Modular Radial Flow Gas-Gas

Exchanger
T. WACKER
Aker Solutions
Vancouver, BC, Canada
The current trend in sulphuric acid plant construction has been to progressively increase the plant
capacity. Gone are the days when the upper limit was 3,000 t/d plant. We have seen the successful
operation of a 4,400 t/d plant and a 5,000 t/d plant is due on line in the near future. Not to be
outdone, a single-train 6,000 t/d plant is on the drawing board. This presents a tremendous
challenge with regard to fabrication and shipping of individual pieces of equipment. One of the
challenges is the gas-gas exchanger. The sheer size and weight of this equipment leads to
problems, especially in remote plant locations where transportation and infrastructure are limited.
The traditional solution for oversized equipment has been to field-erect, but that can lead to
schedule and reliability issues. Field work is slower than the equivalent work in the shop and often
the quality of work is not as good as in a shop environment.
This paper presents a novel approach in meeting the shipping problem through modularization of
the gas-gas heat exchangers. The radial symmetry of Aker Solutions gas-gas heat exchangers
allows them to be easily divided into segments, which are sized to fit into standard shipping
containers. The critical tube-to-tube sheet joints are done in the shop for optimum control of
welding quality, thereby minimizing field work. The size of the segments makes them easy to handle
and assemble at site, thereby often eliminating the need for an expensive heavy lift crane.

INTRODUCTION
The current trend in sulphuric acid plant construction has been to progressively increase the plant capacity. As
plant capacity increases, so does the size of the gas-gas exchangers. As these units approach 6m in diameter and
200 tonnes in weight, this presents a tremendous challenge with regard to fabrication and shipping. This paper
presents a novel approach in meeting the shipping problem through modularization of the heat exchanger tube
bundle. By dividing the tube bundle into segments, which are sized to fit into standard shipping containers, the
shipping issue is solved. Furthermore, field fabrication is greatly simplified because the critical tube to tube
sheet welds are done in the shop.

- 127 -

T. Wacker

RADIAL FLOW GAS-GAS EXCHANGER

The radial flow gas-gas exchanger was developed by Aker Solutions in the late 1970s. A typical unit is shown
in Fig. 1. For the purpose of this discussion, the two important features of this design are the radial tube pattern
and the use of disc and donut baffles.
FIG. 1: RADIAL-FLOW GAS-GAS EXCHANGER

The disc and donut baffles ensure only radial flow of gas across the tube bundle while the patented radial tube
pattern (Fig. 2) produces the same radial flow area and layout angle in all flow directions. By comparison, a
similar arrangement using a conventional triangular pattern would produce flow areas and layout angles varying
from triangular to rotated triangular depending on flow direction. Also, note that the tubes do not fill the entire
interior of the exchanger, as in a conventional segmental baffled exchanger, rather, they are restricted to an
annular area near the shell (no tubes in window).
FIG. 2: RADIAL TUBE PATTERN (PATENTED)

- 128 -

Modular Radial Flow Gas-Gas Exchanger

Another important feature is the tube to tube sheet joint. Because of the high operating temperatures of these
units, an expanded joint is prone to leakage. Aker Solutions employs a two-pass welded joint for superior joint
integrity at high operating temperatures.

RECENT LARGE PROJECTS

Increasing plant capacity has led to some very large gas-gas exchangers. Some recent examples delivered by
Aker Solutions are:
Codelco (El Teniente)
Vale Inco (Sudbury)
BHP (Ravensthorpe)
WMC (Kalgoorlie)

6.1m diameter
5.1m diameter
6.0m diameter
5.8m diameter

11.4m tube length

15.2m tube length
14.5m tube length
18.3m tube length

110 tonnes
126 tonnes (Fig. 3)
133 tonnes
198 tonnes (Fig. 4)

FIG. 3: GAS EXCHANGER EN ROUTE

TO SITE

FIG. 4: GAS EXCHANGER

LEAVING FABRICATION
FACILITY (Note

special support cradle

and number of
wheels)

- 129

T. Wacker
These units were all completely shop assembled
and shipped in one piece.
As can be
appreciated, the sheer size and weight of these
units coupled with the remote locations of some
of the installations presented quite a challenge
for transportation to site and installation. Figure
5 shows the WMC exchanger being lifted into
place. The main crane is 600 tonne capacity, the
largest available in Western Australia at the
time.

