Alfa Laval in brief

Alfa Laval is a leading global provider

of specialized products and engineer-
ing solutions.
Our equipment, systems and
services are dedicated to helping our
customers to optimize the perform-
ance of their processes. Time and
time again.
We help them heat, cool, separate
and transport products such as oil,
water, chemicals, beverages, food-
stuff, starch and pharmaceuticals.
Our worldwide organization works
closely with customers in almost
100 countries to help them stay ahead.
Customized heat transfer
For effective Comfort Heating and District Heating
How to contact Alfa Laval

Contact details for all countries are

continually updated on our website.
Please visit www.alfalaval.com to
access the information.

Literature code number

Market leadership – your assurance

heating
technology
Customers in more than 60 countries have made
Alfa Laval the world market leader in heat exchangers
and thermal solutions.

Over 60 years of dedicated research and develop-

ment in the field of heat exchangers, together with
field experience from some 500,000 heating instal-
lations around the world, are your assurance that
we have the solutions you are looking for. Wherever
you are – and whatever your particular needs.

Welcome to the world of Alfa Laval heating

technology.
A global organization dedicated to excellence

Global experience – always near you

Wherever you are, Alfa Laval is there for you – to answer all your questions and
help you optimize your applications. Your dedicated Alfa Laval team is also just
a phone call away from cutting-edge R&D and a global organization. We will
provide whatever support, service or application expertise you may need – from
the initial studies right through to installation and operation.

• Alfa Laval heat exchangers mean you have a free choice of energy sources – from oil,
• Alfa Laval heat exchangers maximize energy efficiency and provide 95% heat recovery.
natural gas, and surplus heat from waste incineration, industrial processes and drainage.
• Alfa Laval heat exchangers demonstrate the lowest thermal and mechanical fatigue on
This means you can optimize energy sources to minimize costs as prices change, and
the market, and are fully customizable to meet any need.
maximize environmental protection.

Thermal systems and district heating Experienced planning means Alfa Laval heat
projects are complex processes that superior logistics exchangers are avail-
able CE- and UL-
often need to be split into separate At Alfa Laval, we believe that most approved and certi-
projects over a longer period of time. deliveries should not merely be in time. fied by TÜV, Germany,
They should be just in time in order to Det Norske Veritas,
Planning ahead save money and storage space for our Lloyds’ Register, Gost
standard of Russia,
When designing applications, plants customers. This is one of our major UDT of Poland, S.A.,
and substations, consideration must be strengths together with supplying and Swedish Authorities,
shown from the start for legislation and supporting the resources needed at Bureau Veritas,
Germanischer Lloyds
local regulations. Specifications from each different stage of a project.
Register of Shipping,
outside consultants or system owners plus a variety of local
must be taken into account. External From a single product to the approvals.
financing requires thorough preparatory complexity of a power plant
Almost 10,000
work. And projects can also be planned Close collaboration with the customer
Alfa Laval employees
and sized to enable working with local and every one of his partners and advis- in 140 countries serv-
contractors and businesses in order to ers is essential. We contribute actively ice and support our
maximize flexibility, create local jobs, and constructively from the very first customers all over
the world. Dedicated
and establish good relations. enquiry in order to help ensure you the
strategic service cen-
best possible solution – whether you ters for plate heat
We know because need a single product or a full-scale exchangers in eleven
we have been there project. countries support
locations on any con-
Alfa Laval customers always benefit tinent within 24 hours.
from our first hand experience from
hundreds of projects in different coun- The world of Alfa
tries and climates all over the world. Laval spans six conti-
nents. From Germany
You can gain invaluable knowledge via to South Africa, the
our Global Team and their connections USA to Australia, and
with a network of heating plants, district Brazil to South Korea.
heating companies and commercial
The introduction of
building owners. The Alfa Laval Global the Alfa Laval brazed
Team can also provide information heat exchanger in the
about investors, consultants, contrac- 1970s revolutionized
the design of district
tors and local installers.
heating modules.
Since then, Alfa Laval
R&D has been adding
Alfa Laval has 20 R&D centers around the world working closely new designs and
together with 35 production centers and the Alfa Laval Global products on a regular
team to address specific market demands and customer needs. basis.

