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1part of Aker

Modular Radial Flow Gas-Gas ExchangerTom Wacker, P.Eng.Aker SolutionsVancouver, BC, Canada

2009 Aker Solutions

Agenda

Introduction Radial Flow Gas-Gas Exchanger Recent Large Projects Why Modularize? Development of the Modular Radial Flow Gas-Gas Exchanger Two Success Stories Conclusions

2009 Aker Solutions part of Aker

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2Introduction

Acid plant capacities are ever increasing A 4400 MTPD has been successfully operating, with a 5000 MTPD

due on line in the near future Equipment size naturally increases with plant capacity Equipment size naturally increases with plant capacity Gas-gas exchangers are approaching 6m diameter and 200 tonnes Shipping, especially to remote locations, is a big problem Field fabrication is expensive, time consuming and lower quality The solution modularization of the tube bundle


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Radial Flow Gas-Gas Exchanger

Developed by Chemetics in the late 70s Patented radial tube pattern

Constant flow area across bundle Same layout angle in all flow directions Same layout angle in all flow directions

Disc and donut baffles Ensure pure radial flow across bundle No tubes in window arrangement (tubes restricted to annular

region near the shell)

Welded tube to tube sheet joints Critical exchanger component (subject to high temperatures and

cycling)


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cycling)

3Radial Tube Pattern (Patented)


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Gas Flow

Radial Flow Gas-Gas Exchanger

Upper Vesitbule

Disc & Donut Baffles

Shell and tube bundle


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Lower Vesitbule

4Recent Large Projects

Codelco (El Teniente, Chile) 6.1m diameter 11.4m tube length 110 tonnes

Vale Inco (Sudbury, Canada) 5.1m diameter 15.2m tube length 126 tonnes

BHP (Ravensthorpe, Australia) 6.0m diameter 14.5m tube length 133 tonnes

WMC (Kalgoorlie, Australia) 5.8m diameter 18.3m tube length 198 tonnes

Note: length is for tube bundle only - does not include vestibules


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g y

Vale Inco, Sudbury (2003)


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5WMC, Kalgoorlie (2003)


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WMC, Kalgoorlie (2003)Main crane is 600t capacity


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6Why Modularize?

Traditional methods for oversize exchangers Field erect Redesign as multiple units in parallel

Disadvantages Disadvantages Longer construction schedule Welding quality (especially critical welds) Higher cost for multiple units in parallel

Challenge: Modularize exchangers so they can be shipped in standard

containers Maintain shop quality of critical welds


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Maintain shop quality of critical welds Minimize construction schedule

Solution: Modularized tube bundle

Development of the Modular Exchanger

Symmetric radial tube pattern prone to acoustic resonance (especially in large exchangers)

Successfully resolved by adding acoustic baffles Resulting tube pattern is radially symmetric but divided into distinct Resulting tube pattern is radially symmetric, but divided into distinct

equal segments


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7Development of the Modular Exchanger

Radial pattern with acoustic baffles

Can easily be split into segments!


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Development of the Modular Exchanger


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8Development of the Modular Exchanger

Advantages: Segments can be shipped in standard containers Critical tube to tube sheet welds carried out in the shop Site labour and construction schedule are reduced


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Two Success Stories Balkhash and SPCC

Two very large (> 3700 t/d) metallurgical acid plants Very remote locations

Central Kazakhstan Pacific coast of southern Peru Pacific coast of southern Peru

Limited transport infrastructure Rail (3.5m x 3.5m maximum) Two lane undivided highway

Large exchangers 5.4m shell diameter, 210 tonnes fully assembled

Modularization the solution


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9Two Success Stories Balkhash and SPCC


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Two Success Stories Balkhash and SPCC


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Conclusions

Radial symmetry of Aker Solutions gas-gas exchangers makes modularization relatively straight forward

Offers owners the advantages of radial flow exchangers coupled with the opportunity to reduce freight and construction costsy g

Exchanger reliability is maintained by performing critical welds in the shop

Particularly well suited to remote plant locations Can also be considered for retrofits (cost & schedule impact)


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Copyright

Copyright of all published material including photographs, drawings and images in this document remains vested in Aker Solutions and third party contributors as appropriate. Accordingly, neither the whole nor any part of this document shall be reproduced in any form nor used in any manner without express prior permission and applicable acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction.


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Disclaimer

This Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to risks and uncertainties that could cause actual results to differ. These statements and this Presentation are based on current expectations, estimates and projections about global economic conditions, the economic conditions of the regions and industries that are major markets for Aker Solutions ASA and Aker Solutions ASAs (including subsidiaries and affiliates) lines of business. These expectations, estimates and projections are generally identifiable by statements containing words such as expects believes estimates or similar expressions Important factors that couldwords such as expects, believes, estimates or similar expressions. Important factors that could cause actual results to differ materially from those expectations include, among others, economic and market conditions in the geographic areas and industries that are or will be major markets for Aker Solutions businesses, oil prices, market acceptance of new products and services, changes in governmental regulations, interest rates, fluctuations in currency exchange rates and such other factors as may be discussed from time to time in the Presentation. Although Aker Solutions ASA believes that its expectations and the Presentation are based upon reasonable assumptions, it can give no assurance that those expectations will be achieved or that the actual results will be as set out in the Presentation. Aker Solutions ASA is making no representation or warranty, expressed or implied, as to the accuracy, reliability or completeness of the Presentation, and neither Aker Solutions ASA nor any of its directors, officers or employees will have any liability to you or any other persons resulting from your use.


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Aker Solutions consists of many legally independent entities, constituting their own separate identities. Aker Solutions is used as the common brand or trade mark for most of these entities. In this presentation we may sometimes use Aker Solutions, we or us when we refer to Aker Solutions companies in general or where no useful purpose is served by identifying any particular Aker Solutions company.

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