BORSIGPROCESS HEAT EXCHANGER
A Member of KNM Group Berhad
SYNLOOP WASTE HEAT BOILERIN AMMONIA PLANTS
SYNLOOP WASTE HEAT BOILERIN AMMONIA PLANTS
“Tunnelflow” quench coolers
The Company
BORSIG Process Heat Exchanger GmbH (a member of
the BORSIG Group, Berlin/Germany that is owned by the
global process technology player KNM Group Berhad,
Kuala Lumpur/Malaysia) is a worldwide leading manufac-
turer of pressure vessels, heat exchangers and other
systems for special industrial applications.
Our products Waste Heat Recovery Systems, Quench
Coolers and Scraped Surface Exchangers stand for
high quality, competence and reliability.
BORSIG Process Heat Exchanger GmbH is able to pro-
duce according to all applicable codes and standards and
is certified according to e.g. DIN EN ISO 9001:2000,
SCC, ASME U, U2 and S, SQL PR China, Environmental
Management System DIN EN ISO 14001, EMAS II, etc..
Long time experience, state-of-the-art technology, highly
qualified employees as well as innovative engineering
enables us to find the perfect solution for our customers.
Other products of the BORSIG Group:
Membrane technology, compressors, blowers, boiler
and power plant technology and industrial and power
plant services.
For more information please visit www.borsig.de.
Process gas waste heat recovery system
Process gas waste heat boiler
Synloop Waste Heat Boilers in Ammonia Plants
More clients decide in favor of BORSIG Process Heat
Exchanger´s HOT/COLD tubesheet design for synloop
waste heat boilers for their waste heat recovery systems
in ammonia plants, as they are aware of the following
advantages:
= Unique patented HOT/COLD BORSIG tubesheet design
= Use of ferritic tubes
= Hydraulic expansion of tubes through thickness of tubesheet
= Internal gasinlet chamber
= Tubesheet temperature is below temperature, where nitriding starts
= No stress corrosion cracking
= No crevice corrosion
= No welding overlay of gasinlet channel against hydrogen attack and nitriding
BORSIG Process Heat Exchanger GmbH offers an indi-
vidual solution for your waste heat recovery system in
your ammonia synthesis loop.
Waste heat boiler for a formaldehyde plant
Ammonia plant with synloop WHB, reformed gas WHB,
steam superheater and steam drum
1
1: Ferritic tubes are used, which are not sensitive to stress
corrosion cracking, contrary to incoloy tubes
2: Unique patented HOT/COLD tube arrangement which results
in tubesheet temperatures below from where nitriding starts
3: Hydraulically expanded tubes avoid crevice corrosion
4: Hot incoming gas is guided through internal gas chamber
directly to tube inlet ends, no special protection of combined
gasinlet/outlet chamber against nitriding and hydrogen
embrittlement is necessary
BORSIG´S Process Heat ExchangerUnique Patented HOT/COLD Tubesheet Design
U-tubes with hot and cold ends are alternately arranged. The hot shank is surrounded by cold
shanks.
Advantage of this design is that the tubesheet and the hot end tube wall temperature inside
the tubesheet can be kept below 380°C to avoid nitriding and to use ferritic tubes.
As a result the inlet ends of the tubes inside the tubesheet as well as the whole tubesheet
itself are at gas outlet temperature.
The U-tubes are arranged in such way that each inlet is located adjacent to an outlet end. Inlet
end ferrules protude approx. 50 mm from the thick tubesheet into the channel and are fitted to
a dummy tubesheet, which is connected to an internal gas chamber of incoloy for the hot inco-
ming gas.
2
Principle sketch of HOT/COLD tubesheet design
Combined gasinlet/outlet chamber for HOT/COLD tubesheet design
Conventional Tube Arrangement Compared to
HOT/COLD Tube Arrangement
The diagram below indicates the temperature distribu-
tion across the tubesheet thickness. With conventional
tube arrangement the tubesheet temperature will be
above the temperature, where nitriding starts.
But BORSIG´s Process Heat Exchanger unique
HOT/COLD tube arrangement achives an even tempera-
ture distribution across tubesheet thickness, which is
below nitriding temperature. This HOT/COLD tube
arrangment is the best technical solution.
