinyl acetate, and polyvinyl alcohol

• other organic chemicals such assoaps and detergents, paintings andcoatings

Pharmaceutical industry & specialty chemicals• Special 2-pass condenser with built-in

gas/liquid separation chamber andmist eliminator for reactor overheadand vent condensation

• Primary and vent condensation withhygienic design

• Solvent recovery

Coke oven plants• Ammonia liquor scrubber cooling• Debenzolized oil cooling• Benzolized oil heating

Chlorine alkali plants• Chlorine gas cooling (drying)• Hydrogen gas cooling (drying)

Fertilizer production• Nitrogen gas cooling• CO2 gas cooling (3-step compressor

interstage cooler - gas drying)• Ammonia heat recovery and stripping

column reboiler• Nitric acid cooling

Hydrogene peroxide plants• Heat recovery and cooling of process

streams

Ammonium nitrate • Spent sulphuric acid heat recovery.• Oleum cooling

Mining industry• Nickel refining solvent extraction

Vegetable oil & fatty acids• Feed/bottom in deodorization

HVAC, district heating, energy,utilities, general services• Hot water production system• Steam heating• Heat recovery

From oil & gas to district heatingThe numerous advantages of the Compabloc heat exchanger make it suitable foruse in a wide range of industries and applications.

6 Compabloc

Compact facts about CompablocDesign temperature: up to 350°C (660°F), down to -100°C (-148°F).Design pressure: up to 35barg (500psig) depending on models and full vacuum (FV).Maximum heat transfer area: 320m2 (3 450 ft2).Maximum liquid flow rate per unit: 4 000m3/h (17 500 USgpm).Lowest achievable temperature difference: 3°C (5.4°F).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.

In case of service…The flexible construction of Compablocmeans that service is simple.

Chemical cleaningShould fouling occur, it is easy to cleanCompabloc without removing it fromthe plant. Cleaning can be done on siteby circulating cleaning solutions throughthe unit. Chemical cleaning is highlyeffective as a result of the unit’s highturbulence and low hold-up volume.

Chemical cleaning can also be per-formed by removing the plate pack andimmersing it in a chemical bath.

On-site chemical cleaning is performed usingthe Alfa Laval CIP unit by circulating cleaningsolutions through Compabloc. The solutionis circulated from the lower inlet connection,through Compabloc and then dischargedfrom the upper connection to the CIP tank.

Compabloc 7

How to contact Alfa Laval

Contact details for all countries arecontinually updated on our website.Please visit www.alfalaval.com to access the information direct.

Alfa Laval in brief

Alfa Laval is a leading global providerof specialized products and engi-neered 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 transport prod-ucts such as oil, water, chemicals,beverages, foodstuff, starch andpharmaceuticals.

Our worldwide organization worksclosely with customers in almost 100 countries to help them stay ahead.

IB 67229 EN 0205