GEA Luftkhler GmbH

Energy Technology Division

cool engineering

Air-Cooled Heat Exchangers

Air-Cooled Heat Exchangers

Air for Cooling Air cooling is a process of choice in many applications. Modern utility facilities are, of course, among the installations that are usually air cooled.

Air is hardly corrosive, does not cost a price, is an unlimited resource, is a clean cooling fluid, does not need to be treated and is not subject to strict disposal standards. The size of air cooling systems is essentially a function of the maximum air inlet temperature and the desired product outlet temperature of the heat exchanger. For this reason, the surplus capacity of an air cooler is substantial when the outdoor temperature is low. The reduction of air flow under these conditions optimizes cooler performance, lowers energy consumption and reduces noise levels. Wherever water is costly, but product temperatures must be very low, GEA Luftkhler offers evaporative coolers which can be changed over from wet to dry operation. GEA Luftkhler supplies customized coolers designed to GEA standards, recognized international standards and codes of practice and all applicable rules and regulations. Coolers and heat exchangers made by GEA Luftkhler feature a wide range of different fin shapes and headers in any material or combination of materials desired.

Horizontal type air cooler at Shell Per+, Rotterdam / The Netherlands

Central water chilling plant

Sectors and Applications Served GEA Luftkhlers air-cooled heat exchangers serve a wide range of sectors and applications including refineries, the chemical industry, the petrochemical industry, oil and gas production operations, pipeline compressor stations, steel mills, mining, power stations, water recooling systems and large air-conditioning plants.

GEA Luftkhler offers a complete range of services including: feasibility and viability studies, conceptual design, basic engineering design, detailed engineering design, procurement and production, assembly and installation and commissioning including operator training.

Air-cooled condenser in a chemical plant

Air-Cooled Heat Exchangers Finned Tube Details

The cost efficiency of air-cooled heat exchangers depends essentially on the heat transfer capabilities of the finned tube used. Important factors to be considered include the heat transfer rate, the size of the heat exchanger and the airside pressure drop.

FE Tube Applications: The FE tube is a finned tube with an optimized shape which features excellent thermodynamic properties. The airside pressure drop across an elliptical finned tube is lower than the pressure loss in a roundtube exchanger, as less downstream turbulence is developed. Turbulators on the finning which have a negligible impact on pressure loss achieve excellent heat transfer rates. Rectangular fins keep the face area limited and allow a compact design.

Galvanization and the wide fin collar enhance heat transfer between the tube and the fin and make the finned tube insensitive to thermal and mechanical stress. The fin collar and the metal-to-metal joint strengthen the tube. Complete external galvanization provides outstanding protection against corrosion. Cleaning by high-pressure water lancing presents no risk. Manufacture: Fins are punched and then lined up on the tube by an automatic process. The galvanization that follows achieves excellent heat transfer and corrosion resistance properties.

Fin material: Steel Tube material: Steel/stainless steel Working temperature: 360C

XE Tubes Applications: XE tubes are mainly used for high pressure applications where space is limited. The tube combines the excellent properties of galvanized steel tubes featuring steal finning with the geometry of round tubes. The design (two tubes with one fin) minimizes the size of the exchanger. As the fins are very stiff, they can be cleaned easily by high-pressure water without damage to the finning.

Manufacture: The process for the manufacture of the XE tube is similar to the FE tube production process. Fin material: Steel Tube material: Steel/stainless steel Working temperature: 360C L Tubes Applications: The L tube is a finned tube for low temperature applications where a certain degree of protection of the tube wall against corrosion is required. The broad contact surface between the tube and the finning enhances heat transfer.

Manufacture: The foot of the fin is shaped first and the fin is then tensionwound around the tube. Each fin is in contact with an adjacent fin and provides a certain degree of protection in atmospheres which are not highly corrosive. The manufacturing technology allows the use of relatively thinwalled tubes.

Fin material: Aluminum Tube material: Any metal Working temperature: 130C 4

K Tube Applications: The K tube was developed from the L tube for increased temperature levels and provides enhanced corrosion protection to the outside wall of the tube.

Manufacture: The foot of the fin is shaped first and the fin is then tensionwound around the tube. Knurling tools both precede and follow the fin and lock the fin material in the pre-knurled tube. The process increases the area available for heat transfer. The joint between the fin and the tube is air tight and improves corrosion protection.

