GAB neumann graphite presentation

02.2016
Synthetic Graphite Manufacturing
Petroleum and pitch
green cokes
Homogenous KneadingExtrusion, vibro-molding
or isostatic pressing
Carbonization
at 900+°C
(1 month)
Pitch impregnation Graphitization
at 2700+°C
(2 months)
Synthetic graphite suitable
for process equipment
manufacturing
Coking
Coke silos
Grinding Screening

02.2016
Transformation of carbon into graphite
Graphite is crystalline
Easily machinable
Very high electrical and thermal conductivities
Carbon is amorphous
Very difficult to machine
Low electrical and thermal conductivities
Energy
Time

02.2016
Outstanding Thermal Conductivity (SI)
1
12
17
17
25
50
130
130
0 20 40 60 80 100 120 140
Glass
Hastelloy
Stainless steel
Titanium
Zirconium
Tantalum
Silicon Carbide
Graphite
W/m.K

02.2016
Outstanding Thermal Conductivity (USCS)
7
80
120
120
170
410
900
900
0 200 400 600 800 1000
Glass
Hastelloy
Stainless steel
Titanium
Zirconium
Tantalum
Silicon Carbide
Graphite
BTU/hrft°F

02.2016
Process Equipment Graphite Manufacturing
Synthetic graphite
Blocks contain
15 to 20% void
Pre-machining Drying
(>110°C)
Impregnation
(>10 bar)
Curing
(>165°C)
Phenolic
resin
Final CNC
machining
• Porous synthetic graphite
• Impregnation with phenolic resin
• Totally impervious graphite after impregnation Impervious graphite
parts and elements

02.2016
Phenolic Resin Polymerization
OH
CH2
CH2
OH
H2C CH2OH
CH2
OH OH
H2C
CH2
CH2
160°C
CH2 O CH2
CH2
H2O+
ether groups
OH OH
H2C CH2
CH2
CH2
H2O
CH2
+
methylen groups
180°C
2
+ 2
• At 160°C (320°F) polycondensation
occurs (elimination of H2O) and
ether groups are formed
• At about 180°C (356°F) another
polycondensation occurs resulting in
the formation of methylene groups
• Solid and hard polymer
• Three dimensional cross linked
structure resulting in a good
chemical resistance to most
common chemicals especially acids
OH
CH2
CH2
OH
H2C CH2OH
CH2
OH OH
H2C
CH2
CH2
160°C
CH2 O CH2
CH2
H2O+
ether groups
OH OH
H2C CH2
CH2
CH2
H2O
CH2
+
methylen groups
180°C
2
+ 2

02.2016
Quality criteria for impervious graphite
• Graphite:
• Compact grain structure
• Well distributed grain / pore size
• No structural irregularities (cracks, large
pores, impurities, etc…)
Micrograph GAB GX1 magnified x10
Micrograph GAB GX1 magnified x200
• Impregnation:
• Pores totally filled with phenolic resin
• Perfect bond between resin and graphite
• Polycondensation bubbles well distributed

02.2016
Graphite Material Data (SI)
Material Characteristics Units Graphite
Density (20°C) kg/dm³ 1,9
Flexural strength (20°C) MPa 30
Compression strength (20°C) MPa 45
Elastic modulus (20°C) GPa 20
Thermal expansion coefficient (20°C/200°C) K-1 6 x 10-6
Thermal conductivity (20°C/200°C) W/mK 130
Open porosity % 0

02.2016
Graphite Material Data (USCS)
Material Characteristics Units Graphite
Density (68°F) oz/gal 253.7
Flexural strength (68°F) ksi 4.35
Compression strength (68°F) ksi 6.53
Elastic modulus (68°F) msi 2.9
Thermal expansion coefficient (68°F/392°F) K-1 6 x 10-6
Thermal conductivity (68°F/392°F) BTU/hr.ft.°F 901.3
Open porosity % 0

02.2016
Very low adhesion: excellent cleanability
37,3
36,6
36
35,7
31,6
29
25,3
20 25 30 35 40
Stainless steel
sandblasted
Glass lined
Impreglon
coating
Stainless steel
electropolished
Stainless steel
base grounded
Graphite
Perfluoroalkoxy
Degree

02.2016
GAB GPX Graphite Qualities (SI)
GAB Neumann
GPX1 GPX1T GPX2
Density g/cm³ 1,9±0,02 1,9±0,02 1,9±0,02
Maximum grain size mm 0,80 0,8 0,8
Resin content
(Equals to open porosity before impregnation) % 22 22 15
Permeability cm²/s 10-6
10-6
10-6
Tensile strength N/mm² ≥18 ≥18 ≥20
Bending strength N/mm² ≥32 ≥32 ≥35
Compression strength N/mm² 60-80 60-80 60-80
Labelling (acc. AD 2000 - N2) G18-0-180 G18-0-200 G20-0-200
GXX-…-… (tens. strength) N/mm² 18 18 20
G…-XX-… (decrease / +10K) ‰ 0 0 0
G…-…-XX (maximum T) °C 180 200 200
Thermal conductivity W/m.K ≥120 ≥120 ≥150

