How New Materials Ensure Reliable Sealing of Heat Exchangers

Sealings/Heat Exchangers How New Materials Ensure Reliable Sealing of Heat Exchangers

09.09.2015Author / Editor: Christian Wimmer* / Wolfgang Ernhofer

ePTFE gasket tapes for high chemical resistance—The connections to shell and tube heat exchangers pose immense challenges for the seals that are used because of both the chemically aggressive media and the frequent temperature load changes. Despite its excellent chemical resistance, polytetrafluoroethylene (PTFE) is not typically suitable as a sealing material in this case because the creep tendency of this material jeopardizes a reliable seal.

Related Vendors

Maag Pump Systems AG

AZO GmbH + Co. KG

Donadon SDD Srl

W. L. Gore & Associates GmbH Werk 1

Progression of the sealing surface pressure over time. Based on EN13555, PQR, using 15mm x 3mm bands laid to form a closed ring (Ø150mm). The values were determined at 30 MPa and 150 ˚C (302 ˚F).
(Source: Gore, Graphic: PROCESS; Picture: © Robert Kneschke - Fotolia)

Shell and tube bundle heat exchangers generally include not only several connection pieces but also a shell cover flange with a significantly larger nominal diameter. The shell cover flange creates the seal to the tube bundle flange, which then seals the shell flange.

These connections are subjected to the full operating pressure and test pressure of dozens of bar and seal it from the environment. Oftentimes the tube bundles are arranged in several passes that are channeled by the use of partition plates. This requires a seal at the head of the heat exchanger and between the tube passes at the partition plates where the pressure difference is considerably lower. The numerous potential different arrangement of the passes requires specially adapted seal designs.

A thermal design of a shell and tube heat exchanger is meaningful only when it is optimum and the extent of the optimality is constrained by the pressure drop (dreamstime.com / Telecast)

The sealing challenges that pertain to the shell cover flange position can be attributed to a combination of different conditions:

High temperatures/pressures

Temperature load changes caused by starting up and shutting down part of the process

Complex sealing geometries including separators, often combined with large nominal diameters

Chemically aggressive media

Damaged sealing surfaces, due to corrosion or warping

The economic necessity of minimizing downtime

The requirement to document legal compliance

REM images of the Gore ePTFE
(Picture: Gore)

“Creeping“ Gasket Tapes Made of PTFE

Gasket tapes are occasionally used to seal the static connections to shell and tube heat exchangers – sealing materials with a defined width and thickness, but an undefined length. They offer a way of functionally connecting the junction points and can be shaped as desired at the point of installation.

Thermal Processes at Achema 2015

A gas-liquid turbine with pressure support by Frings, which is well suited for huge production volumes in chemical or biotechnical industries

Big, bigger, the biggest – plate heat exchanger by Alfa Lava.

Gallery with 10 images

Since the gasket circumference is completed at the time of installation, it is no longer necessary to completely dismantle the heat exchanger, removal of the tube bundle, for example. It is only important that the sealing surfaces be sufficiently accessible. Gasket tapes have been around in many different industrial fields for several decades.

Additional Information

Characteristics of Gasket Tapes Made of ePTFE

8 Good Reasons for Usage

Easy and fast adaptation to suit even complex flange geometries

Design flexibility because of the various widths, which then allow for higher surface pressures (higher tightness classes)

High creep resistance compared to other PTFE-based materials

Excellent adaptability to flange irregularities

Not reusable (due to the high compression and hardly any spring back)

Non-biodegradable, do not age, UV-resistant

Resistant to all types of media (pH 0 to 14)

Storable for a long time, limited only in terms of the declining bonding strength of the mounting aid adhesive tape

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