Fin material: Aluminum. Tube material: Any metal Working temperature: 220C

G-Fin Tube Applications: The G-fin tube was designed for high thermal or mechanical stress.

Manufacture: The finning is tension-wound into a helical tube groove and embedded in the groove by high-pressure expansion. The material displaced is then pressed against the fin sides.

Fin material: Aluminum Tube material: Any metal suitable for easy mechanical processing Working temperature: 400C

Bimetal Finned Tubes Applications: Bimetal finned tubes are designed for increased temperature service and protect the tube fully against atmospheric corrosion. The extruded fins feature 40 % more aluminum than comparable fins. They are very sturdy and resistant to mechanical stress and can therefore be cleaned easily by steam or water. The tube material can be adapted to the fluid handled. The tube is for this reason fit for nearly all aggressive chemicals.

Manufacture: The fins are extruded from a sleeve around the tube. In this process, the inside diameter of the sleeve is reduced and the sleeve is pressed on the tube. The process produces a strong joint with excellent heat transfer capabilities. Fin material: Aluminum Tube material: Any metal Working temperature: 250C

Air-Cooled Heat Exchangers Header Details

Tube-to-header joints are either welded or expanded depending on header design. A range of header designs has been developed for different applications and requirements. Standard header configurations are presented below.

Welded Header The low-cost welded header is mainly used for clean products or vacuum pressure conditions. The tubes are welded into tube sheets to which the bonnet-type header with the necessary nozzles is welded.

Screw-Bolted Header with Cover The screw-bolted header features a removable cover for easy inspection and tube cleaning. It is normally sufficient to remove a pipe bend for inspection, since the removal of the bend allows the examination of part of the tube array.

Tubes may be weld connected or expanded.

Studded Header with Cover The studded header features top or bottom nozzles to allow cover removal without disassembly of the piping. Nozzles may alternatively be integrated in the cover.

The header is fit for a maximum pressure of 60 bar depending on fluid temperature and the type of sealing. Anon-standard header design is required for higher pressures. Tubes may be weld connected or expanded.

Plug-Type Header Tubing is usually connected to plug-type headers by expansion, but may also be weld-connected to the tube sheet. A threaded plug with a soft iron gasket is provided opposite each tube and may be removed for further tube expansion or tube cleaning. As nozzles are top or bottom mounted, piping does not need to be disassembled for inspection or cleaning.

The plug-type header is normally used for high-pressure applications.

High-Pressure Header with Plugged Reversing Segments A threaded plug with a soft iron gasket is located opposite each tube. The plug may be removed for further tube expansion or for tube cleaning.

High-Pressure Header with Welded Reversing Bends The two high-pressure headers are ideal for high temperature differences, since each tube can expand and contract independently.

Air-Cooled Heat Exchangers Configurations

GEA offers a range of air-cooled heat exchanger configurations to accommodate different process and site requirements. Unrestricted air access and discharge is vital for each of these configurations: Roof-mounted structures are often selected where space is limited. horizontal configuration

vertical configuration

forced draft

induced draft

forced draft

induced draft

roof-mounted configuration

in-line configuration

Fan Details
Fan, motor and reduction gearing selection Fan blading is manufactured from aluminum or fiber-reinforced plastic. The air flow rate and noise emission specifications determine the number of blades, the blade shape and the fan speed. All fans are balanced in accordance with applicable standards and codes.

The following systems are employed to control air flow, either single or in combination: louvers (manual or automatic) pole reversing motors automatically adjustable fan blades frequency converters

Belts and pulleys are normally used for all motor ratings. Dynamic balancing is provided for pulleys. V-belt, toothed belt and power band drives are available. Gear drives are limited to large motors.

standard noise emission requirements

model currently used to satisfy strictest noise emission requirements

v: 50-60 m/s

n:>4 blades

d/D:=0.23

increased noise emission requirements

v: 40-45 m/s

n:>6 blades

d/D:=0.30

strict noise emission requirements

v: 28-32 m/s

n:>8 blades

d/D:=0.37

Air-Cooled Heat Exchangers Fan Drive Details

Direct Drive The fan is mounted directly on the motor shaft. The fan and the motor operate at the same speed.

Forced-Draft Belt Drive The speed of the motor is reduced to the desired fan speed by means of pulleys.