5 Alfa Laval Heat Technology

Local needs and local solutions

Local presence – always there for you

Our future depends on the future of our customers. In a world of constant
change, it can be comforting to know that some essentials will remain the same.
One such essential is the local presence of Alfa Laval and our ability to support,
service and recondition any product in a comfort or district heating system that
has been supplied, delivered or installed by us.

We are always part of the future of our customers.

Many of our customers are engaged in
building a modern infrastructure based
on proven, effective and sophisticated
technology. This calls for customized
design to meet specifications that
address local conditions and specific
needs.
Others are expanding current plant
or designing next generation systems.
This means analyzing the application
benefits that new technology has to
offer, locating opportunities for even
faster return on investment, ensuring
lower than ever Total Cost of Ownership,
and reducing environmental impact.
Local needs require local response
Globalization is an obligation – the
obligation to adapt global experience
to meet local needs.
Your Alfa Laval Support Team is fully
equipped to meet any project require-
ment from day one with fast answers
and timely suggestions for improve-
ments. These are the success factors
that lead to a rewarding, long-term
customer-supplier relationship.
We also work together with our distrib-
utors and system builders to provide
and run software for design and func-
tionality testing, early simulations and
estimates of maintenance costs, and
if needed, test setups. We also offer
on-site training, education, detailed
manuals in a number of languages,
preventative maintenance support to
ensure maximum uptime, and – above
all – a local presence at any time and
in any place.
Leveraging local energy sources
The availability of local energy is an
important cost parameter. By using
heat exchangers from Alfa Laval, you
can choose one or several of a wide
variety of energy sources in order to
maximize economic benefits and
minimize environmental impact.
Global expertise for local projects
District heating system projects typically
span a five-year period. These projects
are complex processes that are often
split up into several stages, each of
which is initiated by a pilot project, and
minutely documented as a basis for
improvements and refining specifica-
tions for coming stages. This meticu-
lous process is even more critical when
external financing and approval need
to be obtained.
At first sight it may seem daunting,
but it is part of our global experience
and everyday work.
Full documentation
We provide documentation and speci-
fications for investors local authorities,
architects, consultants or other con-
tractors on a need-to-know basis.
And we can customize on request
throughout the project – even down
to details such as color and shape.
Always close by
Alfa Laval is represented in all countries
by local sales consultants, and a net-
work of regional authorized distributors
is responsible for serving our customers
at all times.
All of our authorized distributors and
sales consultants are able to perform
dimensioning of heat exchangers based
on application, heat load and available
space, and provide installation guide-
lines together with full price details.
Many distributors also provide service
and maintenance on a local basis.

Alfa Laval solutions and support span the The Heat Exchanger
entire process – from the main heat supply acts like a trans-
plant, through substations and heat exchang- former between the
ers to peripheral equipment in thermal sta- high-pressure network
tions serving end-user buildings. and a low-pressure
domestic system.
District heating typically relies on more than
one energy source. Alfa Laval gives you a This means increased
free choice between oil, natural gas, and sur- safety and reduced
plus heat from waste incineration, industrial investment costs as
processes and drainage. This means you can domestic systems
optimize energy sources to minimize costs can be designed for
as prices change, and maximize environmen- lower pressure.
tal protection.
The picture is of
If you should need a vital replacement part, three AlfaRex units
all you have to do is call your Alfa Laval rep- at the District Heat-
resentative. He can locate the nearest stocks ing Works of Jelenia
on the computer and usually arrange for Gora, Poland.
shipment within 24 hours, thus minimizing Total output: 7 Mw.
any downtime.

