Graphite Condensers for the Pharma Synthesys Brochure

13. Juli 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (0) 7622 6751 0 | F +49 (0) 7622 6751 20 | info@gab-neumann.deGraphite Condensers for the Pharma SynthesysGMPGood Manufacturing Practice21. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (0) 7622 6751 0 | F +49 (0) 7622 6751 20 | info@gab-neumann.deContentsGN-1Leaflet annular-groove heat exchangers Type GNRN-10Leaflet annular-groove heat exchangers horizontal (GMP)RN-9Leaflet annular-groove heat exchangers vertical (GMP)A-1Corrosion resistance listWS 1410Properties of graphite materials DIABONWS 1405Quality assurance processWS 1400Quality assurance systemSPOT 022Maximal admissible temperature differenceSPOT 020Internal stress caused by organic solventsWS 1501Instructions for graphite heat exchangersSPOT 035Carbon-Fibre reinforcement for annular-groove heat exchangersSPOT 002Protect the carbon units from water hammer WS 1504Safety equipment layout WS 1562Annular-groove condensers recommended for glass lined reactorsWS 1560Graphite condensers for multi-purpose ApplicationSPOT 027Acceptability of graphite material DIABON under PIDW rules SPOT 024Report on the resistance to the diffusion of thermo oil ...SPOT 025Material list for annular-groove condensers to meet GMPCertificateSPOT 033Adhesion of contaminants to various materials SPOT 036Rotary tank cleaning nozzleReference listSPOT 031CertificatSPOT 029Statement of the FDASPOT 021Graphite annular-groove condensers (GMP guidelines)SPOT 023Graphite annular-groove condensers (GMP-Design)WS/SPOTText11. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deGraphite Annular-groove Condenser in GMP DesignRemovable headerRotary cleaningnozzle (PTFE)Gasket (Sigraflex)Coolant grooveProcess grooveCIP nozzleProcess inletInspection glassAll discs completelycemented andremachinedSPOT 023/1Inspection glass11. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deGraphite Annular-groove Condensers in GMP DesignNo black particles, no cracked blocks, no batch contaminationwith our new Graphite annular-groove condensers for pharmaceutical drug productionNo cracked blocks,high availabilityNo susceptibility to resin swelling from condensing solvents.Carbon fibre reinforcement (optional).Completely drainable, no process liquid holdoverClear process passageway.In place inspection (access for endoscope), swab test, easy mechanical and chemical cleaningRemovable graphite headerswith inspection glass.No batch contaminationLow adhesion of contaminants to graphite. Rotary cleaning nozzle / CIP.No gaps between the blocks.No cross contamination Bonded construction, eliminating gaskets between process and service media.No contamination by black particles (graphite, resin, cement)All internal passageways are machined afterresin impregnation.All cemented joints are machined after curing.Your benefitsFeatures of the GMP designWe would be pleased to place our detailed GMP documentation at your disposal.SPOT 023/211. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.de1. MaterialOur DIABON® resin impregnated graphite materials are manufactured under strict quality assurance procedures to ensure consistency (WS 1400 und WS 1410).The selected graphite, impregnation resin and cemented compound used during assembly (based on the same Phenolic resin as the impregnation resin) all offer excellent resistance to chemical attack. The ingredients of the resin, of the cement as well as of the impregnated graphite are documented, too (WS 1411).Typical exceptions would be strong oxidizing acids (such as hot Nitric Acid) and strong Alkalis (such as Caustic Soda > 15 %, concentration > 80 °C). For further information please refer to the DIABON® corrosion resistance (Table A-1).2. Application in multi-purpose plantsGraphite Annular-groove Condensers provide an ideal solution in multi purpose plants (typically in conjunction with glass lined reactors - WS 1562), as they are resistant to all organic solvents as well as in composition with Hydrochloric acid and/or Sulphuric acid.For some particular solvents (Dimethylformamid, Dimethylsulfoxide, n-Methylpyrolidone, Tetrahyhydrofurane and some short chained Amines) the wall temperature of the heat exchanger in contact with the process media should be < 60 °C (SPOT 022).2.1. Specific testing has proven the resistance of DIABON® to diffusion through thematerial by heat transfer oils such as Dowtherm, Santotherm and Syltherme(SPOT 024). DIABON® has also achieved PIDW acceptance under certainconditions (SPOT 027).2.2. All materials in contact with the process media are documented (SPOT 025).2.3. Graphite has excellent non-stick properties (SPOT 033).Graphite Annular-groove CondensersAccording to GMP GuidelinesSPOT 021/11/211. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.de3. Design of the condensers (SPOT 023)Our GMP condenser design has the following characteristics:3.1. Clear unrestricted process passageways through the axial length of the condenserwith no gaps, crevices or dead corners in which process could be trapped.3.2. Removable headers, allowing full visual inspection and/or mechanical cleaning.3.3. Bonded construction, eliminating gaskets between process and service media.3.4. The provision of a sight glass in the upper header allows in-situ inspection and/orexecution of a swab test (after removal of the sight glass).3.5. The provision for CIP (Cleaning In Place) capability in the upper header (verticalorientation only) allowing for rinsing. Further options for chemical cleaning areflooding or boiling out of the condenser (SPOT 028).3.6. Machining the internal passageways after resin impregnation and again aftercuring the cement used in assembly eliminated the risk of „black particle“contamination of the process media.4. Security Considerations4.1. The continuous safe operation of our condensers will be ensured by observanceof our installation and operating instructions (WS 1501, WS 1504, SPOT 002).4.2. The annular-groove design eliminates cracks caused by swelling of theimpregnation resin (SPOT 020).4.3. Additional security against pressure shock damage can be obtained by carbonfibre reinforcement (SPOT 035).4.4. The installation of PTFE-bellows (WS 1060) on all graphite nozzle connectionswill protect against damage caused by mechanical stress and/or vibrations fromconnecting pipe work.4.5. Ensuring the DIABON® material does not exceed our recommended operatingconditions preserves the performance and operating life of the condenser(often in excess of 20 years).SPOT 021/22/2Graphite Annular-groove CondensersAccording to GMP Guidelines21. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deFood and Drug AdministrationWashington DC 20204DEPARTEMENT OF HEALTH & HUMAN SERVICESStatement of December 15, 1994..There is no specific food additive regulation to provide for theuse of graphite as a component of food-contact articles. However, in the past, the agency has on numerous occasions ruled that impervious graphite is generally recognized as safe(GRAS) for use in food-contact materials and has offered no objection to such use.Phenol-formaldehyde resins are listed in numerous sections of the Code of Federal Regulations (CFR) for use as components of various types of food-contact materials. Specifically, phenol-formaldehyde resins are listed in 21 CFR 175.300 Resinous and polymeric coatings for use in the manufacture of resinous coatings for food-contact use.Therefore, based on the above comments, graphite sintered treated at 1500° F or impervious graphite impregnated with phenol-formaldehyde resins may be used in contact with food, provided the finished product meets the specification for use of the phenol-formaldehyde resins as specified in the applicable regulations. No other testing or registration of the finished product is required...Statement of the FDASPOT 029/121. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deGraphite as pure carbon is physiologically recognized as safe (c.f. active carbon as oral therapeutics).That is the reason why no explicit FDA regulation is existing for graphite as material in contact with food and drugs.Nevertheless the FDA has stated on various occasions in the past that impregnated graphite is generally recognized as safe (GRAS = generally recognized as safe).Phenolic Formaldehyde resins which are used for the impregnation, are listed in numerous chapters of the Code of Federal Regulations (CFR), especially under 21 CFR.The FDA has stated, that an examination of the final products after contact with phenolic resin impregnated graphite beyond the normal rules is not necessary.GAB Neumann GmbHPeter NeumannConfirmation of the suitability of our Graphite Annular-grooveCondensers in GMP-design under FDA conditionsSPOT 029/211. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 031Certificate for GMP CondensersThis is to certify that our condensers with the designation ...GMP are designed and fabricated according to the GMP rules.1. All surfaces in contact with the process medium are machined afterimpregnation to avoid any residual resin film.2. All graphite discs are cement bonded together without dead areasor gaps. Therefore all surfaces in contact with product are accessible for inspection and the heat exchanger is cleanable in situ.3. All cement joints on the process side are remachined after temper-hardening to remove any excess cement.4. For operations as directed (see our corrosion chart A-1 and observe the max. temperatures) the selected quality of graphite material doesnot affect the process media nor contaminates the product with black particles.5. All heat exchangers are carefully rinsed before dispatch to remove allloose black particles and to clean the process surface properly. However, we recommend to clean the process side again beforeproduction start up (i.e. within the scope of pre-production cleaning of the whole system). 6. For vertical units equipped with the CIP facilities (360° spray nozzle)we confirm that all process surfaces will be rinsed intensively.7. Graphite impregnated with phenol-formaldehyde resins (listed in21 CFR 175.300) is accepted by the FDA (see our SPOT 029, too).This certificate is part of our detailed manual we issue for our GMP condensers17/08/2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deGraphite Annular-groove Condensersin cGMP design (> 535)6 Polanco (E) Moehs2 Grenzach (D) Linde EMS 25 Leverkusen (D) Lanxess2 Ludwigshafen (D) Knoll 2 Pithiviers (F) Isochem1 Boronie (AUS)IDT (Institute for Drug Techn.)5 Macau (PRC), Lissabon (P)Hovione4 Radebeul (D) Hexal Syntech / Novartis8 Bangalore (IND) Hikal1 Huddersfield (UK) Grosvenor Chemicals16 Singapur (SGP) Glaxo Smith Kline 4 Liestal (CH) Genzyme1 Obersontheim (D) FIMA32 Espoo, Hanko, Oulu (FIN) Fermion18 Venlo (NL) DSM Andeno15 Linz (A) DSM Fine Chemicals Austria15 Hanau, Wolfgang (D) Degussa 9 Barcelona (E) DeDietrich7 Monthey, Basel (CH) Ciba16 Budapest (HU) Chinoin / Sanofi4 Leuna (D) Chemtec7 Calais (F) Calaire Chemie47 Ingelheim (D) Boehringer Pharma9 Lessines (B) Benechim109Wuppertal u.a. (D) Bayer Healthcare10 Minden (D) BASF Pharmachemikalien15 Frankfurt, Offenbach (D) Aventis Pharma / Hoechst8 Bubendorf (CH) Amcis17 Arnhem, Oss (NL) Akzo / DiosynthTotal unitsPlace / CountryCustomerRef. List17/08/2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deGraphite Annular-groove Condensersin cGMP design (> 535)3 Pithiviers (F), Darmstadt, Gernsheim (D) Merck Lipha2 Karlskoga (S) Nordic Synthesis / Cambrex9Basel (CH) Novartis4 Linz (A) Nycomed2 Taichun (ROC) Yung Zip20 Taichun (ROC) Yung Shin2 Bulle (CH) UCB Farchim4 Weesp (NL Solvay6 Vionnaz (CH) Sochinaz9Taiwan (ROC)SCI Pharmtech / Siegfried1 Muttenz (CH) Sandoz Produkte8 Basel (CH), Mannheim (D) Roche6 Budapest (HU) Richter Gedeon2 Ashford (UK) Quest International3 Hamburg (D) Proligo3Uppsala (S), Sandwich (UK)Pfizer / Pharmacia2 Brüssel (B) Peptisyntha / Solvay47Wetteren, Balen (B)OmnichemTotal unitsPlace / CountryCustomerRef. List11. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 036Material: Teflon (PTFE) with FDA-approvalMin. vessel outlet (mm): 50 mmWorking pressure: max. 3.5 bar; recommended 1.4 to 2.8 barFlow rate (2 bar): 26 l/min.Connection: ½”Feed temperature, max.: 80°CSpray angle: 360°Design featuresTechnical datesFlow rateDimensions3432262215,327500 E ½-8-TEF3,5 bar3 bar2 bar1,5 bar0,7 barCapacity – litres per minuteOrder-No.28,66049½“flats (mm)Y (mm)X (mm)InletdiameterRotary Cleaning Nozzle made from TeflonHydraulic – Proper DriveOur rotary cleaning nozzles for the GMP condensers allow for cleaning and rinsing duties in very low working pressure applications (from 0.7 bar on). The solid stream spray ensures a high impact power and therefore an excellent cleaning result.The reactionary force of the cleaning liquid rotates the nozzle without external power source, therefore it is especially well suited for CIP application. These TEFLON rotary cleaning nozzles offer a new dimension of performance and versatility thanks to its compact design (diameter 49 mm). The high chemical resistance of Teflon makesthem perfect for multi purpose application.11. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 033SummaryThe favourable ‚adhesive angle‘ of DIABON graphite materials (better than polished stainless steel and glass lined steel) helps to ensure a minimal surface contamination. These test results confirm the long experience of our customers.Graphite Annular-groove condensers in GMP design are suitable for the final stages in pharmaceutical synthesis as well (see our GMP documentation, too).The surface finish of graphite materials may be a concern to customers considering the use of graphite condensers in pharmaceutical synthesis plants.In the consideration of possible drug contamination it is not generally the surface finish but the ability for particles to adhere to the contact surfaces that is decisive. The adhesion resistance ‚non-stick‘ quality of a material can be determined by the ‚adhesive angle‘.Comparison testing was carried out by the process development department of a large international pharmaceutical company in Germany. The results are as follows: Material Average Adhesive Angle IMPREGLON Tempcoat 3053 coating 21,6 GUTBROD DFP (PFA, 3 layers) green coating 23,7 GUTBROD EDLON PFA SC 7005 coating 25,3 Graphite DIABON NS2 29,0 Graphite DIABON NS1 29,7 Stainless steel, polished to 6.3 nm 31,6 Glass lined steel PK 311 35,3 Stainless steel, electro polished to 6.3 nm 35,7 IMPREGLON coat of lacquer 36,0 Glass lined steel K 911 36,6 Stainless steel, glass bead blasted 37,3 Adhesion of Contaminants to Various Materials11. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 025Material List for Graphite Annular-groove Condensersin GMP DesignNotes:1. The base graphite is impregnated in the GAB Neumann works with phenolicresin type P91-1. The impregnated material is designated as “G16-5-180, G18-5-180, G18-8-200 or G20-8-200” according to AD 2000 Merkblatt. The graphite elements of annular groove condensers are cemented usingphenolic cement type P91-1+GK8.2. A “TA-Luft”-certificate is available.3. A FDA-certificate is available.4. The bellows are made of contour moulded PTFE (in contact with process medium) and steel flanges (not in contact with process medium).3Spraying SystemsB27500EPTFE rotary cleaning nozzle7.3,4Resistoflex, PforzheimKKMPTFE bellow6.3Auer SOG GlaswerkeMAXOSInspection glass5.2,3GarlockGylon Blue Style 3504Gasket4.1SGL Carbon, MeitingenP91-1 + GK8Cement3.1SGL Carbon, MeitingenP91-1Impregnation resin2.1SGL Carbon, MeitingenG16-5-180Graphite1.NoteSupplierMaterial / Trade name / TypeNo.Material in contact with the process medium11. