Innovative heat exchangers for the phosphoric acid market

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1 Innovative heat exchangers for the phosphoric acid market Laurent TRABLY, V.P Sales and Marketing Chemical Equipment International symposium on innovation and technology in the phosphate industry. Marrakech, May 2013 Symphos / 11

2 25-years experience on the phosphoric acid market Long-term experience of the phosphoric process with first orders in 1983 More than 400 mixers and 200 heat exchangers delivered for the phosphoric acid market Innovations to cope with stringent process constraints Close partnership with leaders of phosphoric acid market development of specific equipment Symphos / 11

3 Comprehensive solutions Mixers, rakes, heat exchangers, systems Symphos / 11

4 Issues of phosphoric acid industry : Lifetime and high-yield equipment Issues Improve the yield rate : Reduce maintenance time Innovations Heat exchangers with 6- meter length tubes without a joint Mersen s solutions Increase lifetime: Resist corrosion and abrasion High quality graphite heat exchangers reinforced by carbon fiber Improve thermal efficiency Special design of the welded plate heat exchanger 4/11

5 Graphilor 3 To improve lifetime and resist corrosion Graphilor 3 is Mersen s trade mark for impregnated graphite, resulting from the combination between ultra-fine grain graphite (20μm) and specific impregnation resin. Key advantages of Graphilor 3: High resistance to corrosion Resistance to temperature and thermal shock High mechanical resistance with exceptional TUV homologation G for tubes Graphite BS S Fine grain Graphilor 3 XBS XC XTH X Ultra-fine grain Resin Phenolic Phenolic Carbon PTFE Parts Available All diameters All diameters 900 mm < 900 mm 600 mm Temperature 200 C 220 C 430 C 230 C Mechanical strength TUV Homologation G G G G / 11

6 6-meter length tubes without a joint To improve reliability Our graphite tubes are manufactured by an extrusion process, up to 6 meters without a joint Our graphite tubes have the same high mechanical properties as ultra-fine grain isostatic rods To enhance higher performance material, Mersen has mastered in-house all the production stages specifically : Baking Graphitization 1 st worldwide producer of tubes 6/ 11

7 Rigilor for abrasion resistance To improve lifetime Key feature : abrasion resistance x 6 Rigilor is used for large blocks and tubesheets Strengthening of graphite parts by the treatment of a carbon fiber based layer Impregnation after applying Rigilor coating provides excellent homogeneity of the material with the same properties as graphite Mechanical resistance x 2 & erosion resistance x6 7/ 11

8 Amorphous carbon sleeves To improve lifetime Key feature : Erosion resistance Insert amorphous carbon sleeves in the tubesheets in turbulence areas Phosphoric acid evaporator : Tubesheets are reinforced with Rigilor fibers and amorphous carbon sleeves to increase their lifetime 8/ 11

9 HEATEX HXC welded plate heat exchanger Corrugated plate design to improve thermal efficiency High efficiency design of plates Innovative design Spot welding for pressure withstanding Eliminate plate pack pulsating and make it stronger and less sensitive to fatigue Key features : HIGH EFFICIENCY LIFETIME COMPACTNESS EROSION RESISTANCE Plate pack assembly All plate channels are assembled together to form a plate pack with comb on each edge allowing fitting on frame Symphos / 11

10 HEATEX HXC welded plate heat exchanger Free-flow innovation to reduce maintenance time Special design for free-flow: Pressure withstanding by combining corrugation contact points and spot weldings Gap up to 25 mm Combination between high thermal performance and easy maintenance / accessibility / no plugging risk Key features : REDUCE MAINTENANCE TIME ACCESSIBILITY NO PLUGGING RISK AND CLEANABILITY ON ONE SIDE FOR FREE FLOW DESIGN Max Pressure at 200 C = 14 bars Symphos / 11

11 After-sales service After-sales service is available in manufacturing sites (USA, Morocco, France, China, UK, India) and local repair workshops : South Africa, Brazil, Korea, Japan, Taiwan, Italy, Spain, Netherlands Focus on Mersen Morocco : the first local multiactivities site within Mersen Group Facility : 3000 m² Activities : graphite and metal equipment, electrical solutions for motors and generators Spare parts and industrial suppliers : heat exchangers (tubes, plugs, AN cement, inserts, sleeves), mixers, PTFE piping, bellows and compensators On-site services and maintenance work Technical assistance Supervision on-site for tube-sheets repair, retubbing, plugging 11 / 11