6 Alfa Laval Heat Technology Alfa Laval Heat Technology 7

A full range of globally proven heat exchangers

Power in products and performance

Alfa Laval has a full range of heat exchangers catering for every need, however
large or small. Alfa Laval is your assurance of quality in terms of compactness,
ease of installation, low maintenance costs, high energy efficiency, confidence
and flexibility. In other words, reliable operation, unsurpassed operating life
span, fast return on investment and low cost of ownership.

The AlfaRex Brazed heat exchangers Gasketed heat exchangers Steam heat exchangers
• Customized specifications • High energy efficiency • High flexibility • Minimal steam consumption
• Fast return-on-investment • Extreme compactness • Built for long lifetime • Easy-to-change capacity

AlfaRex – smooth and powerful
for fast return on investment
The plates in the AlfaRex are made
from corrosion-free, laser-welded mate-
rials with extremely smooth and strong
seams. The plate package and pres-
sure-retaining frame provides a strong
and elastic construction that tolerates
high loads and offers maximum protec-
tion against material exhaustion and
leakage. Extreme exhaustion tests
show that the AlfaRex is superior to
other welded constructions.
The AlfaRex is available in two different
frame and plate sizes. The AlfaRex
can be optimized to meet any cus-
tomized specifications by adjusting
the size of the plate package. This
means more efficient operation and
enhanced performance for fast return-
of-investment.
A typical AlfaRex installation takes up only
one-sixth of the floor space and is only one-
sixth the weight of a comparable shell- and
tube heat exchanger with a lower capacity.
Brazed Heat Exchanger
– for normal heavy duty service
The principle behind the brazed heat
exchanger PHE’s involves using copper
to braze the stainless steel plates
together, thus avoiding the need for
gaskets and a pressure-retaining ves-
sel. Brazed heat exchangers can toler-
ate higher temperatures and pressures.
The design of Alfa Laval heat exchanger
provides for fast and straightforward CIP
(cleaning in place), easy maintenance and
long service intervals.
Intensive product development at
Alfa Laval has led to a long line of new
and improved BHE designs. This means
that you can choose from a wide selec-
tion of Alfa Laval BHEs ranging in out-
put from 10 kW to 5 MW – enough to
heat as many as 1,000 apartments.
Alfa Laval BHEs are designed to
withstand temperatures of 170˚C and
pressures of at least 16 bars that are
common in district heating networks.
End-users appreciate the small hold-up
volume that means fast response, and
the tap water heater that is simple to
regulate and provides instant hot water.
Gasketed Plate Heat Exchanger
This type of heat exchanger uses a
gasket between the plates to direct
the water into the correct channels.
The number of plates is determined
by a combination of heat load, pressure
drop and temperature settings. The
corrugation causes a strong turbulence
that maximizes heat transfer efficiency.
A plate Heat Exchanger is extremely efficient
with a heat transfer efficiency of more than
95 per cent. It also instantly heats domestic
water without any losses, and without any
need for a large accumulator tank.
Steam Heat Exchanger – specially
designed for industrial steam
The TS-M series represents the new
generation of steam heat exchangers.
The unique geometry and strength of
the stainless-steel plates, special gas-
kets that withstand temperatures up
to 180˚C (356˚F), and the robust heat
exchanger frame, deliver operational
performance and economy unmatched
by either shell-and-tube heat exchangers
or conventional plate heat exchangers.

8 Alfa Laval Heat Technology Alfa Laval Heat Technology 9

 From the heatplant to the tap From the heatplant to the tap

Heat applications Substations

District heating is an environmentally friendly and reliable method of Heat exchangers from Alfa Laval are the most reliable solution for
delivering comfort heating to buildings and dwellings. Owing to differ- substations. There is an option for every need, whether you are pro-
ences in pressure and temperature, the main network and the end- viding heat for domestic tap water and the space heating system in
user system are not directly connected. Heat exchangers play a a building with 500 apartments, or need a small-scale solution spe-
major role in enabling efficient heat transfer between the two systems cially designed for a single dwelling.
in order to deliver hot water and heating to end-users.

