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Volume 2, Issue 1, January 2020
Heat
exchanger Uniting the heat exchanger supply chain
WORLD
Cover story:
Teadit: Leading R&D for critical process sealing solutions
WHEN CONDITIONS HEAT UP DON’T LET CORROSION SHUT YOU DOWN Whether it’s higher temperatures, rising pressures or more acidic media, conditions in oil refineries have never been more extreme. Tube and pipe corrosion are a constant threat, causing as many as half of all major shutdowns. This is why hundreds of the world’s most demanding petrochemicals refiners are turning to the next generation of corrosion resistant alloys. Like one German oil refinery, which used Sandvik SAF 2707 HD hyper-duplex heat exchanger tubes to reduce the number of shutdowns from 8 to 1 over a period of four years. The result was massive savings on material replacement. So as your tubes’ performance is pushed to new heights, find out how we can help keep corrosion from shutting you down. MATERIALS.SANDVIK
Volume 2, Issue 1, January 2020 Editorial
Heat
exchanger
WORLD
www.heat-exchanger-world.com
Heat Exchanger World is the global
magazine connecting those working
in the heat exchanger supply chain Dear Readers,
ISSN: 2666-1241 (Print) A very happy New Year to you all! On behalf of the Heat Exchanger World team, I would like to
ISSN: 2666-125X (Online) take this opportunity to wish you not only a healthy year ahead but also a very successful one for
Director KCI Publishing you and your company.
Robert-Jan à Campo
r.a.campo@kci-world.com
Tel.: +31 575 585 275 At the Heat Exchanger World offices we have a very busy 2020. Apart from six issues of the
magazine this year (January/February, March/April, May/June, July/August, September/
Director KCI Publishing B.V October, and November/December) we will also organize two regional conferences & expos,
Elisa Hannan
e.hannan@kci-world.com which we certainly hope will prove of interest to you to attend depending on your locations and
Tel: +31 575 585 291 business interests. Heat Exchanger World Europe will be held at the RDM in Rotterdam, The
Editors Netherlands, October 7th–8th, followed by Heat Exchanger World USA at the LyondellBasell
John Butterfield Center for Petrochemical, Energy, & Technology (CPET) at San Jacinto College in Pasadena,
j.butterfield@kci-world.com
Tel.: +31 575 585 294 Texas, United States, November 18th–19th. If you would like to take part in the conference in
Pascal Aussendorf Rotterdam then please see the Call for Papers on pages 27–30 this issue. Here you will find
Joanne McIntyre clear instructions as to how you can propose either a paper presentation or a workshop. The
David Sear
Daniel Sweet deadline date for submission of abstracts is February 29th so don’t forget to make a note in your
Sales Enquiries and Marketing
agenda. If you would like to participate in the conference in Texas, please contact either Sarah
Kamiel van Wijk Bradley (s.bradley@kci-world.com) or Brittani Schroeder (b.schroeder@kci-world.com) for more
k.v.wijk@kci-world.com information.
Tel.: +31 575 585 289
Pascal Aussendorf This issue’s cover story comes from Teadit, a worldwide leader in the development and man-
p.aussendorf@kci-world.com
Tel.: +49 2821 711 45 34 ufacture of critical sealing solutions. We talk to Chris Day, President of Teadit North America
Subscriptions Manager about the company’s quality product offering, expanding R&D capabilities, and recent product
Erica Riethorst innovations in the heat exchanger market. From an end-user perspective we have a couple of
e.riethorst@kci-world.com contributions: one from Bob McKaig, a Process Engineer at Par Hawaii in Kapolei, Oahu, which
Tel.: +31 575 585 271
relates about his role with heat exchangers and the challenges he faces in his daily work, the
Heat Exchanger World will be published six times in 2020
in January, March, May, July, September, and November. other is a summary of a workshop that occurred at the recent Stainless Steel World Conference
Publishing House & Expo held in Maastricht, The Netherlands, in November 2019) where panelists from both
KCI Publishing B.V., Jacob Damsingel 17, Shell and Sandvik highlighted many of the significant challenges facing heat exchangers used in
NL-7201 AN Zutphen, The Netherlands critical duties in fundamental industries. On the subject of efficiency – a factor of major impor-
Mailing Address tance in improving competitivity and reducing costs with regard to heat exchangers –we have
P.O. Box 396, NL-7200 AJ Zutphen, The Netherlands
info.zutphen@kci-world.com two papers: ”Boosting CHP efficiency with gas-to-liquid technology” and “Efficient use of waste
Tel.: +31 575 585 270 heat in air conditioning and process air”. On the technical side we look at the dairy industry and
Bank Account: ABNAMRO 56.64.05.164 the problems caused by milk fouling and the use of titanium for heat transfer
BIC: ABNANL2A IBAN: NL50ABNA0566405164
in the chemical process industries. These are just some of the highlights of
China Office
KCI Shanghai, Room 603, 6F, #400 Zhejiang Mid Road, this issue. We leave it to you to discover what you find the most useful
200001, Shanghai, China and interesting, and please don’t forget to contact me with you feedback,
info.shanghai@kci-world.com suggestions, and above all your abstracts for the Heat Exchanger World
Tel.: +86 6351 9609
Europe event.