Tubesheet temperature across tubesheet thickness based on FEM-analysis
Comparison of different synloop waste heat boiler designs
FEM models of HOT/COLD tube arrangement
Synloop WHB furnished as kettle type
Temperature profile of evaporation and
BFW-preheating section
Standard high pressure sealing covers for combined
gasinlet/outlet channel for synloop WHBs and
BFW-preheaters
Diaphram gasket
Bredtschneider
sealing cover
Welded on
hemispherical
head with manholeGas inlet channel of a synloop WHB
Manufacturing of a synloop WHB
Synloop Waste Heat Boiler withIntegrated Boiler Feed Water Preheating Zone
The BFW is entering the BFW section close to the bot-
tom of the tubesheet and is passing through it in coun-
terflow to the converter effluent, is heated up close to
saturation temperature and is entering the evaporation
section. Then the steam/water mixture is flowing
upwards through the cone and “chimney”. Above the
upper end of the “chimney” an impingement plate is
arranged to force droplets and water to flow down
through the inside waterjacket. The steam leaves the
synloop boiler by passing a demister. The down-flowing
water is guided through an annular space to the tube-
sheet. At tubesheet the water flows radially to the cen-
terpart and flows upwards by generating steam.
The arrangement of BFW-section, waterjacket and cone
with chimney ensures that up-flowing water/steam mixtu-
re and downflowing water are separated. This circulation
is a natural circulation and the tubesheet is flushed by
cooling radial incoming down-flowing water. Therefore
no pool boiling areas in the center of the tubesheet are
present.
To reduce investment costs, BORSIG Process Heat
Exchanger GmbH is prepared to offer a design of a syn-
loop waste heat boiler with integrated BFW-preheating
section.
Principle sketch of synloop waste heat boiler with integrated BFW-preheating section Tube bundle of HOT/COLD design
Sketch of synloop waste heat boiler with integrated boiler
feed water preheating zone
6
Synloop Steam Superheater
Tube bundle of steam superheater
Tube to tubesheet welding
Synloop WHB ready for delivery
Steam superheater ready for delivery
Typical Layouts and Arrangements
for Synloop WHB´s
1 - Synloop WHB horizontal design
2 - Synloop WHB designed as reboiler
Synloop WHB with integrated steam drum
Synloop WHB with steam drum designed as compact unit
Arrangement of reformed and synthesis gas waste heat boilers
with one common steam drum:
1 - Reformed gas WHB
2 - HP steam superheater
3 - Steam drum
4 - Shift WHB
5 - Shift BFW preheater
6 - Synloop WHB
7 - Synloop BFW preheater
Lifting of a synloop WHB on site
Engineering and After Sales Services
BORSIG Process Heat Exchanger GmbH has complete
inhouse engineering facilities. Thermal layout and speci-
al heat transfer calculations are performed and checked
with inhouse developed computer programs. For
complex problems the gas flow and the heat transfer are
calculated by three dimensional finite element programs
(computational fluid dynamics).
Calculations of pressure vessels and heat exchangers
are performed according to all worldwide established
codes like AD, TRD, ASME, BS, Raccolta VSR, Codap,
Stoomweezen, IBR, JS, Australian Standard and others.
Critical components are subject to additional strength
calculations by using the finite element analysis.
Flexibility, rooting, foundation loads and forces and inter-
connecting piping are calculated by computer programs.
BORSIG Process Heat Exchanger supplies also the ser-
vice of complete replacement jobs. BORSIG Process
Heat Exchanger supervisors are specialized on replace-
ment performances covering the detailed engineering,
elaborating the shortest time frame, determining the logi-
stic replacement sequence, mobilization of local person-
nel and complete supervision from shutdown to start-up
of plant.
Positioning of a synloop WHB on siteSynloop WHB on site
BORSIG Process Heat Exchanger GmbH with its manu-
facturing methods, workshop facilities and equipment
complies fully with the latest state-of-the-art. The high-
tech welding technology is our core competence:
- Laser controlled narrow gap SAW welding system,
- robot welding technology for GMAW welding for high
pressure vessels,
- TIG-hot wire welding, also on ball valve surfaces,
- mechanical tube to tubesheet welding,
- qualified manufacturing of all steel and nickel-based
alloys.
Quality assurance and control activities are independent
of the manufacturing process or product lines and gua-
rantee that machined and handled materials, compo-
nents, assemblies, products and service operations are
executed in accordance with all specified requirements.
Quality assurance surveils adherence to national and
international specifications, statutory and contract provi-
sions as well as the directives, standards and regula-
tions stipulated by BORSIG.
BORSIG Process Heat Exchanger certification comprise
DIN EN ISO 9001:2000, SCC, ASME U, U2 and S, SQL
PR China, Environmental Management System DIN EN
ISO 14001, EMAS II, etc..
In 2003 BORSIG Process Heat Exchanger GmbH has
introduced the Integrally Management System (IMS)
comprising of quality, works safety and environmental
management systems.
Synloop WHB furnished as kettle type Assembling of a synloop WHB
Automatic SAW nozzle to shell welding
Manufacturing and Quality Assurance
Automatic
tube to tubesheet
welding
BORSIG Process Heat Exchanger GmbH
Egellsstrasse 21
D-13507 Berlin/Germany
Phone +49 (0) 30 / 4301-01 Fax +49 (0) 30 / 4301-2447
E-mail [email protected] http://www.borsig.de
Top Related