Induced-Draft Belt Drive If the discharge air temperature is low, the motor may alternatively be mounted above the heat exchanger.

Geared Drive The motor shaft is coupled directly to the input shaft of the gearing.

10

Luftkhlers Design Details

finned-tube bundle heating coil louver fan fan ring air plenum

pulley belt support structure motor

Air Cooler Bank The air cooler bank consists essentially of finned-tube bundles, fan rings, axial-flow fans with their motors, a support structure as well as any maintenance platforms, louvers and other equipment required by the client.

bracket vent/drain cover tube sheet (fixed side)

inlet header

gasket outlet header guide bolt cover plate side wall lug finned tubes tube sheet (floating side)

Finned-Tube Bundle The finned-tube bundle consists of the finned tubing (or unfinned tubes in certain cases), the headers (manifolds) and a frame.

11

Air-Cooled Heat Exchangers

Quality Management System and Quality Assurance

GEA Luftkhlers quality management system has been certified to ISO 9001 since 1992. The quality management manual contains written instructions for each single operation of a project from design to delivery to assure that each product fully satisfies all requirements of the customer specification or the relevant standards and codes. Qualified staff such as design engineers, welding engineers, non-destructive test examiners and quality inspectors responsible for receiving inspections, interim tests and final tests ensure compliance with all engineering design, production and test quality standards. Pressure vessels can be designed, manufactured, tested and marked in accordance with all relevant international codes including AD-M 2000, Stoomwezen requirements, British standards, ASME codes and standards, API 661 or the European Pressure Equipment Directive 97/23/EC.

Advanced computer-aided quality and weld scheduling to eliminate interface risks and to optimize quality

Quality Management System and Other Certifications ISO 9001 AD Merkblatt HP0 EN 729-2 ASME Pressure Vessel Code, Sec. VIII, Div. 1 and 2 Lloyds Register, class 2/2 -NORM 7812-1 UDT Poland requirements

Notified Bodies for the Verification of Designs and Tests Supervising organizations of the chemical and petrochemical industries RWTV Stoomwezen Lloyds Register Bureau Veritas and others 12

Research and Development

The headquarters Research and Development Center of GEA Luftkhler develops new and improved products with a highly customer-focused approach. Both advanced mathematical modeling techniques and wind tunnel tests visualizing air flows are used. These resources allow GEA Luftkhler to optimize large-scale facilities for local site conditions during the design phase. Finned tubes for air-cooled heat exchangers are also improved continuously using a wind tunnel built specifically for this purpose. Fan design is a function of the fan performance required and applicable noise emission standards. GEA Luftkhler operates its own fan test bay to test the efficiency and the noise emissions of full-scale fans nearly under field conditions and to optimize fan units.
GEA test bench for fans

Flow simulation using the PHOENICS CFD software

Wind tunnel model testing / R&D centre in Bochum / Germany

13

Air-Cooled Heat Exchangers

Major Reference Plants

Refineries
Facility 1. Lingen, Germany 2. Nanking, China 3. Shell Cressier, Switzerland 4. Shell Per+, The Netherlands 5. Samara, Russia 6. PCK Schwedt, Germany 7. Slovnaft, Slovakia 8. Kaucuk, Czech Republic 9. MSPO-2, Moerdijk, The Netherlands 10. DEA Heide, Germany 11. DEA Wesseling, Germany 12. Tar Customer Lurgi Lurgi Comprimo Fluor/Lummus/Comprimo Salzgitter Anlagenbau Edeleanu Leipzig Raytheon Engineers ABB, Lummus Global ABB/Shell Lurgi Edeleanu Alzenau

Petrochemical Plants
Facility 1. Methanol plant, Sabameth, Malaysia 2. Styrene plant, BASF, Germany 3. Urethane plant, China 4. Methanol plant, Trinidad 5. Propylen glycol and ether plant, The Netherlands 6. Styrene expansion project, Antwerp, Belgium 7. Cracker, EC, Dormagen, Germany 8. Methanol plant, Khag Island, Iran 9. EOA plant, BASF, The Netherlands Customer Lurgi Krupp Koppers Hanyang Chemical Ferrostaal John Brown BASF Antwerpen N.V. Bayer Centrigrade, Shiraz Kraftanlagen Energie- und Umwelttechnik GmbH