Germany Office
KCI GmbH, Tiergartenstrasse 64, D-47533 Kleve, Germany
info.kleve@kci-world.com Very best regards,
Tel.: +49 2821 71145 0
Canada Office John Butterfield
KCI Publishing Corporation
36 King Street East, Suite 701, Editor of Heat Exchanger World Online & Print
Toronto ON MSC 1E5, Canada j.buttterfield@kci-world.com
info.toronto@kci-world.com Tel.: +31 575 585 294
Tel.: +1 416 361 7030
Facebook: https://
www.facebook.com/heatexchangerworld/
Twitter: https://twitter.com/htExchangerWrld
LinkedIn: https://
ADVERTISERS’ INDEX
www.linkedin.com/groups/8772873/ Aperam 15
Youtube: https://www.youtube.com/kcipub Aura 45
Dolphin Heat Transfer 39
Heavy Metal & Tubes 25
The publishers and the authors state that this magazine has been compiled IGEFA Weinbrenner 39
meticulously and to the best of their knowledge. However, the publishers
and the authors can in no way guarantee the accuracy or completeness of Kobelco 16
the information. The publisher and the authors therefore do not accept
any liability for any damage resulting from actions or decisions based on Luftmeister 9
the information in question. Users of this magazine are strongly advised
to not to use this information solely but to rely on their professional Ratnamani Metal & Tubes 34
knowledge and experience and to check the information to be used. KCI
Publishing cannot guarantee the accuracy of information provided by par- Sandvik 2
ticipating companies and authorities. The publisher reserves the right to
combine, delete, and change sections. Schniewindt 43
The publisher reserves the right to edit and re-use (parts of the articles
and to distribute the information by any means. Teadit 31
All rights reserved. No part of this publication may be reproduced, store in
a retrieval system, or transmitted, in any form or by any means, electronic VE Group 48
or mechanical, photocopying or otherwise, without the prior permission
of the publisher. Xelsion Heat Transfer Solutions 37
Heat Exchanger World is a trademark of Techni-
cal Business Publications II B.V., Thijs Elshof, PO Zwahlen/Mayr 7
Box 67, 6680 AB Lingewaard, The Netherlands.
© 2020. All rights reserved.
Heat Exchanger World January 2020 3
CALENDAR
Calendar
of forthcoming events
Some important events occurring around the world for the heat exchanger community.
5–8 April 2020 16–18 August 2020
5th Thermal and Fluids Engineering Conference 7th International Conference on Heat
» This conference is for professionals within the Transfer and Fluid Flow
thermal and fluids science and engineering » The conference aims to gather scholars
community. It provides an international forum from all over the world to present advances
27–29 February 2020 for the dissemination of the latest research and in the relevant fields and to foster an
Acrex India 2020 knowledge in the thermal and fluid sciences. environment conducive to exchanging ideas
» The exhibition promises to provide and Location: Sheraton Hotel, New Orleans, LA, USA and information. This conference will also
deliver endless opportunities for companies Ph: +1 212 288 9200 provide an ideal environment to develop
to showcase their products, attend series E-mail: info@astfe.org new collaborations and meet experts on the
of technical workshops by national and URL: https://www.astfe.org/tfec2020 fundamentals, applications, and products of
international speakers and exchange the mentioned fields.
knowledge latest trends, directions and Location: Prague, Czech Republic
topics germane to HAVC and building 12–15 July 2020 Ph: +1-613-834-9999
services industry. Summer Heat Transfer Conference Email: info@htffconference.com
Location: IEML, Greater Noida, Delhi NCR » The conference will bring together international URL: https://htffconference.com
Ph: 011- 29234925 researchers and engineers focusing on heat and
E-mail: info@ishraehq.in mass transfer in a variety of applications. The 16-20 August 2020
URL: http://www.acrex.in/home program of SHTC2020 will include technical paper The 8th International Symposium on
sessions, plenary lectures, committee meetings and Advances in Computational Heat Transfer
social events. » This symposium provides a forum to
16–18 March 2020 Location: Rosen Shingle Creek, Orlando, FL USA exchange ideas, methods and results in
Heat Exchange Engineering 2020 Email: jakubowskiM@asme.org computational heat transfer.
» Heat Exchange Engineering will provide URL: https://event.asme.org/SHTC Location: Rio de Janeiro, Brazil
delegates with a dedicated event where Ph: +90 (312) 210 5213
they can connect with experts and peers to Email: ichmt@ichmt.org
gain knowledge and an understanding of 5 – 7 August 2020 URL: https://www.ichmt.org/cht-20
best practice in industrial heat exchange FLAME - 2020
including the following topics: energy » The FLAME 2020 on-going mission to detect
efficiency, operational modelling, fouling novel trends in Thermal, Fluids, Energy and 6–10 September 2020
mitigation, equipment construction, cost Process Engineering, Mechatronics, Control and EUROTHERM2020
optimisation, equipment design, process Robotics, Material Science and Engineering, Solid » The aim of this conference is to promote
control, heat exchanger maintenance and Mechanics and Structural Engineering, Dynamics and to encourage European cooperation
plant improvement. and control, Engineering Design, Manufacturing in thermal sciences and heat transfer by
Location: Toronto, Canada and Industrial Engineering, Automobile bringing together scientists and engineers
Ph: +44 (0)1789 761 398 Engineering. working in specialized areas.
Email: info@ttmprojects.com Location: Amity University Uttar Pradesh, Noida Location: Lisbon, Portugal
URL: https://www. Ph: 0120-4392640, 0120-4392781 Ph: +351-21 841 7186
heatexchangeengineering.com/event/heat- Email: flame@amity.edu E-mail: ritamaia@tecnico.ulisboa.pt
exchange-engineering-2020 URL: https://www.amity.edu/flame2020/ URL: http://www.eurotherm2020.pt
15-17 April 2020 14-16 August 2020 13–15 October 2020
5th International Conference on Int’l Conference on Heat Transfer and Chillventa 2020
Experimental and Numerical Flow and Heat Thermophysics (HTT 2020) » Suppliers will present a compact display
Transfer (ENFHT’20) » The conference will be a reliable platform for of their components and systems, such
» The goal of ENFHT’20 is to gather scholars inspiring international and interdisciplinary as compressors, heat exchangers, fans,
from all over the world to present advances exchange at the forefront of Heat Transfer ventilation systems, air conditioning systems,
in the relevant fields and to foster an and Thermophysics. It will bring together insulation, and C&I, plus services for these
environment conducive to exchanging ideas academicians, engineers, educators and policy- sectors, which focus mainly on commercial
and information. makers from all over the world. and industrial applications.
