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Plate Heat Exchangers

Process Technology

DIABON®

Broad Base. Best Solutions.

SGL Group is one of the leading manufacturers of carbon-based products and has the broadest product and technol-ogy portfolio, a global sales network and state-of-the-art production sites in Europe, North America and Asia.

Carbon has unique properties. It is indispensable in the production of steel, aluminum and solar energy systems. Carbon increases the performance of wind turbines and reduces the weight of airplanes, cars and sports equipment.

CCarbon substitutes other materials and contributes to a reduction in CO2 emissions.

Carbon is Future. SGL Group – The Carbon Company.

The Business Unit Process Technology is a premium technology provider for chemical and related industry process systems, equipment and after sales services. Our focus are high-tech materials for demanding chemical applications. With smart and sustainable solutions for an in-creasing number of industry we give proof of our strong innovation culture.

Broad Base

Our range of materials: E graphiteE SiCE PTFEE reactive metalsE steel

Our range of services: E process designE engineeringE project managementE production and assemblyE commissioningE after sales services.

With 9 manufacturing sites in 8 countries and a continually growing worldwide sales and service network, we are always close to our customers.

Process Technology

3

In a business that strongly depends on reliability we never compromise on quality and safety. Our products deliver dependable results; our services are fast and competent. The long-standing loyalty of our customers proves that we keep our promises – on-time, on-spec, on-budget.

Tailor made, innovative solutions and an integrated approach on chemistry, materials, technology and design, ensure outstanding efficiency and improved customer value: higher yields, lower operating cost, lower service and maintenance cost, longer service intervals and less downtimes, and the extended product lifetime sum up to significant lower total cost of ownership and to a higher return on investment for our customers.

In all industries that deal with resource- and energy- consuming processes sustainability is of crucial importance. Based on innovative solutions, more than 60 % of our sales contribute to the saving of resources and energy and to the reduction of greenhouse gases.

Powered by our Broad Base of competencies, products and services, we offer Best Solutions to our customers. For the Business Unit Process Technology, those solutions are characterized by reliability, efficiency and sustainability.

Contents

DIABON Plate Heat Exchangers at a Glance 4

Our Motto: Compact, Quick, Innovative 5

Our Design: Solid and Robust 6

Properties and Uses 8

Corrosion Resistance of Process Equipment Graphite 9

Design Data 11

Quality Management and After Sales Service 14

Process Technology – Our Products 15

ReliaBiliTy. effiCienCy. SuSTainaBiliTy.

Best Solutions

E Reliability

E Efficiency

E Sustainability

4

DIABON® Plate Heat Exchangersat a Glance

Advantages of our plate heat exchangersin DIABON process equipment graphite

� The special design of the plates means that ourgraphite plate heat exchangers have a higherheat transfer rate than other graphite heat exchangers

� Our plate heat exchangers are suitable for cor-rosive media on both service and product sides

� The compact construction results in a very lowspace requirement

� Counter-current flow allows optimum utilizationof the temperature differential

� By simply changing the number of plates, our heat exchangers can be optimally adapted toany conditions

� The smaller liquid capacity of our heat exchangers makes for a short residence time.Changes in controlled variables can therefore beresponded to more quickly

� Different plate corrugation patterns and single- ormultiple-pass arrangement allow great flexibilityin the use of our heat exchangers

� High-turbulence corrugation patterns minimizethe tendency to fouling

� The film-type PTFE plate gaskets mean that the heat exchangers are corrosion-resistant in variousenvironments, including the gaskets

� Backflushing enables cleaning-in-place (CIP) tobe carried out. This means that the plates can bechemically or mechanically cleaned without having to disconnect the heat exchanger fromthe connections

� Our large stockholding capacity makes for shortdelivery times for complete heat exchangers andspare parts.

Based on these advantages, DIABON plate heatexchangers are used as � Heaters� Coolers� Interchangers � Condensers for corrosive media, especially in the treatment of:� Hydrochloric acid (HCl)� Sulfuric acid (H2SO4)� Hydrofluoric acid (HF)� Mixed acids (HNO3/HF)� Phosphoric acid (H2PO4/P2O5)� Other organic and inorganic media.

Standard P05, P25 and P40 series plate heat exchangers

5

Our Motto: Compact, Quick, Innovative

System-based heat exchangers That is how we convince our customers. For example, in the field of highly corrosion-resistant,compact heat exchangers. In collaboration with Alfa Laval Thermal (Lund/Sweden), we have developed a special plate heat exchanger in DIABON graphite – an innovative solution for acompact heat exchanger.