District heating Traditional heating

3.
4.

2.

1. 2. 3. 4. 1. 5.

1. Hot water is obtained 2. Water circulates in 3. On arrival, the heat
from a heat gener- the district heating
ating plant, or in the network at high pres-
form of surplus heat sure and at tempera-
from a power station. tures ranging from
Heat is transferred 100 to 150°C (212 to
from the hot water to 302°F). This water
the district heating delivers heat to build-
network via heat ings and dwellings
exchangers. connected to the sys-
tem (red channels).
using a heat space heating. Floor 4. The returning water 1. Hot water is heated space heating. Tap perature of the return the boiler to a heat 4. Solar panels provide a swimming pool.
from the district exchanger that is heating is also a temperature (blue- up to 90°C (194°F) water is heated by water (blue channels) exchanger with a an alternative or Here, a titanium
heating network is correctly dimen- common application. line) normally varies by the boiler, whose transferring heat via can be an important temperature control supplemental energy plate heat exchanger
transferred to the sioned for the avail- The return water between 40–70˚C capacity varies a heat exchanger to factor in protecting device. In many source. will prevent chlori-
internal heating sys- able space, and for (blue channels) is (104–158˚C). depending on the the tap water system the boiler. cases, however, the 5. Hot water can also nated or salt water
tem which operates the required heat normally between required heat load. where water at a 3. Floor heating temperature differ- be circulated to from coming into
at a lower pressure load. The main appli- 40 and 70°C (104 2. The hot water is lower temperature, requires a water tem- ence can be accom- another heat contact with the
and temperature. cations are hot water and 158°F). circulated directly normally between perature of about plished using a exchanger in order main system, thus
This is accomplished from the tap and through the heating 50 and 60ºC 35°C (95°F). This can 3-way valve in which to perform other eliminating the risk
system (red chan- (122–140°F), is be obtained by circu- return water is mixed heating applications of corrosion.
nels) to provide required. The tem- lating hot water from with heated water. such as heating up