02.2016
GAB GPX Graphite Qualities (USCS)
GAB Neumann
GPX1 GPX1T GPX2
Density oz/gal 254±2.7 254±2.7 254±2.7
Maximum grain size in 0.03 0.03 0.03
Resin content
(Equals to open porosity before impregnation) % 22 22 15
Permeability cm²/s 10-6
10-6
10-6
Tensile strength ksi ≥2.61 ≥2.61 ≥2.9
Bending strength ksi ≥4.64 ≥4.64 ≥5.08
Compression strength ksi 8.7-11.6 8.7-11.6 8.7-11.6
Labelling (acc. AD 2000 - N2) G18-0-180 G18-0-200 G20-0-200
GXX-…-… (tens. strength) N/mm² 18 18 20
G…-XX-… (decrease / +10K) ‰ 0 0 0
G…-…-XX (maximum T) °C 180 200 200
Thermal conductivity BTU/hr.ft.°F ≥830 ≥830 ≥1,040

02.2016
Equipment Manufacturing Process
Impervious graphite
CNC
machining
(Inspection)
Impervious graphite
parts and elements
(Individual pressure testing)
Steel parts
(plates, tie rods, springs, nuts, lugs)
Expansion bellows and other suppliers
Carbon fiber reinforcement
Final assembly
(Inspection)
Hydraulic testing
(Leak test, pressure test,
pressure drop, dimensions)
Packaging and shipmentCement
• Quality controls at each stage
• ISO 9001: full traceability
• Final testing guaranties performances
Impervious
graphite
(Inspection)

02.2016
Equipment Manufacturing Process
• Small tolerances
• Repetitious accuracy
• High quality
• Cost efficiency
Latest CNC Machining Technology
Leakage testing of each elements
• 100% testing
• Hydraulic final testing
(Pressure vessel code)
• Only meaningful when impregnation is
made before machining

02.2016
Annular-groove Design
Block or Shell & Tube Design
• Established flow shortly after
disruption (tube or block inlet)
• Laminar flow conditions
• Tendency to fouling / scaling
• Cross flow
> Lower heat transfer
Annular Groove Design
• Always turbulent flow
• Permanent disruption of the flow
• No fouling, no scaling
• Full counter flow
> Excellent heat transfer

02.2016
Annular Groove Design
• Highly turbulent flow
• Thick graphite walls
• Adjustable cross-section
• Self-cleaning design
• Minimized fouling
• Highest heat transfer
• No gaskets
(cemented discs)
• Best thermal
performance
• No leakage
• No cross
contamination
• Lowest
maintenance need
• High reliability and
plant availability

02.2016
Overall heat transfer coefficients (SI)
U Value
Block or
Shell & Tubes
Annular
Groove
Δ
[W/m².K] [W/m².K] %
Two aqueous liquids 500 – 1000 1100 – 1600 +60 - 120%
Water and organic solvents 400 – 700 600 – 1200 +50 - 70%
Water and acid 400 – 700 600 – 1400 +50 - 100%
Water and condensing steam 600 – 1100 1300 – 1800 +60 - 130%
Water and condensing solvents 400 – 700 700 – 1300 +75 - 90%
Heating steam and boiling water 800 – 1100 1400 – 1800 +65 - 75%
Heating steam and organic solvent 600 – 900 800 – 1400 +35 - 55%
Heating steam and acid 500 – 900 700 – 1400 +40 - 55%

02.2016
Overall heat transfer coefficients (USCS)
U Value
Block or
Shell & Tubes
Annular
Groove
Δ
[Btu/(ft2h°F)] [Btu/(ft2h°F)] %
Two aqueous liquids 90 – 180 190 – 280 +60 - 120%
Water and organic solvents 70 – 120 100 – 210 +50 - 70%
Water and acid 70 – 120 100 – 250 +50 - 100%
Water and condensing steam 100 – 190 230 – 320 +60 - 130%
Water and condensing solvents 70 – 120 120 – 230 +75 - 90%
Heating steam and boiling water 140 – 190 260 – 320 +65 - 75%
Heating steam and organic solvent 100 – 160 140 – 260 +35 - 55%
Heating steam and acid 90 – 160 120 – 260 +40 - 55%

02.2016
Better Heat Transfer
• Case study: acid heated with steam
• Block design:
18.8 m2 (202 ft2)
• Annular Groove design:
13.2 m2 (142 ft2)
• Same duty
• Same fouling factors
• Much smaller heat transfer area
Replacement of a block heat
exchanger by an annular
groove heat exchanger