Its advantage is that it combines the universal corrosion resistance of graphite with the high efficiency of plate heat exchangers.

The basis of this new development is the plastic-bonded graphite DIABON F100, which was alsodeveloped by the SGL Group.

Another innovation is our modern processing center for the synthetic resin-impregnated graphitebrands DIABON NS1 and NS2. This extends ourlarge range of graphite plates.

Problem-free servicingServicing of DIABON plate heat exchangers issimpler than with other graphite heat exchangers.So it can be easily carried out on site – by your personnel. In addition, our specialists are alwaysat your service to give training or carry out instal-lation work. We also supply spare parts quicklyand with ease – from stock.

DIABON® F 100 graphite plate pack and LICUFLON® (PTFE)-lined frame plate

6

Our Design:Solid and Robust

The plate pack is secured between two thick steelplates, one fixed and the other movable, by meansof tie rods. It is held in line by an upper and a lower stainless steel bar, which are securely fixedto the frame plate. The rear ends of the two guidebars are fixed to a support column. By this means,the pressure plate can be moved freely after releasing the tie rods. This allows unhindered access to the graphite plates without having to move the exchanger out of its installed position ordisconnect it from the pipe connections.

A further advantage of this design is that the difference in the coefficients of expansion of steeland graphite are compensated for by means ofcompression springs.

88 41 7 6 11 9 11 11 310

1 Frame plate (steel)2 Pressure plate (steel)3 Support column4 Guide bars5 Corrugated plates

(DIABON® graphite)6 End plates (DIABON® graphite)7 PTFE linings8 Graphite gaskets9 Tie rod

10 Compression spring11 Centering disks

8 8 54 6 7 2

7

To protect the frame/pressure plates and the nozzles against corrosion, we use LICUFLON®

(PTFE) linings.

The sealing system of the DIABON plate heat exchanger has very special advantages. A softPTFE O-ring seal is applied to the 20 mm wide sealing strips of the graphite plates and compress -ed to a film thickness of about 0.15 mm whentightening up the plate pack.

AdvantageThe film-type seal can be easily removed when the exchanger is opened; it provides excellent corrosion resistance and an extremely small cross-sectional surface for the media to come in contactwith.

Under the trademarks DIABON F100, NS1 andNS2, a whole range of graphite materials is avail -able. This means that in combination with the different corrugation patterns, we can find an optimum configuration for virtually any application.

The design of the DIABON® plate heat exchanger

allows pure counter-current flow

8

Properties and Usesof DIABON® Graphite Brands

Micrograph of DIABON® NS1 Micrograph of DIABON® NS2Micrograph of DIABON® F100

DIABON® NS1

Synthetic resin-impregnated, fine-grain graphite with a homoge-neous material structure and auniform pore distribution. Thepores of the raw graphite arecompletely sealed with syntheticresin. DIABON NS1 graphiteplates are used mainly at highertemperatures up to 200°C. Thismaterial’s high temperature fatigue resistance and relative insensitivity to thermal shock enable it to be used for largetemperature differentials. In com-bination with the simple geome-try of the flat plates, a higher level of safety is achieved thanwith other graphite heat ex-changers – especially in criticalapplications.

DIABON® NS2

Synthetic resin-impregnated, fine-grain graphite with an extremelyhomogeneous material structureand a uniform pore distribution.DIABON NS2 is characterizedby higher strength and lowersensitivity to swelling than DIABON NS1 graphite. Againwith DIABON NS2, the pores ofthe raw graphite are completelysealed with synthetic resin.

DIABON® F100

Fluoroplastic-bonded, non-porousfine-grain graphite with an ex-tremely homogeneous materialstructure. The plastic is finely dispersed between the grains ofgraphite. DIABON F100 graphiteplates have an anti-adhesive,non-porous surface. Togetherwith the high-turbulence corru-gation pattern, a dual benefit isachieved: maximum efficiencyaccompanied by a minimal ten-den cy to fouling. The fluoroplastic,which envelops the grains of graphite like a protective skin,produces outstanding corrosionresistance in oxidizing mediasuch as mixtures of HNO3 andHF. DIABON F100 graphite isused for applications with liquidmedia at service temperaturesup to 140°C.

