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Heat Exchangers and Components in Graphite and Silicon CarbideHeat Exchangers and Components in Graphite and Silicon Carbide Content PageIntroduction 3The Material Graphite 4The Material Silicon Carbide 5The Designs 6Best Choice for any Application... 7Products in GraphiteAnnular-groove Condenser NB/HB/KB 8Annular-groove Column Heat Exchanger G1 8cGMP Annular-groove Condenser NB/GMP / HB/GMP 9Annular-groove Vent Condenser GN/GH 9Annular-groove Heat Exchanger RA/WA 10Annular-groove Dilution Cooler RA-K 10Annular-groove Evaporator UB/FB 11Conti-Reactor 11Annular-groove Absorber 12Block Heat Exchanger GE/GZ 12Quench 13Columns and Column Internals 13Other Components 14Products in Silicon CarbideSilicon Carbide Shell & Tube Heat Exchanger SR 15Silicon Carbide Block Heat Exchanger SE 16Silicon Carbide Annular-groove Heat Exchanger SB 17Overview on Products and Applications 18-19ContentsFor more than 45 years GAB Neumann have designed and manufactured heat exchangers, equipment and components for applications in the chemical, pharma-ceutical, steel coating and environmental industries.Providing the highest quality and maintaining a strong customer focus are the foundation of our organisation. This is demonstrated by the longevity of more than 18,000 units that have been delivered to a loyal customer base. Our staff are our key, they ?are highly skilled, well experienced and dedicated, ensuring the success of our p?roducts and our company. Across the world, our staff and agents develop solutions with our clients for their specific applications to optimise overall performance and cost.Our experienced staff assist in thermal and physical sizing of uni?ts using customised software (e.g. finite element analysis) which is translated into the automated manu-facturing process to ensure continuity throughout the chain. In addition to our products we offer the respective maintenance services. These activities include chemical cleaning services of process equipment and plants in various materials of construction of various manufacturers.45 years of experience withmore than 18,000 unitsdeliveredPriority to quality and customerfocusSatisfied customers worldwideISO 9001:2000 certifiedDesign following DGRL andother recognised standards3GAB NeumannThe critical success factors for high quality graphite processing ?are: an homoge- neous texture, a uniform grain structure, a perfect graphite impregnation process and consistent mechanical and thermal processing. Providing these, ensures that our products meet the most demanding requirements (e.g. cGMP capabilities).Graphite is characterised by its wide ranging and high level of corrosion resistance. It resists nearly all acids, solvents, chlorides and other halogen compounds as well as their corresponding alloys.Graphite‘s thermal conductivity is much greater than most comparable corrosion resistant materials.A very low tendency to foul compliments and helps to qualify the material for use in onerous applications.Duties as extreme as quenching flue gas at 1,300°C can be accommod?ated with graphite as it is capable of withstanding wall temperatures within the range of ?-60°C to +200°C.Diverse processes can be accommodated with the large available pressure envelope -1 bar to +16 bar .Different raw material manufacturing processes provide for differing graphite grades, i.e. mechanical strengths, allowable operating temperatures and chemical resistance.The Material GraphiteThe main criteria for the qualityare the texture, the gr?ain structure, the impregnation resin and the impregnation processProviding the highest corrosionresistance against ac?ids, solvents, chlorides and ot?her halogenated compoundsExcellent thermal conductivityGraphite is non?-adhesiveA maximum temperature rangeof ?-60°C to +200°C allo?ws process temperature of up to1,300°CA maximum pressure envelope of -1 bar to +16 barWe have 3 graphite quali?ties serving different requirements4Comparison of the thermalconductivity of various corrosionresistant materials used in thechemical processing industryA comparison of the adhesion angle as an indicator for the adherence tendency of various corrosion resistant materialsGlassHastelloyStainlessSteelTitaniumZirconiumTantalumSiCGraphite11214012010080604020017 172560Thermal Conductivity [W/mK] 130130403530252037,3 36,6 36 35,731,625,3Stainless SteelsandblastedAdhhesion Angle [°]Glass linedImpreglonCoatingStainless Steel electropolishedStainless Steelbase groundedGraphite PFA29Due to its hardness, its resistance against abrasion, its thermal properties and the universal corrosion resistance silicon carbide is an excellent material for the