Location: Lisbon, Portugal Location: Guilin, China. Location: Exhibition Centre, Nürnberg,
Ph: +1-613-834-9999 Email: wsaugust@126.com Germany
Email: info@enfht.com URL: https://www.wsaugust.org/conference/ Ph: +49 9 11 86 06-81 95
URL: https://enfht.com/ HTT2020/ E-mail: redaktion@aussteller.chillventa.de
URL: https://www.chillventa.de/en
4 Heat Exchanger World January 2020
ConTENT
COVER STORY: TEADIT: LEADING R&D CRITICAL
PROCESS SEALING SOLUTIONS 10
BOOSTING CHP EFFICIENCY WITH GAS-TO-LIQUID
TECHNOLOGY 14
WORKSHOP REPORT; HEAT EXCHANGERS
CONNECTING INDUSTRY TOGETHER 17
MILK FOULING IN HEAT EXCHANGERS 21
THE USE OF TITANIUM FOR HEAT TRANSFER
IN THE CHEMICAL PROCESS INDUSTRY 23
HEAT EXCHANGER WORLD CONFERENCE & EXPO:
CALL FOR PAPERS 27
OVERSEEING REFINERY PROCESSES AT PAR HAWAII 32
EFFICIENT USE OF WASTE HEAT IN AIR CONDITIONING
AND PROCESS AIR 36
THE BRIGHT FUTURE OF HEAT PIPE TECHNOLOGIES 38
HOW SUCCESS IN THE STATES HELPED A BRITISH
START-UP ACHIEVE GLOBAL RECOGNITION 41
In every issue:
ADVERTISERS’ INDEX 3
CALENDAR OF
FORTHCOMING EVENTS 4
PROJECT NEWS 6
PRODUCT NEWS 42
INDUSTRY NEWS 45
Heat Exchanger World January 2020 5
ProjectNEWS SPIG to supply cooling system for gas turbine power project
SPIG S.p.A. (SPIG), a subsidiary of
Babcock & Wilcox Enterprises, Inc.,
has been awarded a contract by
Industries and thank them for the
opportunity to work on this key in-
frastructure project for the Republic
Renaissance Heavy Industries to de- of Turkmenistan,” Galantini said.
sign and supply fin fan cooler heat SPIG’s experience includes wet, dry
A new application of clean energy heating in South China exchangers for the Turkmenenergo and wet/dry hybrid cooling solu-
432 megawatt, gas turbine power tions as dictated by site-specific re-
plant project in Charjev etrap, Lebap quirements. The company’s cooling
Velayat region,Turkmenistan. systems and designs can be tailored
“SPIG’s custom-designed cooling for a wide range of project specifi-
technologies are an ideal fit for cations such as high seismic loads,
many plants, especially natural gas vibration control, corrosion, noise
facilities, in the rapidly developing control, sub-freezing operation, and
Central Asia region,” said SPIG Man- seawater use. Specialized services
aging Director Alberto Galantini. include preventive maintenance,
“SPIG offers an extensive range of equipment upgrades, replacement,
turnkey cooling systems and can and spare parts, online performance
supply both mechanical and natural monitoring, and a commitment to
draft systems and designs.” research and development to con-
“We appreciate our strong rela- tinually seek new and more efficient
tionship with Renaissance Heavy cooling system solutions.
Accessen was invited to partici- water–water plate heat exchanger
pate in the initial design of the first in the north. In order to overcome
central heating project in Guizhou the special requirements of high
Province, the Phase I central heating temperature, high pressure and
project in the “Sihengshuian” water quality of steam in the project,
residential quarter in Yaxi Town, Accessen provided the design
Bozhou District, Zunyi City and scheme of replacing the traditional
the scheme evaluation of the heat water–water plate heat exchanger
exchange part. unit with the steam–water plate&
Accessen had many field visits shell heat exchanger unit, which was
and technical exchanges for the used to meet the heating demand of
conditions for this project. As a 1800002 m for residents and busi-
pilot project of central heating in nesses in four buildings (18 floors in
the south, the total construction each building).
area of the Sihengshuian project is The plate and shell heat exchanger
about 2700002 m. The heat source unit of Accessen is not only resistant
adopts the primary network steam to high temperature and high pres-
delivered by the Yaxi power plant. sure, but also has lower energy con-
The maximum temperature and sumption and better heat exchange Nederman MikroPul selected by Scania to supply heat
pressure of the steam can reach effect compared with traditional exchangers
350° and 2.5MPa respectively. It tube heat exchangers.
Scania, the provider of transport including heat exchangers on
is different from the traditional
solutions, including trucks and various work stations from melting
buses for heavy transport applica- to finishing, with a total volume flow
tions, is investing EUR 150M in a of 1.254.000 Am3/h. The largest
Alfa Laval wins SEK70M oil & gas order new foundry in Södertälje, Sweden. expected energy savings will be ob-
Scania plans to triple production ca- tained through improvements in the
Alfa Laval the heat transfer, centrif- The order comprises Alfa Laval pacity and achieve a 50% reduction casting process and recovery by heat
ugal separation and fluid handling OLMI heat exchangers to be used in energy consumption compared to exchangers, which will transfer heat
company has won an order for in gas injection for enhanced oil the technology and methods used in from the exhaust to the supply air.
air cooled heat exchangers, to be recovery (EOR) at an oil and gas the current foundry. “Our offer perfectly met Scania’s
installed in an oil and gas production facility near the Tengiz field. The Scania has selected Nederman ambition towards more sustainable
facility in Kazakhstan. The order heat exchangers will be used in a MikroPul for the supply of six filter production. We are proud of being
has a value of approximately SEK demanding cooling application, han- plants for air pollution control, part of a project, which will set new
70M and is booked in the Welded dling high pressure and aggressive standards
Heat Exchangers unit of the Energy gas in the oil extraction process. for modern
Division. Deliveries are scheduled “We have a broad range of reliable manufac-
for 2020. and energy efficient heat exchang- turing in
ers. Our OLMI heat foundries,”
exchangers are among said Markus
the toughest and durable Schilli,
and thereby well-suit- Managing
ed for this demanding Director
EOR application,” says Business
Susanne PahlénÅklundh, Unit FS
President of the Energy Systems.
Division.
6 Heat Exchanger World January 2020
Project News
Sandia analysis evaluating water saving technologies IEC awards second contract to GE
for HA gas turbine technology
To reduce the plant’s water use,
operators at Palo Verde first
looked at commercially available
solutions. When they realized that
nothing available could meet their
needs, they turned to Sandia Labs
to help identify which cooling sys-
tems under development might
eventually offer the greatest water
savings.
