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Gasketed plate heat exchangers ARES and Alfa Laval

Design and Construction

Gasketed plate heat exchangers consist of thin, corrugated stainless steel plates that form channels for fluid flow. Gaskets seal the plates, and the plate pack is compressed between a front and rear frame using tightening bolts. This design ensures high structural rigidity and excellent thermal conductivity. The modular construction allows for easy disassembly, cleaning, and maintenance.

Plate material

The choice of plate material depends on the medium, temperature, and operating conditions. Even drinking water can corrode stainless steel if it contains chlorides, especially at higher temperatures. Common materials include:

• AISI 316L: The standard choice for most applications due to its corrosion resistance.
• AISI 304L: A cost-effective option for low-temperature applications or environments free of chlorides and fluorides.
• SMO 254 (high-molybdenum steel): Offers superior resistance to chlorides and certain chemicals.
• Titanium: Ideal for highly corrosive environments, such as seawater.

Gasket Materials

Gaskets are selected based on the medium and operating temperature:

• EPDM: max. temperature 140–160 °C
• EPDM S: max. temperature 170–190 °C
• NBR: max. temperature 120–140 °C (NBRB 110 °C, NBRP 140 °C)
• VITON/FKM: max. temperature 180–200 °C

For aggressive media, specialized materials are used:

• Sulfuric Acid (H2SO4): Use C276 steel with FKM/Viton gaskets. At low temperatures and concentrations, AISI 316 with EPDM gaskets may suffice.
• Hydrochloric Acid (HCl): Requires C276 steel with FKM/Viton gaskets. For low concentrations, AISI 316 may be adequate.
• Sodium Hydroxide (NaOH): AISI 316 or 316L is suitable for standard temperatures. For higher temperatures or concentrations, use high-nickel/molybdenum steels (e.g., C276, 904L) with EPDM gaskets.
• Mineral Oils: Copper-brazed or AISI 304/316 with NBR gaskets are typically sufficient.
• Salt Water (Sea Water): AISI 304/316 corrodes in saline environments; titanium with EPDM gaskets is required.
• Distilled, Demineralised Water: Known as "hungry" water. Avoid copper-brazed exchangers, as copper dissolves in oxygen-rich or demineralized water. Use "All-stainless" AISI 316 exchangers.

Operating Pressures

Gasketed plate heat exchangers are designed for various pressure ratings: low up to 10 bar, medium pressures PN16, PN25.

Channel Pattern

The common channel patterns are L, M and H.

• L (low theta): the medium flows from port to port through channels with minimal turbulence and lower heat transfer efficiency. Suitable for applications where low pressure drop is required.
• M (medium theta): a compromise between L and H types.
• H (high theta): the medium flows across many obstacles, creating high turbulence, significant pressure drop, and high heat transfer efficiency.

M-type plates are sometimes not manufactured. Instead, H and L plates are alternated (H, L, H, L, …), creating channels with properties similar to M-type plates.

Heat Exchanger Assembly

• Plate arrangement: the assembly begins with a left plate (medium flowing through the left ports). It is followed by a right plate, and these alternate until the final plate (which may be either left or right).
• Gasket installation: gaskets are robotically attached to each plate in a consistent way – all plates are prepared as left plates. They are first snapped into place around the ports, then along the edges of the plate.
• Plate orientation: right plates are created by rotating left plates by 180 ° This ensures that the corrugations of adjacent plates are always oriented in opposite directions.
• Starting plate: in theory, only rings around the ports would be sufficient. However, to ensure even distribution of the gasket and load, a gasket covering the entire plate is used. Two gaskets are used for the starting plate, each cut in half, producing four sealing rings around the ports. The gasket locks are cut off – after rotation, they would not fit the plate and would also interfere with the frame contact. To keep the gasket without locks securely in place, it is glued onto the plate. The web around ports 2 and 3 could remain, but without it the correct plate orientation would be unclear. To avoid confusion, the web is cut out on one side according to the layout.

Notes

• A standard gasket consists of three parts: two around the ports and one for the medium flow. If pressure were to push the medium through the web, the media would not mix – they would drain sideways through the gaps in the gasket.
• NBR/EPDM rubber liner: it also serves as the seal around the port. Therefore, the circular part of the gasket around the port is cut off.

Connection Types

Standard connections include external threads (ISO G 3/4" to 2") for smaller exchangers or flanges (DN50 and larger) for larger systems.

Sizing and Selection

Using specialized software, we design the optimal heat exchanger based on:

• Required thermal output (kW).
• Inlet and outlet temperatures.
• Flow rates.
• Maximum allowable pressure losses.

We supply Sondex (Hang-On) plates and gaskets for Danfoss, Reflex Longtherm heat exchangers.

Performance Overview

The table below provides indicative performance data for ARES gasketed plate heat exchangers at primary circuit temperatures of 90/80 °C90/70 °C and secondary circuit temperatures of 75/85 °C. Contact us for precise calculations and pricing. Approximate prices are in the price list of heat exchangers.

Applications

Gasketed exchangers are ideal for:

• Replacing brazed heat exchangers when frequent cleaning is required.
• Systems requiring scalability (additional plates can be added).
• Industrial cooling applications (e.g., oil or water coolers).
• High-capacity systems (above 500 kW).
• Aggressive media or waters (e.g., chlorinated or saline water).
• Pool heating, especially with saline water (no copper brazing, which corrodes in chlorinated or saline environments).

Installation and Operation

Download the installation and operation manual here.