Wichita Falls, TX

A Supermax® Welded Shell & Plate Heat Exchanger is heading to a facility to be used for oil cooling as part of a gas compression application. The Supermax is a compact welded replacement for Shell & Tube heat exchangers as compressor oil coolers in oil and gas production facilities, refineries, gas liquefaction plants and chemical plants. Contact us today to see if your application benefit from a Tranter Supermax!

Supermax Welded Shell & Plate Heat Exchanger

Wichita Falls, TX

A Supermax® Welded Plate Heat Exchanger will be used as a Heat Recovery Steam Generator (HRSG) at a power plant in the south east. Tranter’s Shell & Plate (Supermax) will take steam from the turbines, condense it and send hot condensate to the deaerator to remove corrosive oxygen from the boiler feedwater. The recovered heat will be used to preheat the boiler feedwater. 

HRSG Supermax Welded Plate Heat Exchanger

Many facilities have been built using shell and tube heat exchangers. When time for expansion comes, whether involving HVAC or process thermal systems, sizing and installing a larger shell and tube exchanger is expensive or impossible because the larger unit:

  • Causes impossible-to-resolve piping conflicts with existing systems
  • Exceeds the load capacity of support structures
  • Has an impossibly large footprint for the available space
  • Would require disconnection and complete removal to pull and clean the tube bundle

When it’s expansion time, and your design team talks about space conflict problems connected with thermal systems, remember Tranter Plate Heat Exchangers. Our compact SUPERCHANGER® Plate And Frame and SUPERMAX® Shell And Plate Heat Exchangers have replaced countless shell and tube exchangers in retrofit or expansion projects where footprint conflicts were difficult or impossible.

Plate And Frame–Orders Of Magnitude More Compact

Tranter has an answer for virually all applications served by shell and tube exchangers. For low temperature and pressure applications, the SUPERCHANGER Plate And Frame Exchanger is the choice. These units can pack greater than 22,000 ft2 (2,044 m2) of super-efficient heat transfer surface in a single unit with flow rates up to 25,400 gpm (5,768 m3/hr). They use only 10-50% of the space required by shell and tube units and are much lighter in weight. And, they cost less.

SUPERCHANGER Plate And Frame Heat Exchangers can be designed for less than 2°F (1°C) temperature approach (compare that with a greater than a 5°F to 10°F temperature approach for shell and tube exchangers). The plate and frame unit opens for access within its own footprint, while the shell and tube requires twice its own footprint to pull the tube bundle. Plus, the surrounding area is much more worker-friendly—there is practically no heat loss, and no insulation is required.

Shell And Plate—The Choice For High Temperature And Pressure Applications

The SUPERMAX Shell And Plate Heat Exchanger is designed for pressures to 200 barg (2900 psig) and at temperatures up to 900°C (1650°F) for standard range units. Extended range units are available for higher temperature and pressure applications.

Compare the SUPERMAX and the shell and tube units in the scale drawing. They have identical heat exchange ratings. The SUPERMAX Model SPW-55 has a 24-in. diameter shell and a 3-ft length, with a 300-plate plate pack. The shell and tube has an 18-in. diameter shell and a 22-ft length. The significantly higher heat transfer rates of the SUPERMAX plates versus the tube bundle are responsible for the striking difference.

The implications are clear: less cost for materials (stainless steel, titanium or other expensive higher alloys), simpler fabrication for shorter delivery lead times, easier installation, simpler support structures and vastly smaller footprints, especially considering dead space required to pull the shell and tube exchanger’s tube bundle for cleaning.

A Plate And Frame requires only 20% to 50% the space of shell and tube units including service footprint. They are much lighter in weight, and they cost less.

Compare the footprint of the SUPERMAX® Shell And Plate Exchanger with an equivalent duty shell and tube. You would have to double the shell and tube footprint to be able to pull the tube bundle for service.

Standard and removable core SUPERMAX® Shell And Plate Heat Exchangers.

CHALLENGE

To save space, improve process and reduce maintenance in critical heat exchanger duties:

  • Ammonia stripper vent condensers
  • Weak nitric acid coolers
  • Stripper condensate exchangers/economizers
  • High-pressure condensate preheaters
  • Ammonia shift condensers

SOLUTION

Tranter SUPERMAX® Shell & Plate Heat Exchangers in ammonia, nitric acid and urea manufacturing.