FIG. 5: 200t GAS EXCHANGER BEING LIFTED INTO

POSITION

THE CASE FOR MODULARIZATION

In the past, there were two ways to get around
the size limitation. First, one could field-erect
the exchanger. This has the disadvantage of
longer construction schedules as well as higher
costs. Field labour is typically less efficient than
shop labour. Also, welding quality can be an
issue owing to the variable environment at a
construction site vs. the controlled environment
in a shop.
The second approach would be to redesign the
exchanger as two smaller units in parallel. This
is clearly more expensive than a single large
unit. There are also costs associated with
additional ducting, duct supports, control
dampers and equipment foundations. Plant
layout may also be an issue where space is at a
premium.
The challenge, then, is to find an economic
means to modularize the gas-gas exchangers so
they can be shipped to site in standard containers
without the need to perform the critical and
time-consuming tube-to-tube sheet welds on
site.

FIG. 6: RADIAL SEGMENTAL TUBE PATTERN WITH ACOUSTIC

BAFFLES

The solution involved a bit of serendipity. The

high degree of symmetry of the radial tube
pattern has the advantages of uniform flow
distribution, low pressure drop and high heat
transfer coefficient. However, the high degree
of uniformity also makes the units (especially
larger ones) prone to acoustic resonance. This
issue has been successfully resolved by adding
acoustic baffles to the tube bundle (Fig. 6). The
resulting segmental pattern is still radially
symmetrical, but is divided into distinct equal
segments.
By simply widening the gap at the acoustic
baffles, it is apparent that tube bundles utilizing
this pattern can be easily split into segments
(Fig. 7). The number of segments can be
adjusted to allow individual pieces to fit in a standard container.
- 130 -

Modular Radial Flow Gas-Gas Exchanger

FIG. 7: MODULAR TUBE BUNDLE

TWO SUCCESS STORIES BALKHASH AND SOUTHERN PERU

These are two very large (3,850 t/d for Balkhash and 3,740 t/d for SPCC) metallurgical acid plants. Both are in
very remote locations with limited transport infrastructure. Modularization was clearly the only practical
solution. Figures 8 and 9 show completed modules being loaded into containers. The modules were
manufactured at the Aker Solutions manufacturing facility in Toronto, Canada.
FIG. 8: MODULES BEING LOADED

- 131

T. Wacker
FIG. 9: MODULES READY FOR TRANSPORT

Balkhash is located in central Kazakhstan. Rail is the only practical means of transport. This limits the shipping
envelope to 3.5m x 3.5m. The largest gas-gas exchanger is 5.4m in diameter and weighs 210 tonnes fully
assembled.
SPCC is located on the Pacific coast of Peru, close to the Chilean border. Access to site is by road or rail.
Figures 10 and 11 show tube bundle segments being assembled. The top and bottom vestibules of these
exchangers were shop fabricated in Lima and shipped in one piece to site.
FIG. 10: TUBE BUNDLE SEGMENT BEING LIFTED INTO POSITION

- 132 -

Modular Radial Flow Gas-Gas Exchanger

FIG. 11: TUBE BUNDLE SEGMENT BEING LIFTED INTO POSITION

CONCLUSIONS
The radial symmetry of the Aker Solutions gas-gas exchanger makes modularization of the tube bundle
relatively straight forward. This option offers owners all the advantages of radial-flow gas-gas exchangers
coupled with the opportunity to reduce the total freight and construction costs. Exchanger reliability is
maintained by performing the critical tube-to-tube sheet welds in the shop.
The modular radial flow exchanger is particularly well suited to remote plant locations. Of course, this design
can also be considered for retrofits in order to reduce cost and schedule impact.

- 133