To evaluate different emerging
technologies, Middleton devel-
oped software that combines the
physics of the cooling process
The Palo Verde Nuclear Generat- charge roughly the same amount such as fluid flow, heat transfer,
ing Station near Phoenix converts they withdrew. atmospheric evaporation and
heat from nuclear reactions into But the Palo Verde plant has limit- water treatment with the financial
electricity. The heat boils water, ed access to water because it is in impact of different solutions.
creating steam that drives turbine the middle of a desert. Its cooling The wastewater that arrives at
generators. Steam leaving a water is treated wastewater, which Palo Verde contains silica, calcium,
turbine must be cooled and con- is becoming increasingly expen- magnesium and phosphate ions.
densed before it is reused. sive as other customers who are These salts concentrate as the
More than 40% of all the water willing to pay higher prices for wa- cooling water evaporates in the
used in the country is for wet ter emerge. To curb rising costs, cooling system, possibly forming GE announced today that it has re-
cooling at power plants. Typically, operators want to reduce the new minerals that might clog the ceived another order from Israel Electric
large thermoelectric power plants plant’s water use by about 9 mil- cooling towers. Currently, opera- Corporation (IEC), the largest generator
are located near lakes or rivers lion gallons a day. Annually, that tors add lime, soda ash and acid and supplier of electricity in Israel, for a
so that operators can draw a savings is roughly equivalent to a to the wastewater before it enters second 9HA.01 heavy-duty gas turbine.
regulated amount of water, run it 16 square mile pool of water one the cooling tower to reduce the IEC is using GE’s HA gas turbine tech-
through a condenser to cool steam foot deep, said Bobby Middleton, a possibility of mineral formation. nology at its Orot Rabin plant, located in
leaving the turbines, and dis- nuclear engineer at Sandia. Hadera, Israel, as part of the conversion
of the existing power station from coal to
gas generation. GE’s HA is the largest and
most efficient gas turbine in the world and
Linde as LNG licensor of Greater Tortue Ahmeyim project recently reached a milestone of 500,000
operating hours, continuing to be the fast-
Linde announced recently that Mauritania and Senegal. est-growing fleet of advanced turbines in
it has been selected as liquefied Under the terms of the the world.
natural gas (LNG) technology signed Master Agreement, The order for the first unit, which is also
licensor for phases 2 and 3 of the Linde will provide tech- the first HA gas turbine in Israel, was
Greater Tortue Ahmeyim project, nology licensing services, announced in 2019. In the latest order,
jointly developed by BP, Kosmos based on the Linde MFC2® GE will also provide a steam turbine,
Energy, Société des Pétroles du liquefaction technology. generator, heat recovery steam generator
Sénégal (PETROSEN), and Société Linde will also manufac- and balance of plant equipment as well
Mauritanienne des Hydrocarbures ture and supply the related as a 15-year multi-year services agree-
et de Patrimoine Minier (SMHPM). cryogenic coil-wound heat ment. Once operational, the Orot Rabin
Greater Tortue Ahmeyim, which exchangers, subject to a combined cycle gas turbines are expected
will be operated by BP, is the future call-off. to be the largest and most efficient gas-
deepest offshore project in Africa The Linde MFC2® liquefac- making it well suited to offshore fired power units in Israel, delivering up to
to date and is located offshore tion technology is both compact projects like Greater Tortue Ah- 1,260MW, more than 8% of Israel’s current
on the maritime border between and highly energy-efficient, meyim. total power generation capacity.
Heat Exchanger World January 2020 7
Project News
Coolair gets on track at platform 21 in Birmingham
Meggitt announces an
Coolair Equipment Ltd is to bring the conditioning with heat investment in HiETA
latest energy-efficient heating and recovery from Mitsubishi Technologies
cooling technology to one of Bir- Electric that enables dif-
mingham’s most prestigious office ferent zones to be cooled Meggitt (UK) Ltd, a subsidiary of
developments. and heated simultane- Meggitt PLC, an international com-
The company’s Midlands operation, ously while also reducing pany specializing in high-perfor-
based in Cannock, has been awarded building operating costs. mance components and subsystems
a £900,000 contract by Imtech As an accredited Dia- for the aerospace, defense, and
Engineering Services Central on mond Quality Partner selected energy markets, recently
behalf of Wates Construction to help of Mitsubishi Electric, announced an investment in HiETA
provide the best possible working Coolair Equipment will Technologies Ltd, a UK company
conditions at Platform 21. supply and install 18 with principal capabilities in metal
The 10-storey building, formerly heat recovery variable additive manufacturing.
known as The Charters, is being refrigerant flow (VRF) The investment will accelerate the
refurbished to create 120,000 sq ft systems along with 218 fresh air to the ground to ninth development of the next generation
of Grade A office space and include ducted indoor fan coil units (FCUs). floors while simultaneously extract- of thermal systems for aerospace
a repositioned double height glazed The company will also install a ing stale air and recovering its heat and energy applications. It enables a
reception in Stephenson Street low-noise flexible direct exchange energy for maximum efficiency. new generation of high performance
facing New Street station. (DX) split system, with roof-level Work on-site on the project is due and light weight thermal systems
Coolair Equipment will provide condensers, and 60 heat recovery for completion in the first quarter to be brought to the market at a
state-of-the-art energy-efficient air ventilation Lossnay units to supply of 2020. critical time for sustainable aviation
and lower carbon power generation
solutions.
Hydroniq’s coolers to the subsea cable installation vessel
of offshore petroleum Marine cooling systems are utilised
installations and creating to reduce temperatures in the ship’s
interconnectors between engines and other auxiliary systems
countries. through the use of seawater to avoid
Under the contract, overheating of the engine and other
Aalesund-based critical systems. Hydroniq Coolers
Hydroniq Coolers will will manufacture to assemble the
supply its Pleat seawater Pleat cooler at its headquarters in
cooling system for the Aalesund, Norway, and deliver it to
CLV Nexans Aurora. The Ulstein Verft in Ulsteinvik, Norway. Meggitt’s experience in design-
Norwegian shipyard Ulstein Verft Pleat coolers will provide CLV Nexans Aurora is a DP3 cable ing and manufacturing advanced
has contracted Hydroniq Coolers to cooling of the vessel’s main engine laying vessel that will be outfitted heat exchanger technologies for
deliver the seawater cooling system and auxiliary systems through the for power cable laying, including mission-critical aerospace and
to a cable lay vessel it is construct- use of seawater. Hydroniq Coolers bundle laying, cable jointing and industrial applications complements
ing for Nexans Subsea Operations. has not disclosed the value of the repair, and cable system protection HiETA Technologies’ experience in
The CLV Nexans Aurora will play a contract. The patented Pleat is a and trenching. The vessel is devel- designing and using additive manu-
vital role in the installation of Nex- module-based titanium cooler for oped for operations in rough weath- facturing to build high-performance
ans’ HV submarine cables that will seawater to freshwater, with design er and has high manoeuvrability and components for aerospace, defense,
connect offshore wind farms to the pressure 6 bars and a design tem- station keeping capabilities. and motorsport applications.
grid, supporting the electrification perature of 0-95°C.