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deReport on the Resistance to the Diffusion of Thermo Oil Through theGraphite Material DIABON® used for Heat ExchangersThe tests were effected by the Techn. University Freiberg at Saxon/Germany inJuly 1994.The impregnated graphite material was tested for diffusion in contact withDowtherm J under temperatures of 90 °C and 130 °C as well as with Syltherm XLTunder temperature of 110 °C in a glass plant with a clamped Diabon graphite disk.Results of the diffusion tests:After a 21 day testing period it was confirmed by spectral analysis that there wasno trace of Dowtherm J in the test control fluid.Conclusion: Heat exchangers made from Diabon Graphite can be used safely in contact withDowtherm J, Sytherm and similar heat transfer media.Experimental arrangement:graphite diskreflux condensersamplingpressure compensatingpipedrainthermo oilDowtherm Jtest controlfluid (CC14)flange withgasketthermostat to controltest temperatureheating oil 130°CSPOT 02411. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 027Acceptability of Graphite Material DIABON®under PIDW (plastics in drinking water) RulesIn considering the use of equipment manufactured in phenolic resin impregnated graphite DIABON material in organic intermediate processes, especially pharmaceuticals the question has been raised about PIDW approval, as this represents the most stringent testing standards for product purity.The first tests were carried out by The Institute Fresenius in Taunusstein-Neuhof, Germany in 1993.DIABON material qualities NS1 and NS2 were tested and it was found that at graphite wall temperatures of > 40°C the test water showed a small alteration in smell and taste.Investigations began into ways of preventing this effect and subsequently a methodof tempering the material was found to be particularly effective.Repeating the PIDW testing procedure resulted in the assessment "+" which means there was no noticeable alteration to taste or smell of the test water, therefore acceptability of DIABON Materials under PIDW rules was possible.It is important to note that the conditions of the test (immersion for 30 minutes at 100°C) are unlikely to be repeated in an actual application of an annular-groove-design condenser as the vapour and condensate are only in contact with the Diabon graphite wall for a few seconds at wall temperatures that are generally much less than 100°C (please see SPOT 022).Summary.-A treatment method has been found that allows PIDW certification for Materials DIABON NS1 and NS2. For this reason we consider DIABON material suitable for use in the synthesis of pharmaceutical and other high-purity intermediates as well as finished products (even without this treatment, the manufacturing methods of the heat exchangers and quality of DIABON material has allowed successful use in these types of applications by a large number of customers for many years).The restrictions according to our list of chemical resistance for DIABON Materials (A-1) should be observed however.Tempered DIABON material is available on request at additional cost.5. September 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deGraphite Annular-groove CondensersWS 1560AC Required transfer area for annular-groove condensers in multi-purposeplants for maximum distillation efficiency of the reactors atheating temperature of the reactorcondensing temperaturecooling water temperature= 165 °C= 55 °C25 °CCondenser:Recommended annular-groove condenser according to leaflet RN-11 andRN-9 GMP (vertical design) or RN-18 and RN-10 GMP (horizontal design). TheGN/GH types for the small reactors up to 250 ltr. as per leaflet GN-1. These heat exchangers are suitable for condensing of Aceton (56 °C) using cooling water at 25 °C. * The transfer area given in for design pressure –1/+3 bar g. Other pressure as per the above mentioned leaflets or on request.horizontalarea m²typeHB7-18 (20.7 m²)HB7-22 (25.3 m²)HB7-24 (27.6 m²)NB7-18 (20.7 m²)NB7-22 (25.3 m²)NB7-24 (27.6 m²)21.024.628.325.229.534.0BE 12500BE 16000BE 20000HB7-14 (16.1 m²)HB7-14 (16.1 m²)HB7-16 (18.4 m²)NB7-14 (16.1 m²)NB7-14 (16.1 m²)NB7-16 (18.4 m²)15.115.017.318.118.020.7BE 6300BE 8000BE 10000HB6-08 (6.4 m²)HB7-07 (8.05 m²)HB7-10 (11.5 m²)NB6-08 (6.4 m²)NB7-07 (8.05 m²)NB7-10 (11.5 m²)6.18.111.27.39.713.4BE 1600BE 2500BE 4000HB5-05 (2.5 m²) HB5-05 (2.5 m²)HB5-08 (4.0 m²)NB5-05 (2.5 m²) NB5-05 (2.5 m²)NB5-08 (4.0 m²)2.12.63.82.53.14.6AE 400AE 630AE 1000verticalGH1-04-9 (0.74 m²)GH1-06-9 (1.08 m²)GH2-06-9 (1.60 m²)GH2-08-9 (2.10 m²)GN1-04-9 (0.74 m²)GN1-06-9 (1.08 m²)GN2-06-9 (1.60 m²)GN2-08-9 (2.10 m²)0.61.01.41.90.560.881.251.70AE 63AE 100AE 160AE 250Condenser (transfer area for 3/3 bar g design*)ACm²ReactorFor block or shell and tube condensers the required mean transfer area is 1.5 x AC of the list above.to be used in multi-purpose plants5. September 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deWS 1562/1Annular-groove Condensersrecommended for glass lined reactors for various solvents / at various condensing temperatures1. GeneralThis is to complete and supplement our Workstandard 1560 (condensers inmultipurpose plants) and is subject to customers requirements to reduce the numberof different types of condensers (e.g. 8 sizes), vent condensers (e.g. 5 sizes) andcoolers (e.g. 4 sizes).2. Basic data and instructions for useThe heating capacity of the vessel is completely utilized. The main condenser (W1) isfor falling condensation, the vent condenser (W3) for reflux condensation but each of them can also be operated horizontally (type H-B-). The sub cooler (W2) is to beflooded and must be vertically installed. The cooling medium for items W1 and W2 is water warming up from t1 = 25°C to t2 = 35°C.* When other coolants are used (e.g. thermo oils with higher viscosity and/or lower temperature) we would be pleased to check up the design if you will give us thedetails.For the vent condenser W3 we recommend to use chilled water, brines etc.Overall heat transfer value (W/m² K)*) The condensation of media such as Methylenchlorid (approx. 40 °C) require very large areas when operating with 25°C cooling water (plus 50 % compared with Aceton). Other coolants, e.g. chilled water = 10°C, are recommended for low boiling solvents.organicsolventswater350600W3vent condenser500900W2sub cooling400700W1for sub cooling condensate8001300W1main condenserCondensing ofItemk=300 W/m² KHeating media (T1)(steam, hot water orthermo oil T1 – T2 = 60 K)5. September 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deWS 1562/23. Main condenser, W1The transfer area (m²) of the condensers (left) relates to -1/+3 bar g design pressure. The area of 6 bar design pressure see our leaflets RN-11, RN-18, GN-1; for GMP-design RN-9 and RN-10.Even higher pressures on request.Annular-groove Condensersrecommended for glass lined reactors for various solvents / at various condensing temperaturesRecommended Types (Transfer area)GN1-06-9 (1,08 m2)NB5-05 (2,5 m2)NB5-08 (4,0 m2)NB6-08 (6,4 m2)NB7-10 (11,5 m2)NB7-14 (16,1 m2)NB7-18 (20,7 m2)NB7-26 (29,9 m2)1)2)3)4)5)6)7)8)Heat loadkW5)5)5)4)4)4)3)3)2)2)1)1)1)1)1)1)8)8)7)7)6)6)5)5)4)3)3)2)2)2)1)1)8)7)6)6)5)5)5)4)4)3)2)2)1)1)1)1)7)6)6)5)5)5)4)4)3)2)2)2)1)1)1)1)34.029.525.220.718.018.113.49.77.34.63.12.51.71.250.880.56Aream²Required transfer area (m²) at condensatingtemperature of…28.322.517.410.2619BE 2000024.619.515.18.9531BE 1600021.016.712.97.6454BE 1250017.313.710.66.2373BE 1000015.011.99.25.4324BE 800015.112.09.35.4326BE 630011.28.96.84.0241BE 40008.16.45.02.9175BE 25006.14.83.72.2131BE 16003.83.12.41.483AE 10002.62.11.60.9356AE 6302.11.71.30.7545AE 4001.91.140.880.52 31AE 2501.40.850.650.38 23AE 1601.00.590.450.2716AE 1000.60.370.30.210AE 63> 55 °CAcetone> 65 °C Methanol> 75 °CBenzene,Ethanol> 100 °CToluol, WaterTypeReactor5. September 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deWS 1562/34. Sub cooler, W2:cooling of condensate to 35-40°C, cooling water warming up from 25 to 30°C.When operating the main condenser vertically as falling-film condenser a separatesub cooler is generally not required.5. Vent condenser, W3:We generally recommend for the vent condenser 15-20 % of the transfer area of the main condenser; therefore we propose:for main condenser up to 4 m²: Type GN1-06-9 (1.09 m²)for main condenser between 4 and 10 m²: Type GN3-06-9 (2.28 m²)for main condenser between 10 and 16 m²: Type GN3-08-9 (2.99 m²)for main condenser between 16 and 25 m²: Type GN4-08-9 (5.15 m²)for main condenser beymond 