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Corrosion Resistanceof DIABON® Process Equipment Graphite

Carbon and graphite are outstandingly corrosion-resistant. Therefore, they are attacked only bystrongly electronegative elements such as oxygenat temperatures above 500°C and elemental halogens. Strongly oxidizing acids such as chromicacid can also destroy the carbon. The corrosion resistance is essentially determined by the behav -ior of the synthetic resin in the case of DIABONNS1 and DIABON NS2 graphite and of the fluoroplastic content in the case of DIABON F100graphite. If in doubt, corrosion tests can be carriedout with standardized material specimens. Analysisof the results in our laboratories then shows whether the material is suitable.

Scanning electron micrograph of a DIABON® F100 fracture surface. The good

distribution of the plastic is apparent from the ultrathin layers between the graphite particles

Sulfuric acid (wt. %)

NS1

F100

NS2

Boiling point curve at 1 bar

40 50 60 70 80 90 100

250

200

150

100

50

0Tem

pera

ture

(°C

)

Corrosion resistance of DIABON® F100, NS1 and NS2 graphite to sulfuric acid

10

DIABON® F100, NS1 and NS2 graphite plates

A reduction in service life is likely with the following media, depending on concentration and temperature:

� Elemental chlorine and bromine in aqueous solution

� Nitrous gases (NOX) in sulfuric acid� Acids with a high oxidation potential

(e.g. chromic acid, sulfuric acid > 90 %)� Organic solvents with high polarity

(e.g. THF, NMP, DMF, MIBK, MEK)� Strong alkalis and amines.

Corrosion Resistanceof DIABON® Process Equipment Graphite

DIABON graphite plate heat exchangers are usedmainly in the following media:

� Hydrochloric acid and HCl gas in all concentrations

� Sulfuric acid up to 90 %� Hydrofluoric acid up to 60 %� Mixed acid (HF/HNO3) up to 30 %� Phosphoric acid in all concentrations� Other organic and inorganic media.

You will find detailed corrosion tables in our brochure „DIABON® Graphite for Engineered Process Equipment“.

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Design Dataof Series P05

DIABON plate heat exchanger P05

Corrugation pattern turbulent flow free flowTypical heat transition coefficients W/K·m2 2000 4500Exchange area per plate m2 0.05 0.04Max. number of plates per frame 80 64Plate thickness mm 8 10Liquid capacity l 0.18 0.12Weight of a plate kg 0.75 0.95Plate seals SIGRAFLEX® graphite SIGRAFLEX® graphite

PlatesProperty Unit DIABON F100 DIABON NS1 (NS2)

Width x height mm 230 x 620Length L mm 350/450/550/650/750/850Max. number of plates for length L 18/30/43/55/68/80 14/24/34/44/54/64Weight excl. DIABON graphite kg 105 – 125Connections of frame plate or S1 – S4 DN 25 DIN 2533 PN 16 or

pressure plate T1 – T4 DN 1” ASME B 16.5/150 lbsTest pressure with water bar standard 9.1Max. design temperature °C 140 200

FrameProperty Unit DIABON F100 DIABON NS1 (NS2)

620 416

123

S3

S4

S2

S1

T2

T1

T3

T4

80 80

230

165

225

90

165

L

416

123

DIABON® plate heat exchanger P05

MaterialsFrame and pressure plate P265GH or SA516 Gr. 60Tie rods and stud bolts 21CrMoV57 alt. SA193 Gr. B7Nuts 25CrMo4V alt. SA194 2HCompression springs 51CrV4Guide bars 1.4301 (stainless steel grade)Lining of frame/pressure platesand connections LICUFLON (PTFE)Painting 2-component epoxy paint

1 priming coat of Hempadur 15570, 100 µm1 intermediate coat of Hempadur 15570, 100 µm

1 top coat of Hempathane 55210, 60 µmshade: similar to RAL 5002 (ultramarine)

DIABON graphite plate heat exchangers are manufactured inaccordance with Pressure Equip-ment Directive 97/23/EC (PED),Categories I to III, Modules B (EC type testing of series-producedpressure vessels) and C1 (con -formity to design). The design calculations for our plate heat exchangers are based on specifi-cation AD 2000-Merkblatt N2.