Chinese nuclear heating project starts up GeoHex: the first RTD project for the Philippines
Shandong Nuclear Power Company This use of nuclear energy heating is Project GeoHex, funded
(SDNPC) a subsidiary of State Pow- expected to avoid the use of 23,200 by European Union’s Ho-
er Investment Corporation (SPIC) tonnes of coal annually, cutting rizon 2020 research and
and the owner of the Haiyang plant emissions of soot by 222 tonnes, innovation programme,
announced that, following a few of sulfur dioxide by 382 tonnes, of is the first RTD project
days of trial operation, the demon- nitrogen oxide by 362 tonnes and of for the Philippines that
stration district heating system had carbon dioxide by 60,000 tonnes. highlights transcontinental
officially been put into operation. The Haiyang Nuclear Energy Heat- technology transfer for the
The system extracts non-radio- ing Project is expected to provide development of advanced
active steam from the secondary heating to the entire Haiyang city materials for cost-effi-
circuit of the two Haiyang AP1000 by 2021. cient and enhanced heat
units, which is then fed through a exchanger performance in heat exchanger (HX) materials
multi-stage heat exchanger in an geothermal applications. addressing both the improvements
on-site heat exchange station. This Quantum Leap, a procurement and in the anti-scaling and anti-corro-
heat is then fed to an off-site heat service company in the power sector sion properties, as well as, the heat
exchange station belonging to local from the Philippines and in con- transfer performance of the HX ma-
thermal company Fengyuan Ther- junction with the Government of the terial leading to more efficient and
mal Power, from where heated water Philippines, is working with experts cost-effective systems. The reduced
flows through municipal heating from research institutes across UK cost of geothermal plant based on
pipes to consumers. The system will and Europe to share cutting-edge GeoHex enabled HX, is proposed
initially heat 700,000 square metres technology towards building a sus- to significantly reduce the levelised
of housing this winter, including SD- tainable renewable energy system. cost of energy (LCOE), which will
NPC’s dormitory and some residents The technology transfer, as part of accelerate the growth of geothermal
of Haiyang. GeoHex project, aims to develop energy.
8 Heat Exchanger World January 2020
Project News
Atommash manufactured steam generators Greenfield projects help sustain market growth
for Kudankulam NPP
Emergence of greenfield projects in Forecast to 2024, examines the
Asia-Pacific to help sustain long- key growth drivers, restraints,
term market growth, finds Frost & product segments, and end-user
Sullivan. industries in the regions of North
While the US-China trade war and America, Europe, Middle East and
downturn in the oil and gas sector Africa (EMEA), APAC, and the
have dampened investments in the Rest of World (RoW). It covers the
heat exchangers market, particularly product segments of shell-and-tube
in North America, the growth of heat exchangers, air-cooled heat
the Asia-Pacific (APAC) market is exchangers, gasketed plate-and-
providing a much-required impetus. frame heat exchangers, brazed plate
Regional growth, along with positive heat exchangers, all-welded plate
economic activity and increased heat exchangers, and cooling tower
investments in the energy sector, is systems. It also includes a CEO’s
expected to drive the market from 360-degree perspective, highlights
The Branch of JSC AEM-technology shipped to the NPP under construc- USD 13.67bn in 2018 to USD 17.33bn future growth opportunities, and
Atommash in Volgodonsk (a part of tion in 2019, the forth Item will be in 2024, at a compound annual presents the strategic imperatives
the machine-building subdivision of shipped to the customer construc- growth rate (CAGR) of 4.0%. that need to be implemented to
ROSATOM – JSC Atomenergomash) tion site in April 2020 when the Frost & Sullivan’s recent analysis, make the most of these opportu-
has finished the production of steam navigation season is open. Global Heat Exchangers Market, nities.
generators set for the Unit No. 4 of The production cycle of steam
Kudankulam NPP in India. generator PGV-1000M manufacture
A steam generator belongs to the takes more than two years from the
Items of safety class 1. The steam start of metallurgical blanks produc-
generator vessel is a horizontal tion to the shipment. To produce one
cylindrical vessel with two elliptical Item it is required to use 340 kg of
bottoms, in the middle part of which welding strip, 5.5 tons of the weld-
there are collectors for the supply ing electrodes and 8 tons of welding
and discharge of hot coolant. The di- wire. 11 thousand heat-exchange
ameter is more than 4 m; the length tubes with a total length of approxi-
of the equipment is about 15m. The mately 130 km are welded inside the
weight of one steam generator is steam generator. The total length of
340 tons. the welds is more than 1 km.
Three heat-exchange Items were
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C ov e r S t o r y
Teadit: Leading R&D for critical
As a worldwide
development and
manufacturing leader
of critical process
sealing solutions, Teadit
continues to exceed
customer expectations
by providing high-quality
service, impressive
testing capabilities,
and a full line of award-
winning products that
are guaranteed to meet
the demands of the most
stringent environments.
Serving the refining,
petrochemical and power
generation industries,
among others, Teadit’s
extensive research and
development (R&D)
group has continuously
developed new products,
helping many end-users
achieve facility emission
goals.