02.2016
Better design against stress cracking
• Thick uniform cylindrical walls
(minimum 15 mm, 0.6 inch)
• Well distributed mechanical
constraints
• No crack
• No leakage / permeation
> Excellent reliability
• Uneven wall thickness
(3 to 5 mm, 0.1 to 0.15 inch)
• Mechanical stresses might exceed
material resistance locally
• Risk of cracks
• High risk of leakage / permeation
> Much lower reliability
Annular Groove Design Block Design

02.2016
Stress cracking due to swelling
• Block cracked by swelling
stress effect
• Some organic solvents
might create physical
expansion of polymer resin
• Reversible effect
• Inhomogeneous structure
and thin walls create stress
peaks
• Common failure in
processes with organic
solvents
Swelling stress crack
(2 days after failure)
Gap width 0.8 to1.2 mm
(0.03 to 0.05 inch)
Same crack
(3 days later)
Gap width 0.2 mm
(0.007 inch)

02.2016
Product Contamination / Black Particles
• More than 95% of black particles
result from resin film
• Film building is side effect of
impregnation
• Manufacturing sequence
(impregnation / machining)
matters
• GAB manufacturing sequence
(machining after impregnation)
completely avoids any product
side resin film in final components
Competitor blocks with
resin film at the surface
(impregnation after
machining)
GAB Neumann annular
groove design totally free
of resin film (machining
after impregnation)

02.2016
Product Contamination / Black Particles
• Batch processes create thermal
stresses that might result in chip-
off of the resin film
• Special situation in fine
chemistry: non-contamination
requirement versus thermal
stress caused by batch
production
Competitor’ block design
with resin film: black
particle chip off after
thermal cycling
GAB Neumann Annular
Groove design without
resin film: no risk of
contamination
Time
Temperature

02.2016
GAB Graphite Equipment Portfolio
Columns and column
internals
Special process
equipment
• Quenches
• Absorbers
• Continuous reactors
• …
Machined componentsHeat exchangers
Unique: Annular
groove design

02.2016
GAB Graphite Heat Exchangers
Annular-groove
Condenser
(GMP compliant)
Annular-groove
Cooler
Block HXAnnular-groove
Condenser
(GMP compliant)

02.2016
GAB Graphite Heat Exchangers
Annular Groove Heat Exchanger
• Transfer area
0,6 to 68 m²
(6.4 to 730 ft²)
• Temperature range
-60 / +200°C
(-76 / +392°F)
• Pressure range
-1 / +10 bar
(Full Vacuum / 145 psig)
Block Heat Exchanger
• Transfer area
0,9 to 163 m²
(10 to 1,755 ft²)
• Temperature range
-60 / +200°C
(-76 / +392°F)
• Pressure range
-1 / +10 bar
(Full Vacuum / 145 psig)

02.2016
Smooth operations
• Never exceed maximum torques indicated
on the drawing. Cross tightening
procedures should be carefully respected
• Avoid thermal shocks: smooth start up and
shut down. Allow sufficient time for the unit
to warm up. Implement automatic start up
and shut down procedures to eliminate the
human factor
• Avoid mechanical stress : ensure
appropriate installation and supporting.
Protect nozzles with expansion bellows.
Avoid pressure surges / water or steam
hammering: turn valves slowly and avoid
butterfly valves, drain condensates lines
Properly operated annular groove graphite
heat exchangers can work properly for more
than 20 years

02.2016
Nozzle protection with expansion bellows
• Nozzles should be protected with expansion
bellows both on service and on process sides
• Expansion bellows protect graphite nozzles
from mechanical stresses due to piping
misalignment / inappropriate supporting
• GAB Neumann offers a complete range of
PTFE expansion bellows perfectly adapted to
ultra-corrosive applications
• We deliver our PTFE expansion bellows
mounted on the graphite nozzlesLarge antistatic PTFE
expansion bellow at vapors
inlet

02.2016
Graphite Equipment Customers Worldwide
Extract of GAB Neumann
worldwide customer base

02.2016
Applications
Steel Pickling Copper Electrolysis Contract Manufacturing Basic Chemicals
Crop Protection Active Ingredients Vitamins Flavors & Fragrances
Titanium Dioxide Synthetic Fibers Fine Chemicals Minerals Refining
Liquid Crystals Pharmaceuticals Electronic Chemicals Accumulator Acid
Extract of applications of
GAB Neumann products

02.2016
GAB Neumann GmbH
Alemannenstrasse 29
79689 Maulburg
Germany
Phone +49 7622 6751 0
Fax +49 7622 6751 20
www.gab-neumann.de
info@gab-neumann.de

GAB neumann graphite presentation

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