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11

70

71

92

58

S3

512

S4

S2

S1

T2

T1

T3

T4

235 (DIN)231 (ASME)

235

L

73

92

48


Corrugation pattern turbulent flow free flow(high and low theta)

Typical heat transition coefficients W/K·m2 2200 4500Exchange area per plate m2 0.25 0.1766Max. number of plates per frame 160 100Plate thickness mm 6.5 10Liquid capacity l 0.7 0.6Weight of a plate kg 2.7 4.2Plate seals PTFE, plastic PTFE, plastic


Width x height mm 512 x 1170Length L mm 912/1162/1512/1762Max. number of plates for length L 32/70/125/160 20/45/80/100Weight excl. DIABON graphite kg 610 – 650Connections of frame plate or S1 – S4 DN 100 (DN 80) DIN 2501 PN 16 or

pressure plate T1 – T4 DN 4” (DN 3”) ASME B 16.5/150 lbsTest pressure with water bar standard 9.1 / special design 10.4Max. design temperature °C 140 200



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1473

1037

241

1037

241

S3

570

S4

240

S2

S1

T2

T1

T3

T4

246 (DIN)255 (ASME)

L


Corrugation pattern turbulent flow free flowTypical heat transition coefficients W/K·m2 2000 4000Exchange area per plate m2 0.4 0.3039Max. number of plates per frame 130 96Plate thickness mm 8 10Liquid capacity l 1.5 1.4Weight of a plate kg 6.1 7.1Plate seals PTFE, plastic PTFE, plastic


Width x height mm 570 x 1473Length L mm 912/1162/1512/1762Max. number of plates for length L 25/55/100/130 16/40/72/96Weight excl. DIABON graphite kg 900 – 940Connections of frame plate or S1 – S4 DN 100 DIN 2501 PN 16 or

pressure plate T1 – T4 DN 4” ASME B 16.5/150 lbsTest pressure with water bar standard 9.1 / special design 10.4Max. design temperature °C 140 200


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Quality Management

Continuous quality assurance is an integral part of the SGL Group corporate philosophy. Our quality management system is certified in accordance with ISO 9001:2008. In order to guarantee consis tently high quality to our customers, we work according to a key performance indicator orientated quality management system.

Depending on specifications we are able to meet specific requirements like the Pressure Equipment Directive 97/23/EC Annex III, Module H/H1, AD 2000 Merkblatt N2 as well as ASME “U” Stamp, Section VIII, Part UIG.

Quality Management and After Sales Service

After Sales Services – Anytime and Everywhere

We take care of our products during the entire operational lifetime. We aim to provide the best customer service anytime and everywhere.

E Maintenance – genuine spare parts supply, failure analysis, repair, field service

E Fast emergency supportE Start-up assistanceE Consulting for continuous improvement

Our service specialists as well as our service centers work in a global network to support you best.

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System SolutionsE Syntheses E Distillation and concentrationE PurificationE DilutionE AbsorptionE DesorptionE Thermal destruction and recyclingE Reactors and convertersE Heat storageE ...

After Sales ServicesE MaintenanceE Emergency supportE Start-up assistanceE ConsultingE ...

Equipment SolutionsE Graphite and SiC heat exchangers –

shell & tube, block and plate typeE Columns and internals E VesselsE QuenchersE PumpsE Rupture discsE PTFE piping and bellowsE PTFE hoses E ...

Process Technology Our Products

Central and East Europe

SGL CARBON GmbHWerner-von-Siemens-Straße 1886405 Meitingen/GermanyPhone +49 8271 83-1564Fax +49 8271 [email protected]

South Europe, Middle East, Africa

SGL CARBON Technic S.A.S.18, Avenue Marcel Cachin38407 Saint Martin d‘Heres/FrancePhone +33 4 7625 9600Fax +33 4 7625 [email protected]

Americas

SGL CARBON Technic, LLC 21945 Drake Road44149 Strongsville, Ohio/USAPhone +1 440 572-3600Fax +1 440 [email protected]

Process Technology

SGL CARBON GmbH

Söhnleinstraße 865201 Wiesbaden/Germanywww.sgl-processtechnology.com

www.sglgroup.com

® registered trademark of SGL Group companies 04 2012/0 1NÄ Printed in Germany

The data contained herein represent the current state of our product knowledge and are intended to provide general information on our products and their application spectra. In view of the variety and large number of application possibilities, these data should be regarded merely as general information that gives no guarantee of any specific properties and/or suitability of those products for any particular application. Consequently, when ordering a product, please contact us for specific information on the properties required for the application concerned. On request, our technical service will supply a profile of characteristics for your specific application requirements without delay.

Regional Sales & Service Center

Asia, Oceania

SGL CARBON Far East Ltd. Shanghai 1208, Shanghai Oriental Plaza31 Wujiang Road/ChinaPhone +86 21 5211 0333Fax +86 21 5211 0085 [email protected]

India

SGL CARBON India Pvt. Ltd.Plot No. E-100, MIDC RanjangaonVillage: Karegaon, Taluka: ShirurDist. Pune - 412 220/IndiaPhone +91 21 386 122-14

[email protected]

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