Heat Exchanger World
spoke with Chris Day,
President of Teadit
North America, about
the company’s high- By Sarah Bradley & Stephanie Matas customers achieve the goal of a leak-free environment
quality product offering, within their facilities while constantly investing in R&D to
keep up with the evolving industry needs.
expanding R&D
Since its establishment in 1958, Teadit has expanded its Teadit is relied upon by many of the country’s top heat
capabilities, and recent production and distribution network across 52 countries. exchanger manufacturers for their products and techni-
product innovations The company has experienced significant growth in recent cal expertise. Depending on the industrial sector, service,
years, with dedicated locations spanning from the USA and heat exchanger type, the gasket recommended and
for the heat exchanger (Texas), to Brazil (Rio de Janeiro and Campinas), Argentina supplied changes. Some designs utilize metal gaskets in-
market. (Buenos Aires and Bahia Blanca), India (Vadodara), Austria cluding spiral wound gaskets, camprofile serrated gaskets,
(Kufstein), Germany (Köln), and China (Shanghai). corrugated gaskets, and double jacketed gaskets. It is also
The Teadit Group is recognized worldwide as a leader in common to use Teadit sheet gaskets or soft gaskets in heat
the development and manufacturing of innovative prod- exchangers including compressed fiber, filled PTFE, and ex-
ucts for critical fluid sealing processes in many industries panded PTFE. Gaskets are supplied with torque values and
including the Refining, Chemical Processing, Pulp and assembly instructions by their engineering department
Paper, and Power Generation. Teadit has helped several when requested. Teadit is a Master Distribution Partner
10 Heat Exchanger World January 2020C ov e r S t o r y
process sealing solutions
« Mr. Chris Day, President of
Teadit North Americas.
« North American Headquarters
in Pasadena, Texas, USA.
of Jet Lube and supplies the thread lubricant Jet Lube 550
Extreme to ensure that the flanges are assembled using
accurate torque values with accurate friction factors.
« Teadit Style 942 camprofile
Award-winning products with graphite facing, a robust
Teadit camprofile gaskets have become the most popular design generally used for high-
temperature and high-pressure
gasket utilized in shell and tube heat exchangers. They can
applications.
produce a reliable seal and avoid field application issues
that other more traditional solutions, such as double
jacketed and corrugated, are not able to address. They are
designed to maintain seal integrity under pressure and
temperature fluctuations, flange rotation, and bolt stress « Teadit Style 942 camprofile with
relaxation. Teadit camprofile gaskets are constructed from PTFE facing, a design utilized for
a precision serrated metallic core with a soft facing materi- high-pressure applications, as well
al bonded to each side, either flexible graphite or expanded as extreme chemical resistance.
Heat Exchanger World January 2020 11C ov e r S t o r y
come up with something, then see if we can sell it. If a
product holds no value in the customer’s eyes, there really
is no reason to bring it to them. ‘Market-driven’sounds
like a buzzword, but we live by it,” commented Day.
When searching for materials, Teadit is very integrated
with the end-user either directly or through their distribu-
tion partners. “A lot of plant employees communicate with
us directly, especially in the Houston industrial region” ex-
plained Day. “Outside of Houston, we still strive to main-
tain direct contact, but much of it is with and through our
distribution partners. We will accompany our distribution
partners into different facilities to talk to the engineers,
planners, and maintenance personnel to find out what their
needs are and any challenges they face.”
Teadit Style 25BI gasket tape PTFE. Teadit camprofile vessel gaskets are used in all major Teadit’s research facilities receive feedback from all over
»
used for fragile flanges, extreme industrial sectors in heat exchangers, but they can also be the world. “We want to be the primary reference and
chemical service, large diameters, found in standard piping as well. prime choice for fluid sealing advice,” said Day. “When
and/or custom-shaped flanges.
For applications that require a high degree of chemical considering what projects to consider working on, we talk
resistance and low stress-to-seal, Teadit 25BI gasket tape, to different customers all over the world. We get their
has raised the bar for what should be expected out of ex- feedback and organize that information in a matrix of pri-
panded PTFE gasket tape. Due to its excellent malleability orities in order to see what would be the easiest to develop
and adaptability, it is particularly well suited to compen- with the quickest and greatest potential for success.”
sate for irregularities or damages on the sealing areas Teadit’s quarterly meetings bringing together their global
and can easily bend around the radius of a round flange. directors and technical experts to share and exchange
A propriety manufacturing process results strong tensile information, to maintain consistency amongst their world-
strength in both the longitudinal and cross direction. As a wide locations. “We always look for opportunities to use
result of this, the material does not change its width under what could have been developed elsewhere,” commented
compression. “Because of this property, it is extremely well Day.
suited as a gasket material for narrow sealing areas and in
all applications where a defined gasket width (under load) Leaders in technological innovation
is required, such as enamelled and glass-lined flanges, heat It is important for Teadit to set the benchmark for the
exchangers, large flanges and containers, pressure vessels, industry, rather than playing catch-up with their compet-
suction filters and strainers, etc.,” said Day. itors. “For a long time, the U.S. market never really knew
who Teadit was. Everyone seemed to think we were only in
Ever-evolving R&D Brazil, as we were the dominant market share player down
Teadit considers themselves a market-driven R&D com- there, taking very good care of our customers, helping
pany, “This means that the market is going to dictate to them meet whatever challenges they encountered,” said
us what we develop. We do not want to sit in our labs and Day. “We knew we had to do something differently in the
» Teadit considers themselves a
market-driven R&D company,
“This means that the market is
going to dictate to us what we
develop. We do not want to sit
in our labs and come up with
something, then see if we can sell
it. If a product holds no value in
the customer’s eyes, there really is
no reason to bring it to them, says
Chris Day.
12 Heat Exchanger World January 2020C ov e r S t o r y
« Many of Teadit’s sealing
solutions are for very unique pieces
of equipment.
US, to allow us to be accepted here, too.” manufacturer with the ability to really dictate the future
Teadit quickly realized the market was not just focused on of the sealing products industry.”
lower pricing, but lower total cost of ownership. “If we can In-house testing is critical to Teadit, because it is one of
provide a better, longer lasting solution with quality ser- their major differentiators from competing manufacturers.
vice, it outweighs product price,” said Day. “We are always “As long as we remain focused on the fact that it is all
looking to elevate Teadit in the eyes of our customers.” about quality, we will forge ahead. We must be able to test
Teadit is also recognized as one of the leading manu- our product; go out into the shop, make it faster, and lower
facturers of standard pipe size and pressure class spiral costs. It is all about performance, in everything that we do.
wound gaskets. “To my knowledge, we are the only global In-house testing gives us the ability to experiment with
manufacturer that does the level of product evaluation and production efficiencies, we put a lot of emphasis into and
testing that we do for the standard size and class range. behind our testing, and we do it well,” stated Day.