RESULTS

  • A smaller footprint, lower cost and simplified mechanical cleanability as desulfurization and CO2 capture lean/rich interchangers
  • Smaller footprint and a significant improvement in the temperature approach of 9°C (16°F) as 4-unit, manifolded, multi-pass, high-pressure condensate preheaters vs. triple series-piped shell & tube heat exchangers
  • Improved product life as weak nitric acid coolers (compared to shell & tube units)
  • Better leak resistance as ammonia stripper vent condensers (compared to block-type welded exchangers)
  • Reduced maintenance burdens

Tranter Shell And Plate HE used as a nitric acid condenser.
Tranter Shell And Plate HEs used as ammonia condensers.

CHALLENGE

Find replacements for shell and tube heat exchangers that improve performance and efficiency with batch reactors using one or more organic solvents and multiple condensers (primary and secondary condensers and vent condensers).

SOLUTION

Tranter SUPERMAX Shell And Plate Heat Exchangers.

RESULTS

Compared with the shell and tube exchangers, the Tranter SUPERMAX Shell And Plate Exchangers are providing:

  • Lower purchase price
  • Reduced structural steel requirements
  • Faster response (shorter vaporization/ condensation cycle time)
  • Higher plant capacity or throughput
  • Reduced maintenance burdens, since pulling long tube bundles has been replaced by pulling short SUPERMAX cores when cleaning is necessary.
Tranter SUPERMAX Shell And Plate Heat Exchangers are improving performance in such duties as solvent condensers and thermal control of reactors.

CHALLENGE

At a combined heat and power plant, on seven engine sets, each of which generates more than 200 tonnes (220 short tons) of steam per hour, find three heat exchangers for each set to:

  • Recover heat from the engine gas generators for preheating boiler feedwater for steam generation.
  • Recover heat for process use, to raise refining process fluids to 80°C (175°F).
  • Recover heat for use in the main building and workshops.

SOLUTION

21 Tranter SUPERCHANGER® Plate And Frame Heat Exchangers to recover heat

RESULTS

Thanks to the exchangers’ thermal efficiency and close approach, approximately 5.5 MW of low-grade heat are recovered, more than doubling CHP plant fuel efficiency, reducing costs and conserving fossil fuel reserves.

Potash plant with Tranter plate heat exchanger recovery technology
Triple Tranter Plate Heat Exchangers installed on each of seven engine sets more than double CHP plant fuel efficiency, heating feedwater, process liquid and employees.

CHALLENGE

Find a replacement for two gasketed plate heat exchangers that will enhance process uptime in resin cooling and heating for an injection-molded sink manufacturer.

SOLUTION

Two Tranter SUPERMAX Shell And Plate Heat Exchangers; one unit cools resin following compounding from acrylic monomer and ethylene glycol. The second heats the resin to 50°C (122°F) using a thermal fluid.

RESULTS

Years of trouble-free resin heating and cooling performance.

The Tranter SUPERMAX Shell And Plate Heat Exchanger, with no gaskets, has proven reliable for years with organic solvents used to compound mineral-filled resins.

CHALLENGE

Find replacements for slow-responding shell and tube exchangers in reactor thermal control loops.

SOLUTION

Either Tranter SUPERCHANGERPlate And Frame Heat Exchangers (gasketed) or SUPERMAX Shell And Plate units, thanks to their high heat transfer rates and smaller hold-up volume.

RESULTS

  • Heating the jacketed reactor to the setpoint faster.
  • Controlling reaction temperature more precisely.
  • Conserving costly heat transfer fluids.
  • Obtaining better yields.
  • Reducing energy consumption
Tranter Plate Heat Exchangers can bring more precise thermal control to reactors.

CHALLENGE

Find a heat exchanger that withstand corrosive attach by potassium hydroxide-treated waste oil while cooling from more than 200°C (392°F) to 120°C (248°F).

SOLUTION

Tranter SUPERMAX Shell & Plate Heat Exchangers manufactured in Hastelloy C276.

RESULTS

  • Succeeded where Inconel units could not in the treatment and recycling of used oil.
  • High efficiency.
  • Light weight and small footprint.
  • Cost-effective alternative.

Wichita Falls, TX

When a new customer reached out to us with an email asking for help sizing a Shell & Tube Steam and Glycol Heat Exchangers into a compact more efficient solution, our team jumped into action and got the ball rolling.  Four welded plate heat exchangers later, the customer was ecstatic with Tranter’s TX, USA Manufacturing. The four Supermax units are ready to ship to South Texas and will be installed soon.