25 m² Type GN5-06-9 (6.91 m²)A suitable cooling medium must be chosen according to the condensing temperature and partial-pressure as well as the required vent temperature.6. Connection of the graphite nozzle (ref. Workstandard 1000)All graphite nozzles must be fitted and operated unstressed, we recommend to use PTFE-bellows (Workstandard 1060). The heat exchangers will be delivered with fitted bellows on request.7. Leaflets, general instructionsFor condensers see our leaflets RN-11, RN-18, RN-9, RN-10, GN-1, for coolers (only vertical installation recommended) leaflet RN-2.For installation and operation see our Workstandards 1501 ff, for special applications see the details (SPOTs) in our catalogues.8. Design dataPressureTemperatureHeat exchangers for deviating design data on request.up to reactor type AE 630: Type R-1.0-01/01 (1.0 m²)up to reactor type AE 1000 to 2500: Type R-2.3-02/02 (2.3 m²)up to reactor type BE 4000 to 8000: Type R-4.6-05/03 (4.6 m²)beymond reactor type BE 10000: Type R-6.9-05/03 (6.9 m²)cooling side:cooling side:-1 / +3 (+6) bar-30 to +180°Cprocess side:process side:-1 / +3 bar-30 to +180°CAnnular-groove Condensers recommended for glass lined reactors for various solvents / at various condensing temperatures21. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deWS 1504/1Safety Equipment Layout to Protect the Cooling Media Side of Graphite Condensers from Pressure ShocksHeatExchangerExplanations on the reverse21. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deWS 1504/2Safety Equipment Layout to Protect the Cooling Media Side of Graphite Condensers from Pressure Shocks1. Before operating the graphite unit the valve (V1) at the cooling media inlet must be open. A method to ensure an open valve at start up is to lock it with a temperaturesensor (TIC 1) at the vapor nozzle.2. By using the by-pass to the regulation valve (V2) ensure cooling media is flowing through the graphite unit. The flow trough the by-pass should be the minimum cooling flow rate (M min) for the design of that specific graphite unit and indicated on the related GAB drawings.3. If the specific coolant consumption exceeds M min., the flow rate can be regulated by the valve V2 linked either to the condensate temperature TIC2 or the coolant exit temperature (TIC3) or both.4. Safety devices (S1, S2) which could be overflow valves, bursting discs or else should be fitted as shown to avoid pressure shocks from the cooling media flow line.5. Routine checks must be made to ensure the safety devices are functioning.6. All graphite nozzles must be protected against external strain. GAB Neumann recommend that PTFE bellows (B1, B2) should be fitted to all graphite nozzles.To protect graphite heat exchangers and condensers from pressure shocks or over pressurization on the cooling media side we recommend the following procedure:11. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 002Protect the Carbon Units from WATER HAMMER caused by rapid operating valvesGraphite is a brittle material (see our WS 1501 ff).There is an increased risk of damage to the carbon units by water hammer when the system uses fast operating VALVES (e.g. Ball valves).The table below shows the pressure shocks overlaying the normal system pressure as a function of the effective closing time of the valves.As the effective closing time means the time between the 75° position and the 90°position, (0° completely free, 90° completely closed) values between 0.1 and 0.2 sec. are to be expected, these pressures are not acceptable for the graphite equipment.55< 0.033540.05520.1330.2190.3140.4110.581Max. pressure shock (bar)Effective closing time (s)11. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 035The application limits for graphite annular-groove heat exchangers can be extendedby external reinforcement with pre-stressed carbon fibres. The following figures show the maximum tension and stress distribution in a cylindrical wall of 300 mm outside diameter under an internal pressure of 12.5 bar g (tension determined by finite element method FEM).Figure 2C-Fibres reinforcement heat exchangerThere are similar benefits for C-Fibres reinforcement of annular-groove design heat exchangers as they (mainly) consist of cylindrical concentrically arranged walls. Reinforcement of the outer wall also strengthens the whole structure.The other main advantages are:The C-Fibre prevent any crack in the outer graphite wall even in case of major pressure shocks such as the „Joukowski-shock“. Thus providing benefits of personnel and local environment protection.The heat exchanger has approximately 15 % more heat transfer area for a given unit size due to the reduced external wall thickness allowed by C-Fibre reinforcement as well as the improved structural integrity.Carbon-Fibre reinforcement for Annular-groove Heat ExchangersThe additional cost for C-Fibre reinforcement of annular-groove heat exchangers (see figure 2) is approximately 20 % on smaller units and 15 % on larger units. The thickness of the C-Fibre reinforcement is generally 2 mm.Figure 1a: without C-Fibre reinforcementtension between 5.8 and 7.9 N/mm²Figure 1b: with 2 mm C-Fibre reinforcementtension between 3.7 and 5.4 N/mm²Example21. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deWS 1501/1Experience:It is the experience at GAB Neumann that all of their Graphite Heat Exchangers, Condensers and Equipment when installed and operated in accordance with the above recommendations will give a long and satisfactory service life.Many annular Groove Heat Exchangers supplied more than 20 years ago are still giving good service.To ensure a long, trouble-free operation please read carefully before starting your new heat exchanger:Summary:All graphite nozzles must be connected without external mechanical stress.All control valves should be operated slowly as a general rule. Before start up check the tightening torque and make (eventually) a pressure test as per Workstandard No. 1589.Start Up Operation Check List1) Any shut-off devices in outlet pipes should be opened.2) The steam side must be drained completely.3) Turn on colder medium (e.g. cooling water) first.4) Turn on warmer medium (e.g. steam).For H2S04 Dilution Coolers: first dilution water, then concentrated acid.5) Monitor any pressure gauges and/or thermometers installed in front of heat exchanger.Do not exceed admissible operating pressure or temperatures.Shut Down Operation Check List1) Turn off warmer medium (e.g. steam).For H2S04 Dilution Coolers: first concentrated acid, then dilution water.2) Turn off colder medium (e.g. cooling water).3) Drain the heat exchanger if freezing could occur.Installation and Operating Instructions for Graphite Heat Exchangers21. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deWS 1501/2Installation InstructionOn assembling graphite heat exchangers, it is advisable – appropriate to the graphite material – to proceed with care. They should be installed by experienced fitters acquainted with the handling of graphite or glass fittings.Special care should be taken that connecting nozzles made of graphite are never subjected to strain or bending stress during assembly or operation. Pressure loads applied to such nozzles are only admissible to very limited extent. We therefore strongly recommend that connections to all graphite nozzles are made by means of PTFE-bellows (Work standard 1060 and 1260). Should the unit be exposed to vibrations it may also be necessary to install bellows on the metallic connections.Pressure and flow controls must always be installed in front of the heat exchanger. Horizontal installed heat exchangers must be mounted with an inclination of 2° to the condensate outlet.Before start up especially if the heat exchanger (new or already used) was out of operation for some months or longer, we recommend an additional pressure test.First all gaskets must be tightened (tie-rods, flanges, bellows etc.) observing our Work standards No. 1101, 1102, 1201 and the drawing. Then the unit is to be pressurized slowly and shock-free up to the working pressure (indicated on the name plate and the drawing. Please observe the Work standard 1589 Operating InstructionsAs graphite heat exchangers are designed for a limited operating pressure (see name plate or drawing), all precautions must be taken that the pressure limits stated are not exceeded. Before start up, make sure that any shut-off devices installed in the outlet pipelines are fully opened.Please observe:- on start up always feed the colder of the two heat-exchanging media into the unit before feeding the warmer medium.