This allows us to ensure that all the standards that we put Typical gasket testing is conducted in two phases – de-
forth meet or exceed the new performance specifications structive, and then performance. The first phase involves
mandated,” said Day. conducting a destructive test, where multiple pieces are
Teadit’s flagship packing product, style 2236, was born destroyed, to ensure full compliance to specification
from the desire to create a better product for the mar- construction requirements. In the second phase, leakage
ket. “We saw an opportunity to make things simpler for tests and compression tests are performed to ensure the
our customers - a single material making up a complete specification requirements are met per ASME B16.20
packing set providing the best emissions results at that (2017). Testing lasts approximately four hours from start
time. The simplest solution for the best results,” said Day. to finish. For this evaluation, Teadit has logged data now
“Our customers are the driving force behind our advanced for the last four years, which gives operators a backlog of
testing capabilities and market-driven R&D initiatives.” case studies to extract information from if they do ever
encounter a problem.
In-house testing capabilities Day mentioned the group has two testing rigs in North
The Teadit Group has robust in-house testing capabilities America, two in Brazil, and one in India. “We can conduct
in all the regions that it serves. This testing includes com- twenty gasket tests per week here – and can do twenty
pression and leakage monitoring for metal gaskets, ranging in Brazil, and ten in India. We are testing a wide range of
from ½” to 18-inches in size, across multiple pressure sizes to ensure consistency. We want to make sure that
classes. “This gives us the ability to not only measure how wherever we are producing a product, it holds the same
good our gaskets are, but measure the effectiveness of caliber of performance regardless of the manufacturing
process improvements we develop,” said Day. “When we site. Everyone is starting to demand this in the industry –
first started testing, we saw that we were, what I consider, quality control across the globe,” said Day.
in the middle of the road. We did things about as well as
everybody else and in about the same way.” Looking ahead
Teadit then started looking at incorporating improvements When asked about the future of the industry, Day is
into different aspects of the gaskets based on a variety of hopeful for future generations. He maintains that it is
variables that affected ultimate sealing ability. They found not difficult to produce great quality products over lower
that those variables sometime fit together in different quality items. “With genuine and sincere effort, the price
ways, to produce different results. “We finally got the to produce and the price to procure can both be about
right combination that would enable the parts to perform the same, it is almost negligent to supply to the market
very well, but this testing dictated a lot of tweaking of without proven quality gaskets and packing these days,”
our processes,” commented Day. “We’re testing up to fifty said Day. “If we stop emissions, we’re stopping the loss of
gaskets per week in our facilities to make sure that we can product, right? It’s the product that’s going in the air rath-
validate our performance and continue to look for opportu- er than going through the piping. We need refineries and
nities to improve performance. It gives us a very clear industry to thrive, but I also want this world to be around
indicator of where we are and where we need to be.” for my grandkids to enjoy. We get too caught up in our
Day stands behind the company’s testing procedures. “This day-to-day routine to really worry about this thing called
evaluation process is something nobody else is doing, a ‘carbon footprint’, but it’s important,” commented Day.
but everyone should be. We have reached a critical point “It’s important for our future and I want to make a differ-
where we want to continue to differentiate ourselves in ence. That is what is cool about being part of a company
the market. We are a high quality, high volume production like Teadit, they help me accomplish this!” «
Heat Exchanger World January 2020 13Case Study
Boosting CHP efficiency
with gas-to-liquid technology
Looking at how Hubert By Aaron Kahn, Pyramid Agency, United Kingdom
Tippkötterre-uses the
heat produced from the
Hubert Tippkötter GmbH is a designer and manufacturer
electricity generated of complete combined heat and power (CHP) systems.
in its combined heat The company has been in operation since 1970. Based in
and power systems to Warendorf, Germany, it engineers flexible solutions that
generate anywhere from 30 to 2100 kw of electrical power,
increase the efficiency of
and which are fully adapted to match specific customer
the system as a whole. circumstances.
By simultaneously generating electricity and re-using the
resulting heat, CHP, or cogeneration, is a highly efficient
solution for a number of modern applications. Like all
CHP manufac turers, Tippkötter works to optimize its
technology and maximize the efficiency out of its systems.
This has included considering a number of new methods
to take advantage of the heat transfer involved in cooling
modified turbo-charged engines that drive the systems.
However, this is easier said than done. CHP systems
typically use air–air coolers, with ambient air cooling The optimal charge air cooler solution
the engine’s compressed charge air to the required inlet The company has been able to overcome these challenges
temperature of 75°C. It has traditionally been difficult – if by equipping their CHP plants with Alfa Laval gas-to-
not outright impossible – to reuse the energy generated liquid plate heat exchangers. In contrast to traditional
through this process due to the challenges of working air–air cooler technology, Alfa Laval’s gas-to-liquid design
with gas media. As a result, there have been limits to the makes it possible to use water as the cooling medium. This
potential efficiency that can be achieved with the system improves the overall energy balance by as much as 5% of
as a whole. the engine’s power.
14 Heat Exchanger World January 2020Case Study
GL model heat exchangers use cold water in a countercur-
rent flow arrangement to cool a relatively smaller amount
of compressed charge air to the correct inlet tempera-
ture. An additional advantage of the GL design is that
all connections are integrated in the unit, including two
connections for gas, two for water and one for condensate.
The result is an ultra-compact heat exchanger, which
makes installation easier, quicker and more cost-effective
for Tippkötter and allows them to provide a smaller system
footprint for their customers.
The use of Alfa Laval GL gas-to-liquid heat exchangers has
played a major role in Tippkötter’s ongoing development
to drive forward the optimization of their CHP technology.
Customers are therefore able to benefit from a cogenera- « The prototype
heat exchanger
tion efficiency of 91% or even higher. « in the lab.
Hot gas in
100kg/h
Water out 421°C «« GL100 heat exchanger model.
