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DIABON

Shell & Tube Heat Exchangers

Process Technology

Broad Base. Best Solutions.

Carbon is Future.
SGL Group The Carbon Company.

Process Technology
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 increasing number of industry we give proof of our
strong innovation culture.
Broad Base

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.

Carbon substitutes other materials and contributes to a


reduction in CO2 emissions.

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

Our range of materials:


E graphite
E SiC
E PTFE
E reactive metals
E steel
Our range of services:
E process design
E engineering
E project management
E production and assembly
E commissioning
E 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.

Reliability.
Efficiency.
Sustainability.

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.
Best Solutions
E

Reliability

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.

Efficiency

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.

Sustainability

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.

Contents
DIABON Shell and Tube Heat Exchangers

Carbon Fiber-Reinforced DIABON Components

Technical Information

Multi-Tube Bundle Heat Exchangers

10

Design Options

Quality Management and After Sales Service

14

Properties and Applications

Process Technology Our Products

15
3

DIABON Shell and Tube Heat Exchangers


at a Glance

Advantages of our shell and tube


heat exchangers in DIABON process
equipment graphite

High efficiency

Large heat exchange areas possible


(over 2,000 m2)

Price advantage for medium and large


heat exchange areas

High heat transfer capacity

Abrasive wear protection minimizes erosion

Low pressure drops

All seals are external for ease of inspection

Ease of repair

Excellent drainage of condensate in steam


applications

Complete drainage of product and service side

Wide range of material combinations for shell


and header (FRP, rubber-lined steel, enamel,
steel/PTFE)
On this basis, DIABON shell and tube heat exchangers are used as heaters, coolers, condensers and
falling-film evaporators and absorbers, especially
in the treatment of:

Hydrochloric acid

Sulfuric acid

Hydrofluoric acid

Phosphoric acid

Chlorinated hydrocarbons

Organic and inorganic media

Waste acids

Combustion gases

DIABON tube bundle

Corrosion resistance
The basic materials for our shell
and tube heat exchangers, DIABON NS1 and DIABON NS2
process equipment graphite, are
resistant to virtually all organic
and inorganic media. For heat
exchange between two corrosive
media, we supply special designs

Pressures and

on request with a suitable anti-

temperatures

corrosion lining or coating of the

A maximum permissible material

steel shell (rubber, PTFE, enamel,

temperature of 200 C has been

etc.)

certified for DIABON NS1 and


NS2 tubes by the South German

O-ring seal

Technical Supervisory Board

Our long experience has shown

(TV). Moreover, strength certifi-

that O-ring seals offer substantial

cation up to G32-0-200 (32

advantages over stuffing box

N/mm2 with 0 strength de-

packings:

crease up to 200 C) can be given


for the tubes. The standard design

Extremely low coefficients

allows for optional pressures of up

of friction

to 6 bar gauge for both service

Low sealing forces required

and product sides. Special designs

Universal resistance of

for higher pressures up to 16 bar

O-ring seals

gauge on the service side and up

Ease of adjustment

to 12 bar gauge on the product

Ease of replacement

side can be supplied on request.

Long service life

Low servicing cost

Shell and tube heat exchanger


with DIABON NS1 tubes

Terms of reference
Training

To be able to offer the same standards of quality

Servicing of our DIABON shell

anywhere in the world, our shell and tube heat

and tube heat exchangers is sim-

exchangers are designed to meet the following in-

ple and can be carried out on site

ternational standards:

by your own personnel. On re-

AD specification

Germany

quest, we put your technical per-

APAVE

France

sonnel through our training cour-

ASME

USA

ses. This enables repairs and

BS

United Kingdom

overhauls to be carried out even

Chinese Requirements

China

more quickly and economically.

ISPESL

Italy

In addition, our specialists are

JIS

Japan

always at your service whatever

Stoomwezen

Holland

your problem. We also supply

SVTI

Switzerland

spare parts quickly and easily.

UDT

Poland
5

Technical Information
DIABON Shell and Tube Heat Exchangers
DIABON shell and tube heat exchangers
are constructed from the following components:

Two tube sheets with or without carbon fiber


reinforcement one fixed and the other
floating, relative to the shell

Baffle cages with DIABON baffles

Headers made from DIABON NS1/ NS2


graphite or other materials. Depending on the
application, the header in contact with the
floating tube sheet is braced against the tube
sheet by a dual clamping tie rod system

Shell made from steel, with


anti-corrosion lining on request,
or from other materials

Partition plates in the headers


allow several passes
through the tube bundle,
when required in the

DIABON tube sheet with wear sleeves

process

Technical specification

Tubes

Material

Others

d1 [mm]

d2 [mm]

t [mm]

Tube type 0

15

26

33

Tube type 1

22

32

39

Tube type 2

25

37

44

Tube type 3

37

50

57

Tube length

1 bis 9 meter (standard)