10 Alfa Laval Heat Technology Alfa Laval Heat Technology 11

What the customers say
Around the world
No two customers are ever the same. But most customers agree
about why they prefer Alfa Laval. For some a compact, high-per-
formance solution is essential. For others flexibility, reliability and
heating speed are the vital factors. All value their close cooperation
with Alfa Laval engineers in the field. It all boils down to rapid return
on investment and low total cost of ownership.
South Korea
Excess steam turned into profits
Han Wha Energy Co, located in Inchon
just outside Seoul, is one of very few
private electricity power stations in South
Korea. This GTCC plant consists of
four generator units with a total capacity
of 1650 Mw delivering supplementary
electric power to the state-owned
Korean Electric Power Cooperation.
Han Wha Energy Co decided to
streamline its operations by utilizing
the surplus heat from their electricity
production by acquiring an AlfaRex
TM10 in 1999. Han Wha Energy now
utilizes surplus heat from steam that
previously went unused. Steam enters
the heat exchanger at 200˚C and is
condensed, releasing its heat to water
that is used to heat the facility during
winter. In spite of the AlfaRex unit’s
compact size, its capacity is impres-
sive, heating 31.5 cubic meters of
water an hour from 10 to 100˚C.
“At first we considered an ordinary shell-
and tube solution for this purpose”, says
Mr. Soon-Bok Kim, General Manager
of Han Wha’s operations department.
“But space was at a premium and
reliability was key, so we contacted Alfa
Laval for an alternative suggestion.
When we took a closer look at size,
reliability, cost, and ease of mainte-
nance, the choice was simple. We are
satisfied with our AlfaRex unit and its
trouble-free operation without any need
for maintenance.”
12 Alfa Laval Heat Technology
South Korean Han Wha Energy
Co., one of very few private
electricity power stations in
South Korea. Space limitations
and high reliability requirements
made the all laser-welded AlfaRex
TM10 a natural choice for turn-
ing surplus steam into profits.
Denmark
No more unscheduled downtime
Metro Therm in Denmark has installed
Alfa Laval brazed plate heat exchangers
(BHEs) in its smaller tank modules för
district heating and in oil and gas
combu boilers. They offer a wide range
of solutions for providing hot water
from electric heating, district heating,
central heating and alternative heat
sources such as solar energy. To meet
the demand the company has factories
in Denmark, Norway and Poland.
Metro Therm has been integrating Alfa
Laval components into its own system
since Alfa Laval first introduced the
brazed heat exchanger in the late 1970s.
Russia
From Moscow to Novosibirsk
Moscow has always been the Russian
center where new scientific inventions
meet industrial trends and spring to
life. This spirit of innovation was the
soil in which the seed of cooperation
between Alfa Laval and the Russian
capital’s authorities and organizations
was sown.
The first Alfa Laval heat exchangers
were installed in Moscow already in
the 1970s and have since functioned
smoothly in local authority district heat-
ing systems, and in industrial and local
authority ventilation, air-conditioning
and refrigeration applications.
Today, more than 7,000 Alfa Laval heat
exchangers are installed in Moscow.
Main customers include design bureaus,
construction and maintenance compa-
nies building and supporting industrial
and civil objects, offices and residential
areas, hospitals, schools and kinder-
gartens. Alfa Laval has helped to make
the dream of a new standard of living
come true for the citizens of Moscow.
Alfa Laval heating equipment can be
found in the Armory Chamber of the
Moscow Kremlin, in the building of
References
the Russian Government, Moscow
City Hall, and the Duma. It also serves
in the unique Christ the Surveyor
Cathedral, in The International Opera
School, in the stadium of Luzhniki
– one of the biggest in Europe – as
well as in the Moscow Metro, the
Pushkin Art Museum, the Zoo, banks
and hotels, and large department stores.
The extreme efficiency and reliability
of Alfa Laval heat-transfer equipment
have considerably reduced operating
costs and downtime, demanding a
minimum of effort and money to keep
it running.
Alfa Laval’s plate heat exchangers are – “We are proud of the high level of quality,
also widely used as the key element in design and service we give our customers and
we look for the same qualities in our suppliers.
heating modules manufactured by our Alfa Laval provides both the technology and the
Russian partners. In the Siberian city of high quality we need to be competitive”, says
Novosibirsk, for example, more than Henrik Jensen, purchaser at Metro Therm.
350 plate heat exchangers have been
installed during the last five years,
mainly in heating modules.
The implementation of uniform equip-
ment from a single supplier such as
Alfa Laval provides the opportunity to
try new approaches in relationships
among cities in the region, and the
ability to solve problems in heat supply
at minimal cost.
Since the mid 1990s, Alfa Laval has
been able to offer locally produced
components to Russian customers.
All equipment produced by Alfa Laval
Potok is fully certified in accordance
with Russian standards, making the
decision procedure even easier for
potential customers.
At the beginning of 1999, a major mile-
stone in the history of thermal plant in
Russia was passed with the ISO 9002
certification of the leading-edge quality
control system installed at Alfa Laval
Potok. Production at the Alfa Laval
plant in Potok is constantly growing
with current output at some 3,000
PHEs a year.
Alfa Laval Heat Technology 13
References