- use only slowly operating valves or alternatively suitable modified ball or butterfly valves - the coolant flow shall be regulated in front of the heat exchanger and the exit must be unrestricted to ensure free flow without back pressure. If it is nevertheless necessary to install valves locally down stream of the heat exchanger, it is important that operating instructions include a requirement to check that they are open before the equipment is brought onto stream.- it must be ensured that liquids are not trapped in the heat exchanger to prevent damage by thermal expansion. The heat exchanger should be protected by safety valves if necessary.-at temperatures in the process nozzle of > 60°C the coolant flow valves should open auto-matically to avoid overheat, thermal shocks or evaporation of the cooling medium.- when cooling by means of cooling water the cooling water outlet temperature should remain < 50°C; on exceeding of this value the cooling water quantity has to be raised (automatically);Installation and Operating Instructions for Graphite Heat Exchangers21. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.dePlease observe the following minimum and optimum flow rates:for vertical heat exchangers:Minimum quantity = 0.125 x cross sectional area (cm²).For example at 24 cm² cross sectional area:0.125 x 24 = 3 m³/hr = minimum quantity.Optimal operating quantity = 0.55 x cross sectional area (cm²).For example: 0.55 x 24 = 13,2 m³/hr = optimum quantity.Horizontal heat exchangers need for a good venting of the coolant side the start up quantity for a period of about 10 minutesStart up quantity for venting = 0.55 x cross sectional area (cm²).For example: 0.55 x 24 = 13.2 m³/hr = start up quantity.Minimum quantity = 0.36 x cross sectional area (cm²).For example at 24 cm² cross sectional area:0.36 x 24 = 8.6 m³/hr = minimum quantity.Optimal operating quantity = 0.55 x cross sectional area (cm²).For example: 0.55 x 24 = 13.2 m³/hr = optimum quantity.When regulating the coolant quantity automatically (for example dependent on the condensate outlet temperature) this minimum quantity must be guaranteed – if necessary by the installation of a flow control bypass loop.On shutting down, first turn off the warmer medium before the cooler medium. Vapour operated heat exchangers have to be drained completely before heating again. On starting up we recommend to keep open the condensate drain until vapour escapes.If the heat exchanger is not designed as an evaporator, the boiling of the coolant medium (e.g. the cooling water) must be absolutely impossible (even under operating errors).The freezing in the heat exchanger must be avoided. As far as such a danger exists, the unit must be drained completely. We recommend to dry the equipment with air or nitrogen to remove residual coolant or process fluids from any horizontal passageways within the unit.WS 1501/3Installation and Operating Instructions for Graphite Heat Exchangers5. September 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 020/1Some organic solvents (like Methanol) are swelling the phenolic resin used for impregnating the graphite. The increased volume of the swollen resin results in „Internal Stress“ causing possibly the graphite elements to crack.Further thermal or mechanical stress increases the risk of cracking. The characteristics of damage due to swelling are wide cracks with a noticeable smell of the organic solvent. Usually the cracks decrease as the solvents volatilize.GAB Neumann avoid this risk by proper design of the equipment and by fabricating the units of the suitable graphite grade.Material: The content of resin decreases across the range DIABON® N - NS1 - NS2. Less resin means less swelling stress.Design: The GAB Neumann annular-groove units are based on simple shapes with regular wall thickness between the process and service side grooves. The tendency of swelling stress is reduced.Where ever is a risk of stress due to resin swelling GAB Neumann recommends annular-groove condensers. The design ensures a greater efficiency of cooling reducing thermal stress. In annular-groove units resin swelling causes no damage through swelling. If customer prefers block design GAB Neumann recommends the use of DIABON® NS2 (with less resin but higher price).Damage of condensers by swelling resin can be avoided by the appropriate choice of design and material. Internal Stress caused by Organic Solventsextension caused by swelling resintangential tension (not critical)Annular-groove Heat Exchanger(cylindrical walls, not cross-drilled)Block Heat Exchanger(cross-drilled)maximum tangential due to the edge stress at the coolingmedium bores (critical)processmediumcoolingmediumcooling medium holesprocess medium holesWe are pleased to answer any further questions.5. September 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 020/2Typical crack caused by organic solventswelling stress to graphite block condensers11. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deMaximal Admissible Temperature Differenceand Resistance to Thermal Shocks for Graphite Heat ExchangersIt is very difficult to define a maximum temperature difference between operating mediadue to the influence of a number of factors, for example, the heat transfer coefficients,thermal conductivity, shape and thickness of graphite walls separating the media, anyfouling or scaling as well as other possible sources of mechanical stress in the graphitee.g. pressure shocks or by swelling of the impregnation resin due to exposure to certainprocess media such as Methanol.The temperature change characteristics during the heat transfer through an evenwall can be represented graphically as follows:Example 1 –gas cooling:Low heat transfer value onthe warm side (50 W/m²K), high heat transfer value onthe cold side (6000 W/m²K)Example 2 –condensation of solvents:Medium heat transfer valueon the warm side(2000 W/m²K), high heattransfer value on the coldside (6000 W/m²K)Example 3 –condensation of steam:High heat transfer value oneither side (6000 W/m²Keach)The simple graph above shows clearly the critical influence of the heattransfer conditions on the temperature gradient in the graphite wall (in this examplethe wall is 15 mm thick with a thermal conductivity of 100 W/mK).160150140130120110100908070605040302010016015014013012011010090807060504030201001601501401301201101009080706050403020100SPOT 022/11/211. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (7622) 6751 0 | F +49 (7622) 6751 20 | info@gab-neumann.deSPOT 022/2As an example: It would be possible for a graphite heat exchanger to operate successfully in a system with for example, hot flue gases at 400 °C providing coolant flow (e.g. water at 20°C) is established first with sufficient rate to maintain the graphite wall temperature at an acceptable level. The important point to note is that the flow of the higher heat transfer value media (in this case water) is established first. Had the hot gas flow been established first then the thermal shock caused by the introduction of the cooling water would certainly damage the heat exchanger.As mentioned in the above introduction, another important source of mechanical stress in the graphite is that caused by pressure shocks. This could typically be created by rapid operation of valves (see SPOT 002). Additionally exposure to certain media can cause the impregnation resin to swell (see SPOT 020).Whilst these factors may individually not result in failure, their presence at non-critical levels individually can in combination result in failure of the graphite material.Please note: When installed and operated according to GAB Neumann recommendations WS 1501/1504, damage does not occur. This is endorsed by many years experience with our customers.Summary:It can be seen that it is the temperature difference/gradient across the graphite wall and not the temperature difference between the operating media that is the critical consideration but the assessment should be made in combination with the following factors:1. If sufficient flow of the better heat transfer value media is established first (whereboth media are of different heat transfer coefficients), then independent of thetemperature no critical thermal stress is caused.2. With temperature differences through the graphite wall of more than 60°C (notdifference in operating temperatures of the service and process media) damagesbecome more likely and the resistance to pressure shocks is greatly reduced.3. With exposure to certain (swelling) organic media (such asMethanol for example) the resistance of the material against thermal and/orpressure shocks can be greatly reduced.Should you require any further explanation or information, please contact our technical department who would also be pleased to advise on the effects created by particular process conditions.2/2Maximal Admissible Temperature Differenceand Resistance to Thermal Shocks for Graphite Heat Exchangers15. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (0) 7622 6751 0 | F +49 (0) 7622 6751 20 | info@gab-neumann.deWS 1400/1Quality Assurance System15. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (0) 7622 6751 0 | F +49 (0) 7622 6751 20 | info@gab-neumann.deQuality Assurance SystemWS 1400/215. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (0) 7622 6751 0 | F +49 (0) 7622 6751 20 | info@gab-neumann.deQuality Assurance Processprocured partssteel parts cement components graphiteimpregnation resinrejectionware-housepreliminaryinspectionimpregnation processimpregnated graphitecomponentsdiabon N, NS1, NS2processinginspectioncementinginspection ofcomponentsassemblyfinal-inspectionshippingreprocessingpossibleprocessinginspectionreprocessingreimpregnationpossiblerefusepreprocessingpossibleinspectioncoatingrefuseyesfailyesyesfailyesfailfailyesyesyesfailfailfailfailyesfailware-houseware-houseware-houseware-houseware-houseWS 140515. August 2006Graphite Heat Exchangersand ComponentsGAB Neumann GmbH | Alemannenstrasse 29 | D-79689 MaulburgT +49 (0) 7622 6751 0 | F +49 (0) 7622 6751 20 | info@gab-neumann.deProperties of Graphite Materials DIABON®WS 1410Diabon N:Diabon NS1:Diabon NS2:Graphite impregnated; standard-quality for annular-grooveheat exchangersGraphite impregnated; standard-quality for blockheat exchangersGraphite impregnated; special quality, higher strength,smaller content of impregnation resin1) Ash content (average): FeSiCaAlMg, V0,02 to0,04 to0,02 to0,01 to0,10 %0,10 %0,08 %0,05 %< 0,001 %%cm²/sW/(K*m)µm/(K*m)N/mm²N/mm²N/mm²kN/mm²%g/cm³< 0.5< 0.5< 0.5Ash content10-610-610-5Coeff. of permeation= 140= 120= 120Thermal conductivity8 - 108 - 104 - 6Coeff. of lin. expansion= 20= 18= 16Tensile strength60 – 8060 - 8040 - 50Compressive strength30 – 4025 - 3520 - 25Bending strength15 – 2015 - 2015 - 20Young‘s modulus0 (12-15)0 (20-23)0 (23-25)Pore volume(before impregn.)1,88-1,921,88-1,921,85-1,90Bulk densityDIABON NS 2DIABON NS 1DIABON N05.04 General Information Impervious Graphite DIABON® excel in their resistance to chemical attack by most acids and solvents andby combinations of such media. Only strong oxidising agents such as Oleum, concentrated Chromic acid,Nitric acid, Bromine, Fluorine and a few alkalis will attack and corrode impregnated Graphite. DIABON NS1 and even more DIABON NS2 have less and smaller pores filled with impregnation resin. In case of critical chemical or thermal application we recommend these qualities.Strong oxidizing media tend to attack the graphite itself, strong alkalis and solvents tend to attack more the resin/cement.Temperature LimitationsNormally, tolerable working temperatures fall between -60°C and +180°C. Under specific wet conditions working temperatures of up to 200°C can be tolerated provided that appropriate constructional design para-meters and chemical conditions are taken into account at the onset. Variations from the above mentioned temperature are listed in the resistance chart.RemarksAll information is given in good faith and is in accordance with our current knowledge and is valid for the entire heat exchanger including gaskets or cemented joints if any.We cannot, however, honor or accept any liabilities of any kind, and none are implied or intended herein. If there is doubt concerning the workability of our equipment for a specific application, we invite special enquiries, including a detailed statement specifying the degree of corrosion protection required, so that appropriate design and testing measures may be taken. Graphite samples for corrosion tests are available on request.A-1Corrosion resistanceof impervious graphiteDIABON® N, NS1 and NS2Impregnated GraphiteDIABON® NS1 Scale 100:1Clear parts: GraphiteDark parts: Impregnation ResinBlack dots: hardening bubbles to improve the impermeabilityand the elasticity.The figure shows the resin completely filling the pores of the graphite material.Special DataAs it is almost impossible to compile a completelycomprehensive resistance chart we have selec-ted some representative examples e.g. alcohols are displayed in bold type and from this main group only a few common solvents such as methanol are singled out. 1) The recommended inlet temperature is deter- mined by the expected temperature of the interior of the heat exchanger. With intensive cooling (e.g. in annular groove units) inlet tem- peratures higher than those listed here may be tolerated. 2) Resistance Category: + = Resistant C = Corrosion possible. We advise corrosion tests under conditions as near todesired working conditions as possible. - = Not resistantChemicals Concen- Tem- Resis-tration perature tancemax. % °C Cat.Acetaldehyde all 180 +Acetates of all common metals all 180 +Acetic acid all 180 +Acetic acid ester all 180 +Acetic anhydride all 180 +Acetone all 180 +Acetonitrile all 180 +Aldehydes all 180 +Aliphatic hydrocarbones all 180 +Alcohols all 180 +Allyl chloride all 180 +Amidosulphone acid 20 180 +Amino acids all 180 +Ammonia all 180 +Ammonia carbonate saturated 180 +Aniline all 180 +Aniline hydrochloride all 180 +Aqua regia -Arsenic acid all 180 +Benzaldehyde all 180 +Benzene all 180 +Benzenesulfonic acid all 180 +Benzoic acid all 180 +Benzyl chloride all 150 +Boric acid all 180 +Bromine Br2 -Butanol all 180 +Butyric acid all 180 +Calcium bisulphite solution(pulp digesting liquor) 50 180 +Calcium hypochlorite all = 50 +Carbon bisulphide all 180 +Carbon dioxide all 180 +Carbon monoxide all 180 +Carbon tetrachloride all 180 +Carboxylic acids all 180 +Chloroacetic acid (mono-,di,tri-) all 180 +Chloral all 180 +Chlorides of all common metals all 180 +Chlorine gas, dry all = 50 +Chlorine gas, moist all = 50 CChlorine gas, moist, with HCl 100 +Chlorine liquid -Chlorobenzene all 180 +Chlorocyan all 180 +Chloroform all 180 +Chlorosulphonic acid 20 = 20 CChlorosulphonic acid all -Chromic acid <10 = 20 +Chromic acid <20 = 20 CCresols all 180 +Cyanide galvanising baths all 180 +Cyclohexane all 180 +Dibromoethane all 180 +Chemicals Concen- Tem- Resis-tration perature tancemax. % °C Cat.Dichlorobenzene all 180 +Dichloroethane all 180 +Dichloroethylene all 180 +Dichloromethane all 180 +Dimethylacetamide all 180 +Dimethylaniline all 180 +Dimethylformamide all = 60 +Dimethylsulphoxide all = 60 +Dinitrobenzene all 180 +Dioxane all = 60 +Esters all 180 +Ethanol all 180 +Ethers all 180 +Ethyl chloride all 180 +Ethylene chlorohydrin all 180 +Fatty acids all 180 +Fluoboric acid all 180 +Fluorides of all common metals all 180 +Fluorine gas -Formaldehyde all 180 +Formic acid all 180 +Glycol all 180 +Glycerine all 180 +Heat transfer fluids(Dowtherm, Diphyl, Marlotherm,Syltherm, all