Tube bundles and headers

DIABON NS1 / NS2 / HF1 / HF2

Shell and flanges

DIN standard steel, P 265 GH

Acceptance inspection

CE, TV and other authorized test institutes

Design pressure

-1 / 6 bar gauge (standard)

Design temperature

180 C (standard)

Options
for Various Designs

Top header with


laterial nozzle and
removable top cover

Falling-film
DIABON header

Cooled DIABON
header for high gas
inlet temperatures

Standard
steel shell

Steel shell with


steam inlet
distributor

Steel shell with


conical steam
inlet nozzle

Conical steel
bottom header with
corrosion-resistant
lining

Extended DIABON
bottom header for
separating gases
and liquids

Steel shell with


360 steam distributor

Properties and Applications


of DIABON Graphite Brands

Micrograph of DIABON NS1

Micrograph of DIABON NS2

DIABON NS1

DIABON NS2

Properties

Properties

Standard material for a wide

Graphite material for superior

range of applications in chemi-

demands. This graphite brand

cal technology, environmental

is distinguished by its lower pore

protection and similar industries.

volume combined with reduced

DIABON NS1 is an impervious,

pore size and greater mechani-

synthetic resin-impregnated pro-

cal strength. The maximum per-

cess equipment graphite with a

missible material temperature is

highly homogeneous material

200 C.

structure. This results in excellent


corrosion resistance and thermal

Applications

stability. The maximum permissi-

DIABON NS2 is suitable for

ble material temperature under

heat exchanger tube sheets and

permanent load is 200 C.

tubes, if these are subjected to


elevated mechanical stress

Applications

and/or extremely corrosive

Standard material for the pro-

media and solvents.

duction of heat exchangers and


for all pressure- and temperaturestressed components.

Carbon Fiber-Reinforced Components


for Increased Safety
In developing the carbon fiber reinforcement of components (DIABON HF), SGL Group has found a way to increase the operational
reliability of DIABON graphite components appreciably and expand
their range of application under high-stress conditions. The fiber reinforcement is used for tube sheets, headers and column sections and
especially for tubes.

Properties of graphite tubes with


carbon fiber reinforcement

Carbon fiber-reinforced tube sheet

Increased bursting pressure

The tube becomes more resistant to steam hammer


and service pressures above the permitted limit, its
bursting pressure at room temperature being raised
to 130 to 140 % of that of a non-reinforced tube,
depending on the tube dimensions.

Resistance of a cracked tube to leakage

Should a longitudinal crack occur in a DIABON HF


tube as a result of overstressing, the tube will not
allow any major leakage up to a differential pressure of some 2 to 5 bar. In all instances, the reinforcement prevents any spalling from the tube and

DIABON HF tubes

a consequent escape of product in large quantities. Usually the


equipment can continue in operation without interruption until the next
planned shutdown.

Comparison of tube properties


Unit

DIABON HF1

N/mm2

> 52

> 52

Bursting pressure at 20 C

bar

110

80

Bursting pressure at 50 C

bar

120

75

Resistance to pressure surges

relative %

250

100

Leakage pressure2) 5)

bar gauge

2-5

Thermal conductivity

W/(Km)

50 3)

> 60

200

200

Flexural strength, longitudinal

Maximum material temperature4)

1)

DIABON NS1
1) DIABON tube reinforced
with SIGRAFIL HF fibers
2) on a cracked tube under
internal pressure from
water
3) effective value,
calculated from the tubes
heat transfer capacity
4) depends on service
medium
5) pressure up to which no
appreciable loss of
medium occurs from the
cracked tube under brief
pressure surges

Multi-Tube Bundle Heat Exchangers


made from DIABON Process Equipment Graphite

A new generation of heat exchangers


Unlike conventional products, our DIABON multitube bundle heat exchangers feature an exchange
surface area distributed over several identical small
tube bundles instead of a single large bundle.
Separate graphite tube bundles are incorporated
in a shell made from carbon steel. One or more of
these elements can be integrated in a frame of support plates. The tube bundles are sealed against

DIABON bundles of a multi-tube bundle heat exchanger

both the steel flanges and headers with O-ring seals


made from a high-quality sealing material.

The special design of multi-tube bundle heat


exchangers allows single or multiple counter-current
flow, or several different applications in a single

The special design features make for a whole

unit, e.g. in

range of advantages:

condensation

Technical

residual gas and condensate sub-cooling

using different cooling media for the purpose

10

High performance combined with small heat


exchange area

Savings in heat exchange area of up to 40 %

Modular design

Multi-mode operation in a single unit

Flexibility in use

Connection scheme adjustable to requirements

Stress-free installation of tube bundles

DIABON multi-tube bundle heat exchangers (2 bundles)

Design advantages

Design ideally matched to graphite material


sliding seal to compensate for thermal
expansion
minimal axial and radial movement

Automatic ventilation and emptying


possible

Identical and standardized assemblies

Long servicing intervals

Ease of handling

Practical sealing system with reliable O-rings

Ease of servicing

and sealing cords in high-quality materials

Maximum operational reliability

Optional inspection glass allows

(tube bundles, modules, headers, etc.)