design of heat exchangers and other process equipment. Regarding its complete lack of ductility and other mechanical treatment it is very different from any metallic ma-terials.Crucial to the application of the pressureless and directly sintered silicon carbide SSiC employed in GAB Neumann products is its excellent chemical and abrasion resistance.Silicon carbide shows a very high purity and consecutively does not cause any pro-duct contamination. For the use in ultra pure processes, e.g. in the manufacturing of electronic chemicals, SSiC is cleaned by a a special cleaning agent before use.This enables the material for the use in ppt applications.The ceramic also offers excellent properties with respect to thermal shock. The al-lowable short term temperature gradient exceeds 200 K. This ensures highest ope-rational safety of heat exchangers and condensers especially at start up and shut down procedures.To comply with the different challenges of diverse applications GAB Neumann deve-loped three heat echanger designs:| CORRESIC® Shell and Tube Heat Exchangers| CORRESIC® Block Heat Exchangers| CORRESIC® Annular-groove Heat ExchangersThe specific characteristics of the different designs result in diverse benefits as per the respective application. This ensures best performance throughout all thermal processes.The Material Silicon CarbideUniversal chemical resistance and excellent resistance against abrasionNo risk of product contami-nationUse in ultra pure processes (ppt level)Excellent resistance against thermal shocks, especially during start up and shut down proceduresAdmissible operating tempe-ratures: -60°C to +220°CAdmissible operation pres-sures: -1 bar to +16 bar g5Chemical resistance of pressureless sintered silicon carbide (SSiC)Ablation Rate [mg/cm2a]H20 dest.H2SO4 96%H2SO4 98%HNO3 65%HNO3 70%H3PO4 85%HCI 32%HCI 25%HF 53%HF/HNO3NaOH 30%NaOH 50%KOH 30%KOH 45%1010,10,010,001170°C120°C100°C25°Ctechnically no corrosion (< 0,2 mg/cm2a) suitable for long-term use (< 9,9 mg/cm2a) The DesignsKey design and one focus of the GAB Neumann product portfolio is the annular-groove heat exchanger design.This unique design developed by GAB Neumann enables us to adapt the heat exchanger to the specific needs of the customer‘s operating requirements. The geometry and design provides high turbulence, resulting in low fouling, automatic cleaning and high heat transfer. Potential leak paths and cross contamination is minimised by eliminating or reducing gasketed joints.Block and shell & tube heat exchangers complete the various modifications of the annular-groove heat exchanger design. This portfolio enables us to cover the complete range of thermal processes perfectly.6Broad design portfolio to cover all thermal applications perfectlyUnique designHighly turbulent forced flow provides excellent automatic cleaningMinimum fouling and high thermal conductivity provides best heat transferLeak paths minimised with no or few gasketsBest Choice for any Application...The combination of the designs developed and the two high performance materials impregnated graphite and silicon carbide result in heat exchangers that are applied successfully in both, mono and multi purpose plants. According the specific thermal processes the optimal design and the suitable material can be chosen.Depending on the application, for example, best thermal performance at small overall size, product purity, cGMP compliance in API synthesis units or other specific process conditions are crucial to the best choice.In any case, this broad portfolio ensures best operational saftey, highest equipment reliablity at competitive prices and low operating and maintenance cost.Technically perfectUse in single or multipurpose plantsHigh thermal performanceSmall overall sizecGMP-compliant / qualified for API-productionLong lifetimeEconomically outstandingLow cost priceShort delivery timeLow operating expenses7Annular-groove Condenser NB/HB/KB- Condensers for highly corrosive applications with high heat transfer- Corrosion resistant on both service and product side- Vertical or horizontal installation?- Dephlegmation applications possible- Carbon fibre reinforcement (optional)- Detachable header and bottom for mechanical cleaning of product side (optional)Applications (examples) - Condensing of chlorinated solvents and acidic chlorides in pharmaceutical, agrochemical or dyestuff industries- Condensing vapours in inorganic processes (e.g. sulphur-acidic vapours, hydrochloridic vapours)Special FeaturesBoth flow cross?-sections arevariable, thus resulting in highheat transfer rates and? self?