Germany
Speed and flexibility
Staudinger Kraftwerk is a member if the
E.on Group, one of Germany’s leading
industrial groups with over 200.000
employees and sales for the year of
some 76 billion euros. The power facil-
ity is in the 2000 Mw class, and runs
on a combination of coal and gas.
“Electricity demand varies from day
to day”, says Ludger Hentschel, sys-
tem engineer at Staudinger Kraftwerk.
“That means we have to be flexible
and ready to close down or start up
the steam turbine at short notice.
One problem is that the start-up
steam is not good enough to drive
the turbine.”
The water level in the boiler drops
when steam is released. This means
that more hot water has to be supplied
from a special accumulator tank.
Staudinger Kraftwerk uses an AlfaRex
TM10 to heat this water.
“It’s an easy task on paper”, says
Ludger Hentschel. “You warm water
from 25 to 95˚C using steam at 120˚C
under a 9 bar working pressure. The
stop-and-go nature of operations
means, however, that the heat
exchanger is often exposed to uneven
loads. Earlier, we used a gasketed
plate heat exchanger from another
manufacturer, but gasket changes
were both costly and time-consuming.
“The AlfaRex Heat Exchanger is perfect
for this application because of its flexible
construction that easily copes with
pressure and temperature variations.
Another advantage, of course, is that it
is almost completely maintenance-free.
A tube Heat Exchanger might also have
done the job, but it would have taken
up at least ten times as much space”.
“The AlfaRex performs perfectly in spite of
stop-and-go processes, uneven loads and
variations in pressure and temperature.”
Ludger Hentschel, system engineer.
Italy
Reliability and efficiency
Montegrotto is a peaceful region in
the Euganean Hills in north-eastern
Italy, famous for its hot springs. Three
of the most prestigious hotels in the
region, the Neroniane, Commodore
and Marconi, use geothermal water as
their primary source of heating energy.
“We have many different heating appli-
cations ranging from radiators, ventila-
tion, tap water, floor heating and swim-
ming pools,” says Mr. Mario Martelli,
the owner of the three hotels.
A string of applications
At each hotel, geothermal water at
87°C (189°F) from depths down to
800 m is passed through a string
of five different Alfa Laval heat
exchangers, serving a number of
separate applications with a temper-
ature drop at each one.
The first plate heat exchanger transfers
heat from the geothermic water to the
radiator heating system at 75°C (167°F).
The same water then proceeds to a
second plate heat exchanger where
its heat is transferred to the heating
ventilation system at 70°C (158°F).
Tap water requires a lower temperature
of about 65°C (149°F). The heat for
this application is extracted by a third
heat exchanger, after which the water
proceeds to the fourth heat exchanger
where it is transferred to the floor
heating system at a temperature of
40°C (104°F).
Finally, the fifth heat exchanger utilizes
the remaining heat from the geothermal
water for the swimming pool where
a heating temperature of between
30 and 35°C (86 and 95°F) is needed.
High capacity and long life
“We have a total of 20 plate heat
exchangers at the three hotels, in a
number of different sizes and capaci-
ties,” Mr. Martelli explains. “The heat
exchangers employed are mainly
M6 and M6-M models, and plant
capacity at the hotels ranges from
42,000 liters an hour (2,780 kW) at
the Hotel Commodore to 24,000 liters
an hour (1,590 kW) at the Hotel
Neroniane.”
“Our oldest Alfa Laval plate heat
exchanger is more than 20 years old,
and is still working perfectly,” says
Mr. Martelli. “We have never had any
problems and it has never needed
repairs.”
Reliability is the keyword
The three hotels are open 24 hours
a day, 365 days a year. Many guests
start therapeutic treatment as early as
4 o’clock in the morning, while others
are still active late at night. This means
that the three hotels are entirely
dependent on a reliable and efficient
heating system in order to maintain
their high standards of service at all
times.
“Alfa Laval has never failed us,”
Mr. Martelli adds. “The benefits they
offer us are reliability, efficiency, inno-
vation and service. Together with their
local agent, Mr. Piero Bertin, Alfa Laval
provides solutions that address our
specific needs, together with excellent
customer care and after sales service
at all times.”

Staudinger Kraftwerk
in Germany invested
in an all laser-welded
AlfaRex plate heat
“Our mission is to build
exchanger in order
to obtain the neces-
value for our customers by
sary steam quality helping them to optimize
for the turbine as
fast as possible on processes and resources.”
start-up.

14 Alfa Laval Heat Technology