Meets cGMP requirements


(current Good Manufacturing Practices)

short tightening distances

process control

Flexible design allowing


co-current-flow operation
multi-mode operations

Cost advantages

Low space requirements due to


compact design

Operational advantages

Vertical and horizontal installation

Antifouling properties

Optimum design for CIP procedures

Low capital expenditure


Up to 80 % savings on servicing
and repairs

(Cleaning in Place)

11

Multi-Tube Bundle Heat Exchangers


made from DIABON Process Equipment Graphite

Another special advantage of this design is that it


allows pure counter-current flow. Compared with
standard equipment, the temperature differential
can be used to full advantage. Moreover, the design can be individually adapted and optimized for
each application. The resulting savings in heat
exchange area can be as much as 40 %.
DIABON multi-tube bundle heat exchanger (5 bundles)

The equipment design is optimized to allow an ideal


inlet flow profile for the cylindrical tube sections. As
a result, flow conditions for each tube bundle are
identical, without dead spaces or areas exposed to
undercurrents and turbulence. This is why our equipment displays excellent antifouling behavior when
used for media with an inherent fouling tendency.

12

A further advantage of this design is its ease of


handling. Since the heat exchanger has only a few
components, dismantling is just a short sequence
of operations that can be easily performed by the
operators themselves.
DIABON multi-tube bundle heat exchanger (3 bundles)

The availability of the equipment can be increased


significantly by keeping spare bundles in stock.
During heat exchanger cleaning operations, tube
bundles can be replaced as required in a minimum
of time. This ensures nearly 100 % availability of the
equipment and associated plants.

Multi-tube bundle heat exchangers are suitable

Damaged tube bundles can be re-

for a wide range of chemical processes when

paired at any time and even repeat-

used as

edly, thereby minimizing the cost of

Coolers

Heaters

Condensers

Evaporators (forced and natural circulation)

Falling-film evaporators

Integrated equipment for condensing

servicing.

with simultaneous residual gas cleaning


(cold trap)

Heating and cooling of pickling lines

13

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.
Quality Management
E

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 consistently high
quality to our customers, we work
according to a key performance
indicator orientated quality
management system.

14

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.

E
E
E

 aintenance genuine spare parts supply,


M
failure analysis, repair, field service
Fast emergency support
Start-up assistance
Consulting for continuous improvement

Our service specialists as well as our service centers


work in a global network to support you best.

Process Technology
Our Products

System Solutions
E Syntheses
E Distillation and concentration
E Purification
E Dilution
E Absorption
E Desorption
E Thermal destruction and recycling
E Reactors and converters
E Heat storage
E ...

Equipment Solutions
E Graphite and SiC heat exchangers
shell & tube, block and plate type
E Columns and internals
E Vessels
E Quenchers
E Pumps
E Rupture discs
E PTFE piping and bellows
E PTFE hoses
E ...

After Sales Services


E Maintenance
E Emergency support
E Start-up assistance
E Consulting
E ...

15

Regional Sales & Service Center


Central and East Europe

Asia, Oceania

SGL CARBON GmbH


Werner-von-Siemens-Strasse 18
86405 Meitingen/Germany
Phone +49 8271 83-1564
Fax +49 8271 83-2101
pt-europe@sglgroup.com

SGL CARBON Far East Ltd.


Shanghai
1208, Shanghai Oriental Plaza
31 Wujiang Road/China
Phone +86 21 5211 0333
Fax +86 21 5211 0085
pt-asia@sglgroup.com

South Europe, Middle East,


Africa

India

SGL CARBON Technic S.A.S.


18, Avenue Marcel Cachin
38407 Saint Martin dHeres/France
Phone +33 4 7625 9600
Fax +33 4 7625 6277
pt-europe@sglgroup.com

SGL CARBON India Pvt. Ltd.


Plot No. E-100, MIDC Ranjangaon
Village: Karegaon, Taluka: Shirur
Dist. Pune - 412 220/India
Phone +91 21 386 122-14
pt-india@sglgroup.com

Americas
SGL CARBON Technic, LLC
21945 Drake Road
44149 Strongsville, Ohio/USA
Phone +1 440 572-3600
Fax +1 440 572-9570
pt-americas@sglgroup.com

registered trademarks of SGL CARBON SE

11 2014/0 5N 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.

Process Technology
SGL CARBON GmbH
Shnleinstrasse 8
65201 Wiesbaden/Germany
www.sgl-processtechnology.com
www.sglgroup.com