-cleaningNo gaskets and therefore norisk of leakageNo critical swelling stresscaused by the use of organicsolventsBenefitsHigh operational safetyHigh operational availabilityMinimised maintenance needsSmall heat transfer arearequirementsSmall space needs8Annular-groove Column Heat Exchanger G1- Heat exchanger for highly corrosive applications- For direct vertical installation in columns- Corrosion resistant both on the service and product side- cGMP design (optional)Applications (examples) - Use as a dephlegmator in the partial condensation of solvents- Heat input into a column (e.g. as an evaporator ”Robert” type)- Application as a head condenser in a column with reflux separatorSpecial FeaturesDirect access to productgroovesExtremely small overall heightBenefitsEasy to clean on theproduct sideSmall required space in column- Condenser for cGMP applications (e.g. in pharmaceuticals synthesis)- For highly corrosive applications at a high thermal efficiency- Corrosion resistant both, service and product side- Vertical or horizontal installation- For applications where FDA or other special food processing requirements need to be met- Carbon fibre reinforcement (optional)Applications (examples)- Condensing of solvents in synthesis plants, especially in multi?-purpose plants in the pharmaceutical and speciality chemical industry- Condensing duties within the production of APIs (active pharma- ceutical ingredients)- Use within the production of food and food ingredients (i.e. flavours and fragrances)cGMP-Annular-groove Condenser NB/GMP / HB/GMPSpecial FeaturesDetachable header and bottomRotating cleaning device (PTFE)No gaps, crevices and deadcornersBonded construction withoutgaskets between product andservice mediaInspection glassBenefitsCleaning in Place (CIP) andmechanical cleaning possibleCompletely drainableInsitu inspection with access for endoscopes and swab testingNo batch or cross-contaminationNo black particles due to special mechanical processing and cleaning9Annular-groove Vent Condenser GN/GH- Condenser for highly corrosive applications- Corrosion resistant both, service and product side- Vertical or horizontal installation- Dephlegmation applications possible- Inclusion of demister possible- Carbon fibre reinforcement (optional)Applications (examples) - Vent cooling of exhaust gas or vent con-? densing of corrosive vapours, e.g. for complying with VOC regulations (volatile organic compounds)- Condensing and separation of corrosive vapours at the inlet or outlet of vacuum pumpsSpecial FeaturesLarge flow cross sectioncGMP design (optional)BenefitsExcellent separation efficiency,e.g. for complying with exit air regulationsSmall required spaceCompletely drainableNo batch or cross?-contamination riskAnnular-groove Heat Exchanger RA/WA- Heat exchanger for heating or cooling of highly corrosive media- Corrosion resistant one side: RA series- Corrosion resistant both sides: WA series- Wavy groove design (optional)- Carbon fibre reinforcement (optional)Applications (examples)- Heating or cooling of hydrochloric or sulphuric acids and solvents- Heat transfer between two corrosive media- Use as feed preheater for sump of columnSpecial FeaturesBoth flow cross?-sections arevariable, thus resulting in high heat transfer rates and? self-?cleaningNo gaskets and therefore norisk of leakageSmall overall heightBenefitsExcellent heat transferperformanceSelf-cleaningNo cross?-contaminationLow maintenance costHigh plant availability10Annular-groove Dilution Cooler RA-K- Dilution and cooling unit for the dilution of sulphuric acid- Separate inlets for concentrated acid and dilution water- Inlet of acid through PTFE tube- Carbon fibre reinforcement (optional)Applications (examples)- Production of battery acid- Dilution of concentrated acids in chemical production plants or fertiliser production- Sulphate production for water treatmentSpecial FeaturesDilution and cooling combinedin one unitDilution directly in the cooledsegmentsContinuous dilution and mixingprocessBenefitsAchieving final dilution and final temperature in one singleprocessHigh efficiencyAnnular-groove Evaporator UB/FB- Evaporator with forced or thermosiphon circulation: UB series- Falling film evaporator with special distribution disc design: FB series- Corrosion resistant both, service and product side- Carbon fibre reinforcement (standard)- Detachable header and bottom for mechanical cleaning of product side (optional)- cGMP design (optional)Applications (examples)- Evaporating organic media in continuous and batch processes (e.g. distillation, fractionation)?