Steel Mills
Facility 1. Kursk steel mill, Russia 2. Posco steel mill, Korea 3. ICDAS steel mill, Turkey 4. Water recooler, Germany 5. Water recooler, Germany 6. Water recooler, Russia 7. Evaporative air cooler, Germany 8. Water recooler, Belgium Customer DSD, Dsseldorf Mannesmann Demag ICDAS, Istanbul Dillinger Htte Stahlwerke Bremen VAI, Linz Salzgitter Anlagenbau Sidmar, Belgien

14

Gas Facilities and Compressor Stations

Facility 1. Orenburg pipeline, Russia 2. Yamal pipeline, Russia 3. Gas coolers, Germany 4. Berlin gas plant, Germany 5. Grijpskerk II, The Netherlands 6. Gas coolers, Czech Republic 7. Gas coolers, TAG II 8. Gas coolers, ARAK, Iran Customer Mannesmann Anlagenbau AEG Kanis PLE/Ruhrgas Babcock Borsig NAM B.V. CKD, Prag OMV, Wien PLE, Essen

Other Installations
Facility 1. Cabora Bassa, Apollo, Mozambique 2. Aramco gas program, Saudi Arabia 3. Sasolburg coal gasification plant, South Africa 4. Medina air conditioning plant, Saudi Arabia 5. Condenser, Saudi Arabia 6. Evaporative cooler, Schwarzheide, Germany 7. Condenser, Al-Jubail, Saudi Arabia Customer AEG, Frankfurt Aramco, Dhahran Lurgi/Linde/Fluor York Intl, USA ABB/SADAF BASF Schwarzheide ABB Lummus B.V.

Erection of an air-cooled heat exchanger

High-Pressure, plug type, alloy steel header

Roof type condensers, BASF Antwerp / Belgium

Air cooler, LGN plant Woodside / Australia

15

Emmerich/Arnheim

Mnster

Recklinghausen

Bremen
A1

Gelsenkirchen
A3 A43
Ab.-Kr. Recklinghausen

Hannover
A2 A2 A42
Ab.-Kr. Herne

Bottrop
A42

A45

Dortmund
A40

A1 A44

Kassel

Oberhausen
A40

Essen Bochum
A52
Ab.-Kr. Breitscheid

Ab.-Kr. Bochum

Ab.-Kr. Dortmund/Unna

Venlo

A2

Duisburg

Westhofener Kreuz

A43

A1

A52

A3

Ab.-Kr. Wuppertal-Nord

Hagen
A45

Mnchengladbach

Dsseldorf
A46

Wuppertal
A46
Ab.-Kr. Hilden

A3

A1

Leverkusen
A1

Frankfurt

Kln Frankfurt
AB.-Kr. = Autobahnkreuz/motorway intersection

Mnster, Recklinghausen Ab.-Kreuz/motorway intersection HERNE Ausfahrt/exit HERNE-CRANGE Duisburg, Oberhausen, Gelsenkirchen

14

20

A42

Castrop-Rauxel, Dortmund

A42 A43
B 226
Dor e sten r Str ae
Ausfahrt/exit HERNE-ZENTRUM

13 HERNE

Boch um e

rh Holste Holste a er Str rhaus e

Dor e sten r Str

auser

Stra

e Sdst rae

r Stra e
Ausfahrt/exit BOCHUM-RIEMKE

16

GEA Luftkhler GmbH Dorstener Strae 18-29 44651 Herne

HERNE
Ausfahrt/exit BOCHUM-HAMME

B 226

ae

e Herzogstra

Wilber gst

A43
r.

Am Garte

Dor sten er S tra e

Hern

nkamp

BOCHUM

B 51

er Str

ae

33

A40 A40
Essen Bochum (Zentrum/city centre) Ausfahrt/exit BOCHUM-ZENTRUM

A40
Hern er Str
Bochum (Zentrum/city centre) Ab.-Kreuz/ motorway intersection BOCHUM

Dortmund

38
Wuppertal, Kln

ae

BOCHUM

GEA Luftkhler GmbH

Energy Technology Division

A company of mg technologies group

GEA Luftkhler GmbH Dorstener Strasse 18-29 D-44651 Herne, Germany Tel. ++49/234/980-0 Fax ++49/234/980-1974 www.gea-luftkuehler.com