53.5°C
Example specifications for the Tippkötter CHP system
Water in Engine
1.0 m3/h Engine type: Diesel
Motor power: 120 kW
49°C
Electrical power: 50 kW
Heat exchanger
Type: Alfa Laval GL gas-to-liquid brazed plate heat exchanger
Hot gas out Condensate Material: Stainless steel with copper brazing
105°C 5.6 l/h Number of plates: 10H x W x D: 320 x 727 x 48 mm
Weight: 22 kg
Evaporator
Flexible Tank Beam
Water
Process
Umbilical Equipment Facade
Building
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Heat Exchanger World January 2020 15Conference Discussion
Workshop report:
heat exchangers connecting industry together
» Top row from left to right: Arjan
Woerden, Shell, The Netherlands;
Willem Maarten van Haaften,
Shell, The Netherlands; Barinder
Ghai , Sandvik, UK; bottom row
from left to right: John Butterfield,
KCI Publishing, The Netherlands;
and Bernardo Siza Vieira, Sandvik,
Portugal.
During the Stainless Steel
World 2019 Conference
& Exhibition, which was
held in Maastricht, The
Netherlands, November
26–28, a special workshop
was dedicated to the huge
variety of heat exchangers
that perform critical duties
in fundamental industries.
Over sixty participants
freely shared their
experiences with an expert
panel.
By David Sear For convenience, each topic was further broken down
into a series of short questions. This write-up follows the
same structure, presenting comments from the panel and
Background audience per topic and per question.
The workshop was a collaborative effort from Barinder
Ghai and Bernardo Siza Vieira (both Sandvik Materials Topic one: what are the current challenges with
Technology), together with Shell’s Arjan Woerden and heat exchangers?
Willem Maarten van Haaften. The meeting was facilitat- 1: Quality assurance
ed by John Butterfield (KCI Publishing). Barinder acted - “My company has well-defined Design Engineering
as moderator, inviting expert comments from Bernardo, Practices which nicely indicate relevant QA issues. How-
Arjan and Willem Maarten whilst ensuring all participants ever, I wonder whether others in the supply chain have
had ample opportunity to raise questions and contribute to access to equivalent details.” End user
discussions. - “Do end users sometimes rely too much on accrued
knowledge? Using internal standards drawn up in the
Presentation structure 1950s can be a major hindrance.” Consultant
The heart of the workshop was formed by three top-lev- - “I am often submerged under quality documents
el topics: 1) what are the current challenges with heat submitted by end users. They take a long time to sort
exchangers? 2) What are the factors influencing upgrading through with many proving irrelevant. End users should
from low alloy to duplex stainless steels/high-nickel al- indicate which quality documents are applicable and
loys? 3) What are the current limitations when upgrading? which are not.” Tube supplier
Heat Exchanger World January 2020 17Conference Discussion
- “ We purchase equipment for end user clients using a
policy of zero based execution. Hence we refer to indus-
try recognized standards such as ASME and NACE for
heat exchangers, impressing on end users that putting
their own extra standards to one side helps to get a qual-
ity product in the required timeframe.” EPC
- “Globalisation is driving many fabricators to invest in
novel technologies that promise to be faster and cheaper.
If there is no time to iron out the teething problems
in new technology that can create headaches later on.”
Heat exchanger manufacturer
3: Operating conditions
- “In addition to the standard operating conditions you
should also consider upset conditions, possible fouling
and also feed flexibility. So materials engineers must
never work in isolation but should always be talking to
process engineering, the project department, the fabrica-
tors and the inspector.” End user
- “Designing a heat exchanger which will meet future
needs is a real challenge, and it can be hard to justify
extra outlay for more exotic alloys.” End user
- “Thirty years ago heat exchangers were either carbon
steel or rusty carbon steel! Now even duplexes are being
specified, often simply as a way to keep process systems
up and running. For a new grade is to be commercially
successful parties in the supply chain must cooperate to
A tube sheet being cleaned. - “ Why can’t I speak directly to end users? I often have to ensure the ready availability of all the standard products
»
Photo: Hammelmann work via three or four intermediaries in the chain, which that could be needed.” End user
unnecessarily complicates getting answers to questions.”
Primary product supplier 4: Life cycle costs
- “Heat exchangers are not commodity products. I recom- - After identifying corrosion in a heat exchanger I
mend that everyone involved should check all details in proposed three or four solutions, including renovation
advance.” Fabricator. and upgrading. All were perceived to be too expensive!
- API standards are my starting point. If a tailor-made People holding the purse strings simply don’t look at the
product is needed I discuss critical issues with the man- long term.” End user
ufacturer and we jointly modify the standard specifica- - “What should be included during life cycle costing?
tions. My tip to ensure heat exchangers work as expected Conducting inspections every three months could be
is to buy from a reliable manufacturer to start with. costing EUR 280,000 per year! Factor that in and the
And even then you must pay close attention to quality case for investing in a corrosion resistant alloy is more
control!” End user easily made.” End user
- “For us it is equally important to visit pipe mills regu- - “If your carbon steel product is failing every two to
larly and to perform our own quality assurance checks.” three years then it is definitely time to consider stainless
Heat exchanger manufacturer steel.” End user
- “A lack of regular inspection and cleaning can lead to
many heat exchanger problems. Maintenance crews 5: Material selection
used to inspect equipment much more regularly, at - “Issues which are important are surely costs, corrosion
the same time cleaning the tubes and conducting small issues and thermal properties.” Tube manufacturer
repairs. With today’s risk based inspection there is an - “Not all fabricators seem to know how to correctly weld
assumption that heat exchangers are working fine. The or pickle certain alloys.” End user
only people who ever see them regularly are the process
technicians and they have not been told to conduct 6: Availability of product forms
inspections let alone cleaning!” End user - “2205 duplex in all product forms is easily obtained in
Western Europe, making it suitable for grassroots pro-
2: Fabrication issues jects. The position can be very different in Asia and the
- “There are sufficient documents explaining how to weld US.” End user with global responsibilities
even the most exotic of alloys; it is simply a question of - “In Europe you can find good fabricators such that
applying them.” Fabricator a 2205 duplex heat exchanger is price competitive to
- “Time is often the critical factor. In a process facility we 316 stainless steel and can be delivered in under three
need to replace leaking heat exchangers right away. A months. Alloy 59 heat exchangers can also be obtained
lack of time for planning is a feeding ground for prob- but take from six to eight months. That is not likely in
lems.” End user the United States.” End user
18 Heat Exchanger World January 2020You can also read