- Concentration of diluted sulphuric or hydrochloric acids- Desorption of hydrochloric acidSpecial FeaturesCompact designEasily and completelydrainableBenefitsSmall required spaceHigh operational safety11Conti-Reactor- Mixing, heating and cooling of two or more process media reacting exothermically or endothermically within one continuous process- Multiple heating and cooling circuits possible- Maximum dwell time / reaction time depending on size of unit and volume flow (e.g. 15 min at 0,7 m3/hr)- All circuits are corrosion resistantApplications (examples)- Synthesis of active ingredients in agro?- chemical industry by three separate, individually controlled steps- Continuous chlorination (CI2+HCI+Educt)Special FeaturesDesigned for specific processesControlled input and output of heat at any stage of the processMeasuring of process data at any stage of the unitBenefitsControllable, continuous mix?ing and heat exchanging pro?cesses with isothermal dwell sections in one unitHigh process efficiency and re?coverySignificantly lower equipmentcost by combining reactor, heat exchanger and controlli?ng devices in one single unit12Annular-groove Absorber- For absorbing HCl and other halogenated? hydrogen based gases- Use in scrubbing applications- Co or counter current flow options- Design for small, medium and large inert gas content- Capacity for 40 kg/hr to 2,000 kg/hr HCl gas at 100 % concentrationApplications (examples)- Production of high purity hydrochloric acidSpecial FeaturesCross sectional flowcorresponding to decreasinggas volumeHigh mass transferRobust constructionBenefitsWide load area at highestabsorptionHigh performanceGreat operational safetyBlock Heat Exchanger GE/GZ- All?-purpose unit for cooling, heating, condensing and evaporating duties- Vertical or horizontal installationApplications (examples)- Heating pickling baths in steel industry- Cooling of galvanising baths in steel fin?ishing processes- Condensing and cooling of hydrochloric acid in adiabatic absorption operations- Evaporation of organic solventsSpecial FeaturesSingle or double-?row boringsat the product sideRobust constructionModular designEasy to disassembleBenefitsLarge transfer areas and com?paratively low pressure drop on the product sideHigh operational safetyMechanical cleanability13Quench- Quench with spray lances- For gases up to 15,000 m3/hr volumetric flow- For gases up to 1,300°C inlet temperature- Suitable for gases with halogens (e.g. CI2, Br2) and NOXApplications (examples)- Quenching of exhaust gas containing HCl, HBr and CI2 within organic polymer production- Quenching in ore refining processes with approx. 15 kg/hr of solids content- Quenching of CFC vent gas containing PTFE dustSpecial FeaturesTwo or more spray lancesExcellent cooling due ?to continuous water film on wal?l surfaces and the cooling grooves in the wallBenefitsSuitable even with large gasvolume variationsTreatment of highly oxidisinggasesVery low maintenance andoperational costColumns and Column InternalsBased on customer‘s drawings and requirements we manufacture - distribution trays- sieve trays- bubble?-cap plates- cascades- supporting trays- hold?-down platesOn request, or if necessary we perform strengthcalculations (e.g. finite element analysis).Applications (examples)- Column header with inlet pipe and distribution tray (Ø500 mm)- Distributor for column (Ø400 mm)Columns and Vessels up to DN 800 Internals for vessels up toDN 800Strength calculations (e.g.finite element analysis)14Other ComponentsBased on customer‘s drawings and requirementswe manufacture- jet nozzles- steam and water jets- thermowells- wiper blades (for thin film evaporators)- inlet pipes for liquids, gases and vapours- heating / cooling candlesOn request, or if necessary, we perform st?rength calculations (e.g. finite element analysis).Applications (examples)- jet nozzles for corrosion resistant vacuum jet pump (e.g. Ø38 x 125 mm)- overflow cartridge for distribution tray (e.g. Ø92 x 115 mm)Wide range of applicationsStrength calculations (e.g.finite element analysis)15Silicon Carbide Shell & Tube Heat Exchanger SR- CORRESIC® silicon carbide shell & tube heat exchanger with universially corrosion resistant tube material silicon carbide (SSiC) with very high thermal conductivity- Resistant against all brines, acids, solvents and halogenes- Leakage free tube sheet system (patent pending)- MOC selection according application (carbon steel, stainless steel, glass lined steel, PTFE lined steel (for headers))- Various installation modes possible (vertical, horizontal, inclined)Applications (examples)- Liquid/liquid heat exchange at all acids, brines and organic solvents, e.g. mixed acid, sulphuric acid, nitric acid- Condensation processes- Condenser skids containing main and vent condenser and condensate cooler- Cooling of humid gases containing elementary halogenes- Acid concentration