types) all 180 +Hydrobromic acid all 180 +Hydrochloric acid all 180 +Hydrofluoric acid <50 160 +Hydrofluoric acid <60 = 50 +Hydrofluoboric acid all 180 +Hydrofluosilicic acid all 180 +Hydrogen all 180 +Hydrogen bromide gas all 180 +Hydrogen chloride gas all 180 +Hydrogen fluoride gas, dry all 100 +Hydrogen peroxide <5 = 50 CHydrogen peroxide >5 -Hydrogen sulphide all 180 +Javel water -Ketones all 180 +Lactic acid all 180 +Methanol all 180 +Methylchloroform all 180 +Methylene chloride all 180 +Methylethylketone all 180 +Methylisobuthylketone all 180 +n-Methylpyrolidone all = 60 +Monochloroacetic acid all 180 +Nitraniline all 100 +Nitrates of all common metals all 180 +Nitric acid <20 = 30 +Nitric acid <20 -Nitrites of all common metals all 180 +Chemicals Concen- Tem- Resis-tration perature tancemax. % °C Cat.Nitrobenzene all 180 +Nitrophenol all 100 +Nitrous gases, dry <20 = 60 +Nitrous gases, moist <20 = 60 CNitrotoluene all 180 +Oleum -Perchloroethylene all 180 +Perchloric acid all = 100 +Phenol all 180 +Phosgene all 180 +Phosphoric acid all 180 +Phosphorusoxichloride all 180 +Phosphorustrichloride all 180 +Photographic solutions all 180 +Pickling baths (HCl + H2SO4) all 180 +Plating baths all 180 +Potassium hydroxide <10 = 60 +Potassium hydroxide <30 = 20 +Potassium hypochlorite all = 30 CPotassium permanganate all 180 +Propanol all 180 +Pyridine all 180 +Sea water all 180 +Sodium carbonate all = 100 +Sodium chlorate all 180 +Sodium hydroxide <10 = 60 +Sodium hydroxide 10-20 60-20 CSodium hydroxide >20 -Sodium hypochlorite all = 40 CSodium hypochlorite >40 -Sodium thiosulphate all 180 +Spinning bath solutions (H2SO4) 50 180 +Sulphates of all common metals all 180 +Sulphites of all common metals all 180 +Sulphur dioxide, gas all 180 +Sulphuric acid <80 180 +Sulphuric acid 80-95 180-30 +Sulphuric acid >95 -Sulphuric acid + Nitric acid -Sulphurous acid all 180 +Sulphuryl chloride all 180 +Tetrachloroethane all 120 +Tetrachloroethylene all 180 +Tetrahydrofurane all = 60 +Thionyl chloride all 180 +Toluene all 180 +Trichloroethylene all 180 +Uric acid all 180 +Vinyl chloride all 180 +Water (distilled as well) 180 +Water, vapour 180 +Xylene all 180 +GAB Neumann GmbH Alemannenstr. 29 · D-79689 Maulburg or POB 1227 · D-79690 MaulburgTelephone (07622) 6751 -0 · Telefax (07622) 6751 -20e-mail: info@gab-neumann.de · Internet: www.gab-neumann.deFields of ApplicationFor the following heat exchanging duties we can offer favourable solutions for your problems.Condensation of corrosive organic and inorganic vapours:Annular-groove design: NB, HB, G1, G2, G3 series; our leafl ets RN-11, -18, -7.1, -7.2. GMP design: RN-9, -10.GN design: our leafl et GN-1.Block design: our leafl et BL-1.Partial condensationby cooling of vapour-gas mixtures and condensing the vapourous part corresponding to its partial pressure. On the process sidewith cross sectional areas constant or adapted to the reduction in gas volumes.Annular-groove, GN- or Block design according to the requirement.Cooling of corrosive media:Annular-groove design: R series; our leafl et RN-2.Block design: our leafl et BL-1.Dilution of sulphuric acidwith water or diluted acid and coincidental cooling of the mixture to the desired concentration and temperature in one singleoperation.Annular-groove design: R series with dilution head K; our leafl et RN-5.Heat exchange between two corrosive liquids:both heat exchanging media are in contact only with graphite:Annular-groove design: UVG, WA1, WA2 series; our leafl ets RN-3, -6.Block design: our leafl et BL-1; steel shell with corrosive resistant lining.Combined heat- and masstransfer processes:for example isothermal absorption of HCl gases, isothermal scrubbers for waste gases, continuous mixing reactors with alternatesections for heat and mass transfer and residence times: our leafl ets S-1, -2 (annular-groove units in special design).Heating of corrosive media:Annular-groove design: R, UVG, WA series; our leafl ets RN-2, -3, -6.Block design: our leafl et BL-1.Evaporation of circulating liquids:Annular-groove design: UVG, G1, G3 series; our leafl ets RN-3, -7.1, -7.2.Block design: our leafl et BL-1.Falling fi lm evaporation of corrosive liquids:Annular-groove design: FVG series; our leafl et RN-4.Block design: our leafl et BL-1, but with a special header for suitable liquid distribution.For presenting a complete and detailed quotation we require the following data of the heat exchanging media: type and quan-tity, inlet temperatures and desired outlet temperatures, operation pressure and permissible pressure drops.As far as these particulars are unknown we ask for description of the heat exchanging problem informing about:1) concerning condensation by mentioning the size of the (glass lined) reactor, of heating and cooling media and of the ranges oftemperature and pressure in which evaporation and condensation are expected to occur;2) concerning pickling baths by mentioning the wanted output, heating period, tank dimensions and tank insulations;3) concerning galvanic baths by mentioning the electrical power;4) or size and type of units already installed in the actual or in similar plants.For technical advice please contact us. TypeHeat Transfer Area3/3 bar 1)6/3 bar 1)6/6 bar 1)3/3 bar 1)6/3 bar 1)6/6 bar 1)serviceprocessserviceprocessserviceprocessserviceprocessserviceprocessserviceprocessm²m²m²DHH1H2EE1E2E3E4E5N1N2N3N4N5N6kgkgkgcm²cm²cm²cm²cm²cm²llllllN-B-2,0/GMP21,41,25008402451080100 5)85 5)85 5)100 5)315100 ³)5050505050 4)25626727181548998811116101199N-B-2,5/GMP2,51,751,55009502451080100 5)85 5)85 5)100 5)315100 ³)5050505050 4)2762892948154899881141712121110N-B-3,0/GMP32,11,850010602451080100 5)85 5)85 5)100 5)315100 ³)5050505050 4)2963103168154899881161914131411N-B-3,5/GMP3,52,452,150011702451080100 5)85 5)85 5)100 5)315100 ³)5050505050 4)3163323391615416991681192117141612N-B-4,0/500/GMP42,82,450012802451080100 5)85 5)85 5)100 5)315100 ³)5050505050 4)3373543611615416991681222219151813N-B-4,5/GMP4,53,152,750013952451080100 5)85 5)85 5)100 5)315100 ³)5050505050 4)3573763831615416991681252422172114N-B-5,0/GMP53,5350015052451080100 5)85 5)85 5)100 5)315100 ³)5050505050 4)3773984061615416991681272624182315 N-B-3,2/GMP3,22,62,2600840245510011090901103651508050505050406417425162501619016171162715221220N-B-4,0/600/GMP43,252,75600950245510011090901103651508050505050438452462162501619016171203018241622N-B-4,8/GMP4,83,93,36001060245510011090901103651508050505050472487498162501619016171243322261924N-B-5,6/GMP5,64,553,856001170245510011090901103651508050505050504522534162501619016171283525282226N-B-6,4/GMP6,45,24,46001280245510011090901103651508050505050537556570242501619024171323829302527N-B-7,2/GMP7,25,854,956001395245510011090901103651508050505050570591606242501619024171364133332829N-B-8,0/GMP86,55,56001505245510011090901103651508050505050603626642242501619024171404436353131 N-B-4,6/GMP4,64,4 ²)3,670084024551101408510515041520010050508050547553568163601633016272244124392034N-B-5,75/GMP5,755,5 ²)4,570095024551101408510515041520010050508050593600618163601633016272304530432437N-B-6,9/GMP6,96,6 ²)5,4700106024551101408510515041520010050508050638648668163601633016272364935472940N-B-8,05/GMP8,057,7 ²)6,3700117024551101408510515041520010050508050684695718243602433024272425341503443N-B-9,2/GMP9,28,8 ²)7,2700128024551101408510515041520010050508050730742767243602433024272485747543946N-B-10,35/GMP10,359,9 2)8,1700139524551101408510515041520010050508050776789817243602433024272546153584449N-B-11,5/GMP11,511 ²)9700150524551101408510515041520010050508050821837867243602433024272606559614852 N-B-12,65/GMP12,6512,1 ²)9,9700161526051101408510515041520010080808050870887920403604033032272676965655455N-B-13,8/GMP13,813,2 ²)10,8700172526051101408510515041520010080808050916934969403604033032272737371695958N-B-14,95/GMP14,9514,3 ²)11,77001835260511014085105150415200100808080509629821019403604033032272797777726361N-B-16,1/GMP16,115,4 ²)12,6700194526051101408510515041520010080808050100810291069403604033032272858183766864N-B-17,25/GMP17,2516,5 ²)13,5700205526051101408510515041520010080808050105310761119403604033032272918589807367N-B-18,4/GMP18,417,6 ²)14,4700216526051101408510515041520010080808050109911231168403604033032272978995837870N-B-19,55/GMP19,5518,7 ²)15,370022752605110140851051504152001008080805011451171121840360403303227210393101878373 N-B-20,7/GMP20,719,8 ²)16,27002385270511014085105150415200100100100805011851213126080360803306427211695113899574N-B-21,85/GMP21,8520,9 ²)17,170025002705110140851051504152001001001008050123012591309803608033064272122991199310177N-B-23,0/GMP2322 ²)18700261027051101408510515041520010010010080501275130613588036080330642721281031259610680N-B-24,15/GMP24,1523,1 ²)18,97002720270511014085105150415200100100100805013211353140780360803306427213510713110011183N-B-25,3/GMP25,324,2 ²)19,87002830270511014085105150415200100100100805013661400145680360803306427214111013810311686N-B-26,45/GMP26,4525,3 ²)20,77002940270511014085105150415200100100100805014121447150680360803306427214711414410712189N-B-27,6/GMP27,626,4 ²)21,67003050270511014085105150415200100100100805014571494155580360803306427215411815011112792 N-B-29,9/GMP29,928,6 ²)23,47003270270511014085105150415200100100100805015471587165380360803306427216612616211813798N-B-31,05/GMP31,0529,7 ²)24,37003380270511014085105150415200100100100805015921634170212036012033096272173130169121142101N-B-32,2/GMP32,230,8 ²)25,270034902705110140851051504152001001001008050163816811751803608033064272179134175125147104N-B-34,5/GMP34,533 ²)277003715270511014085105150415200100100100805017291775185012036012033096272192142187132158110Dimensions of the support at the lower steel pressure plate:E6E7E8D = 500 mm64020075D = 600 mm740300100D = 700 mm840300100E9E10E11D = 500 mm2230350D = 600 mm2230400D = 700 mm22305006/6 bar 1)Cross sectional areaVolume3/3 bar 1)6/3 bar 1)6/6 bar 1)3/3 bar 1)Main dimensionsNozzlesWeight dry6/3 bar 1)1) e.g. "6/3 bar" means: design pressure on service side -1/+6 bar / on process side -1/+3 bar2) with C-fibre reinforcement, coding e.g. N-B- 11,5/GMP-C3) Execution for 6/6 bar: DN 80 instead of DN 1004) not applicable for 6/3- and 6/6 bar execution5) Execution for 6/3 bar: E1 and E2 not applicable; E3 = 0 mm; E4 = 115 mm Execution for 6/6 bar: E1 and E2 not applicable; E3 = 0 mm; E4 = 105 mmFor presenting a complete and detailed quotation we require the following data of the heat exchanging media: type and quantity, inlet temperatures and desired outlet temperatures, operation pressure and permissible pressure drops.For technical advice please contact us.GAB Neumann GmbHAlemannenstrasse 29 * D-79689 Maulburg / P.O.Box 1227 * D-79690 MaulburgPhone: +49 7622 6751-0 / Fax +49 7622 6751-20e-mail: info@gab-neumann.de * Internet: http://www.gab-neumann.deType3/3 bar 1)6/3 bar 1)6/6 bar 1)3/3 bar 1)6/3 bar 1)6/6 bar 1)servic eprocessserviceprocessserviceprocessserviceprocessserviceprocessserviceprocessm²m²m²DHH1H2EE1E2E3E4E5N1N2N3N4/N5N6N7kgkgkgcm²cm²cm²cm²cm²cm²llllllH-B-2,0/GMP21,41,25008401024531580135 4)135 4)85 5)100 5)100 ³)5050502550263275280815489988111171012910H-B-2,5/GMP2,51,751,55009501024531580135 4)135 4)85 5)100 5)100 ³)50505025502832973028154899881141912131111H-B-3,0/GMP32,11,850010601024531580135 4)135 4)85 5)100 5)100 ³)50505025503033183248154899881162014141412H-B-3,5/GMP3,52,452,150011701024531580135 4)135 4)85 5)100 5)100 ³)50505025503233403471615416991681192217151613H-B-4,0/500/GMP42,82,450012801024531580135 4)135 4)85 5)100 5)100 ³)50505025503433623691615416991681222419161814H-B-4,5/GMP4,53,152,750013951024531580135 4)135 4)85 5)100 5)100 ³)50505025503633843921615416991681252522172114H-B-5,0/GMP53,5350015051024531580135 4)135 4)85 5)100 5)100 ³)50505025503834064141615416991681272724182315 H-B-3,2/GMP3,22,62,26008405245365100185 6)170 7)901101505080502550415428437162501619016171163015241222H-B-4,0/600/GMP43,252,756009505245365100185 6)170 7)901101505080502550448463473162501619016171203218261623H-B-4,8/GMP4,83,93,360010605245365100185 6)170 7)901101505080502550481497509162501619016171243522281925H-B-5,6/GMP5,64,553,8560011705245365100185 6)170 7)901101505080502550514532545162501619016171283825302227H-B-6,4/GMP6,45,24,460012805245365100185 6)170 7)901101505080502550547567581242501619024171324129332529H-B-7,2/GMP7,25,854,9560013955245365100185 6)170 7)901101505080502550580602617242501619024171364333352831H-B-8,0/GMP86,55,560015055245365100185 6)170 7)901101505080502550613637653242501619024171404636373133 H-B-4,6/GMP4,64,4 ²)3,6700840524541511023020510515020050100502580553559577163601633016272244524442037H-B-5,75/GMP5,755,5 ²)4,5700950524541511023020510515020050100502580599607626163601633016272304930472440H-B-6,9/GMP6,96,6 ²)5,47001060524541511023020510515020050100502580644654676163601633016272365335512943H-B-8,05/GMP8,057,7 ²)6,37001170524541511023020510515020050100502580690701726243602433024272425741553446H-B-9,2/GMP9,28,8 ²)7,27001280524541511023020510515020050100502580736749776243602433024272486147583949H-B-10,35/GMP10,359,9 2)8,17001395524541511023020510515020050100502580782796825243602433024272546553624452H-B-11,5/GMP11,511 ²)97001505524541511023020510515020050100502580828843875243602433024272606959664855 H-B-12,65/GMP12,6512,1 ²)9,97001615526041511023020510515020050100802580876894928403604033032272677365695458H-B-13,8/GMP13,813,2 ²)10,87001725526041511023020510515020050100802580922941978403604033032272737771735961H-B-14,95/GMP14,9514,3 ²)11,770018355260415110230205105150200501008025809689881027403604033032272798177776364H-B-16,1/GMP16,115,4 ²)12,67001945526041511023020510515020050100802580101410351077403604033032272858583806867H-B-17,25/GMP17,2516,5 ²)13,57002055526041511023020510515020050100802580106010831127403604033032272918989847370H-B-18,4/GMP18,417,6 ²)14,47002165526041511023020510515020050100802580110511311177403604033032272979395887873H-B-19,55/GMP19,5518,7 ²)15,3700227552604151102302051051502005010080258011511177122640360403303227210397101918376 H-B-20,7/GMP20,719,8 ²)16,27002385527041511023020510515020050100100258011911219126880360803306427211699113939578H-B-21,85/GMP21,8520,9 ²)17,1700250052704151102302051051502005010010025801236126613178036080330642721221031199710181H-B-23,0/GMP2322 ²)187002610527041511023020510515020050100100258012821313136680360803306427212810712510110684H-B-24,15/GMP24,1523,1 ²)18,97002720527041511023020510515020050100100258013271360141680360803306427213511113110411187H-B-25,3/GMP25,324,2 ²)19,87002830527041511023020510515020050100100258013721407146580360803306427214111513810811690H-B-26,45/GMP26,4525,3 ²)20,77002940527041511023020510515020050100100258014181453151480360803306427214711914411112193H-B-27,6/GMP27,626,4 ²)21,67003050527041511023020510515020050100100258014631500156380360803306427215412315011512795 H-B-29,9/GMP29,928,6 ²)23,470032705270415110230205105150200501001002580155415941661803608033064272166130162122137101H-B-31,05/GMP31,0529,7 ²)24,37003380527041511023020510515020050100100258015991641171012036012033096272173134169126142104H-B-32,2/GMP32,230,8 ²)25,270034905270415110230205105150200501001002580164416871759803608033064272179138175129147107H-B-34,5/GMP34,533 ²)277003715527041511023020510515020050100100258017351781185812036012033096272192146187136158113Heat Transfer AreaMain dimensionsNozzlesWeight dryCross sectional areaVolume3/3 bar 1)6/3 bar 1)6/6 bar 1)3/3 bar 1)6/3 bar 1)6/6 bar 1)GABNeumannGmbHGABNeumannGmbHAlemannenstrasse29-D-79689MaulburgP.O.B.1227-D-79690MaulburgPhone(07622)6751-0-Telefax(07622)6751-20E-mail:info@gab-neumann.de-Internet:http://www.gab-neumann.deGraphiteheatexchanger-GN/GHSeriesGraphiteheatexchangerGN-1GN-1GN/GHSeriesDesigndataSpecialAdvantages:Designtemperature:Designpressure:-30,(-60,-80)upto+180(+200)°C-1upto6(10)bargSturdy,spacesavingdesignHighefficiencyLowpressuredroponprocesssideNoimpregnationresinontransferareasHighflowvelocityonservicesideBothmediacontactgraphiteonlyGN/GHSeriesDesigndataSpecialAdvantages:Designtemperature:Designpressure:-30,(-60,-80)upto+180(+200)°C-1upto6(10)bargSturdy,spacesavingdesignHighefficiencyLowpressuredroponprocesssideNoimpregnationresinontransferareasHighflowvelocityonservicesideBothmediacontactgraphiteonly