processesSpecial FeaturesHighest corrosion resistanceOptimised sealing system (double sealing FKM / FFKM)Leakage control system (optionally)Improved ratio transfer area / shell volumeExcellent thermal conductivityAbrasion resistanceBoth sides are corrosionresistantBenefitsCompact and cost efficient designHigh operational safetyLow leakage riskNo product contamination by particlesSilicon Carbide Block Heat Exchanger SE- CORRESIC® silicon carbide block heat exchanger with universially corrosion resistant block material silicon carbide (SSiC) with very high thermal conductivity- Resistant against all brines, acids, solvents and halogenes- Robust, modular design ensuring long lifetime and low cost maintenance- Especially applicable for steam heated evaporation or heating processes- Various installation modes possible (vertical, horizontal, inclined)Applications (examples)- Liquid/liquid heat exchange at all acids, brines and organic solvents, e.g. mixed acid, sulphuric acid, nitric acid- Reboiler evaporation, especially steam heated- Condensation processes with special need of robustness- Pickling applications in steel and galvanic industries (heating, cooling, acid regeneration)- Acid concentration processesSpecial FeaturesHighest corrosion resistanceExcellent thermal shock resistanceRobust and modular designAbrasion resistanceBenefitsEspecially applicable in steam heated processesNo product contaminationLow maintenance needHigh operational reliability in robust applications16Silicon Carbide Annular-groove Heat Exchanger SB- CORRESIC® silicon carbide block heat exchanger with universially corrosion resistant block material silicon carbide (SSiC) with very high thermal conductivity- Resistant against all brines, acids, solvents and halogenes- Virtually monolithic design with no dead space enabled by Tasic fusing process for long lifetime and easy maintenance- Especially applicable in multi purpose plants, also in cGMP processes- Various installation modes possible (vertical, horizontal, inclined)Applications (examples)- Condensation of organic solvents in active pharmaceutical ingredients manufacturing (API) even under cGMP regulation- Heat exchanging processes in crop protection chemical synthesis- Condensation processes in ultra pure electro chemicals manufacturing- Applications in manufacturing of flavours and fragrances- Falling film evaporation in organic synthesis- Liquid/liquid heat exchange at all acids, brines and organic solvents, e.g. mixed acid, sulphuric acid, nitric acidSpecial FeaturesHighest corrosion resistanceApplications in all organic syn-thesis processesDead space free design ensu-ring complete drainability and excellent cleanabilityHigh reliabilty of sealing systemExcellent resistance against thermal shockBoth sides corrosion resistantBenefits100% GMP/FDA compliantNo risk of product contamina-tion (MOC, batch, cross)Outstanding thermal perfor-mance and compact designBest operational safety and availability17Overview on Products and ApplicationsGraphite Equipment18Pleas ask us for special designs and applications.CondensationPartial CondensationCooling of CorrosiveMediarecommendedsuitableHeating of CorrosiveMediaHeating Exchange of twoCorrosive MediaDilution Cooling (Sulphuric Acid)Mixing (+ Cooling/Heating)Circulating EvaporationFalling Film EvaporationAbsorptionOther Mass and HeatTransfer ProcessesAnnular-groove Condenser NB/HB/KBcGMP Annular-groove Condenser NB/GMP / HB/GMP Annular-groove Vent Condenser GN/GHAnnular-groove Heat Exchanger G1Annular-groove Heat Exchanger RA/WAAnnular-groove Dilution Cooler RA-KConti-ReactorAnnular-groove Evaporator UB/FBBlock Heat Exchanger GE/GZAnnular-groove AbsorberQuench19Overview on Products and ApplicationsSilicon Carbide EquipmentPleas ask us for special designs and applications. Shell & Tube SR Block SE Annular-groove SBCooling2 corrosive media Feed heating Circulation evaporation Falling film evaporation Condensation Desublimation GMP compliant processes recommendedsuitableCorresiC®We have successfully delivered to:| Ajinomoto Omninchem| BASF | Bayer| Clariant| DSM| Egis| Evonik| Glaxo Smithkline| Hindustan Insecticides| H.C. Starck| IFF| ICL (Rotem, Industrial Products)| Lanxess/Saltigo| Merck| Plinke| Roche| Sanofi-Aventis/Chinoin| Symrise| Syngenta| Wacker ChemieDetails on corrosion resistance, materials, designs and products can ? be found in our product information, work standards and SPOTs on the internet.www.gab-neumann.dePlease ask us for detailed references. GAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (0) 76 22/67 51 0 | F +49 (0) 76 22/67 51 20info@gab-neumann.de | www.gab-neumann.deHeat Exchangers and Components in Graphite and Silicon Carbide