Cleaning and temperature control of industrial fluids

Go with the flow

Technology has moved on… Automotive, metalworking, electronics, plastics – whatever yourindustry, service fluids are probably an important part of yourprocess – for lubrication, cleaning, cooling, corrosion preventionor transmission of mechanical motion via hydraulic systems.

For maximum uptime in production and long service life of equipment and fluids, these fluids must be heated, cooled andcleaned efficiently.

During recent years the technology to achieve this has movedsteadily forward. At Alfa Laval, with our extensive know-how in the fields of heat transfer and separation technology, we havebeen the driving force behind this development.

As a result, we have the most reliable, cost-effective equipmentand systems for maintaining your industrial fluids. And the globalparts and service network to back them up.

You can rely on our solutions to ensure maximum uptime andlowest operating costs in your plant. So, consult Alfa Laval and…

Go with the flow.

Heat exchangers for precisetemperature control

Alfa Laval Plate Heat Exchangers come ina variety of materials, sizes and capa-cities – from copper and nickel brazedunits up to large gasketed PHEs withstainless steel or titanium plates. Therange also includes electrical plate heatexchangers, versions with graphite plates

and units for heating water usingindustrial steam. Alfa Laval also suppliesliquid coolers for the production ofindustrial cooling water.

Cooling:

• Hydraulic oil

• Lubrication oil

• Quench oil

• Compressor oil

• Ultra Pure Water (semi-conductors)

Heating:

• Thermocontrollers (plastics)

• Steam heating/generating

• Burners

Process heating for surface treatment:

• Copper plating

• Nickel plating

• Chromium plating

• Zinc plating

• Degreasing

• Anodizing

• Pickling

• Phosphatizing

• Passivating

Efficient cleaning by centrifugal separation

Whatever the application, whatever thefluid to be cleaned, Alfa Laval has acentrifugal separation system that canhandle the job. Small separation systems

that can be integrated into your produc-tion line, compact, trolley mountedseparators that can be wheeled aroundyour plant, large module-mounted separ-ation systems – whatever you need interms of size, capacity and performance,we have it.

Cleaning:

• Hydraulic oil

• Lubrication oil

• Quench oil

• Compressor oil

• Test bed oil

• Cutting, grinding, honing and lapping oil

• Diesel fuel

• Waste oil

• Wash liquid

• Water

• Water-based grinding liquids

• Coolant

• Paint waste

• Ultra Pure Water (semi-conductors)

• Water de-oiling

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Diabon Plate Heat Exchangers

Brazed Heat Exchangers, BHE

Dedicated Oil Coolers, DOC™

Plate Heat Exchangers, PHE

TSM Steam Heater

Platelec® Liquid Coolers

Brazed Heat Exchangers, BHEAlfa Laval BHEs, in copper or nickel, aredesigned to handle pressures from fullvacuum to 30 bar and temperatures from–160°C to +400°C. Although extremelycompact, they offer the same performanceas a shell & tube unit three times as large.

Applications: Cooling of oil, equipmentcooling, process temperature control for a wide range of applications in the manu-facturing industries.

Dedicated Oil Coolers, DOC™The Dedicated Oil Cooler, DOC, is anefficient solution for cooling hydraulic oil.Innovative design, combined with lowpressure drop over the oil inlet and outlet,ensure the highest cooling effect in relationto flow rate on the market today.

Applications: Hydraulic oil cooling andlubrication oil cooling.

Plate Heat Exchangers, PHEIn terms of capacity, Alfa Laval gasketedplate heat exchangers, PHEs, take overwhere the BHE ranges stop. Easy to cleanand requiring very little maintenance, Alfa Laval PHEs can be supplied withcorrosion-resistant titanium plates for usewith aggressive media.

Applications: Cooling of oil, equipmentcooling. Process temperature control for awide range of applications in the manu-facturing industries, including surfacetreatment.

Steam Heaters, TS-MSteam heaters in the TS-M Series arepurpose-built for heating and condensingduties using industrial steam. The uniquegeometry and strength of the stainless

steel plates, the special high-temperaturegaskets and robust frame provide levels ofeconomy, performance and temperaturecontrol unmatched by shell & tube orconventional plate heat exchangers.

Applications: Space and water heatingusing industrial steam.

Diabon Plate Heat ExchangersDiabon, the only graphite plate heatexchanger on the market, utilizes dense,resin impregnated or fluoroplastic encap-sulated graphite plate material. Able tohandle tough steam heating duties andhighly corrosive mixed acids, Diabon opensup new application areas for the PHE.

Applications: Surface treatment, steamheating and cooling of pickling baths,etching of aluminium foils.

Platelec® ElectricalPlate Heat ExchangerIn industries such as plastics, efficientthermal control is crucial to product quality.Offering 100% electrical/thermal efficiency,Platelec® provides immediate heating thatwill give you shorter production cycles andimprove your productivity.

Applications: Thermocontroller in rubberand plastics industry, water heating,lubrication and fuel oil heating, steamgeneration.

Liquid CoolersSuitable for cooling industrial water, LiquidCoolers are equipped with high efficiency,variable speed fans with specially louvredfins. Power consumption and noise levelsare low.

Application: Cooling of industrial water.

AlfaPure Cleaning ModulesAlfaPure is a range of advanced mobilemodules for cleaning oil or water-basedfluids. Each module is a complete systemthat includes a separator and peripheralequipment. Innovative designs ensurehighest separation efficiency with minimumspace and service requirements.

Applications: Cleaning of hydraulic oil,quench oil, lubrication oil, compressor oil,test bed oil, diesel fuel, coolant, wash liquidand oily water.

Alfa Heavy DutyAlfa Heavy Duty is the ideal solution forcleaning heavily contaminated waste andlubrication oil. A complete, static systemmounted on a module, it comprises aseparator and all peripheral equipment.

Applications: Cleaning of waste oil andlubrication oil.

Basket CentrifugesAlfa Laval Basket Centrifuges are anefficient solution for handling paint waste.Installed as painting booth cleaners in theautomotive and other manufacturingindustries, they can reduce waste disposalcosts by up to 85%. Booth water isrecycled. Basket Centrifuges are also aneconomic alternative for cleaning oils andwash liquid.

Applications: Dewatering of paint waste.Cleaning of oils, grinding coolant andphosphatizing liquids.

Emmie Mobile Separation SystemA fully mobile, plug-and-play system,Emmie can be wheeled between oil tanks

in your plant to serve different productionstations. Hooked up to your system,Emmie removes nearly 99% of all particlesin the 2 µm – 5 µm range. Emmie alsoremoves virtually all water, withoutremoving the additives.

Applications: Cleaning of hydraulic oil,lubrication oil, compressor oil, test bed oil,diesel fuel.

Alfie 400 Mobile Separation SystemUsing the same concept as Emmie, Alfieseparates tramp oil, metal fines and solidparticles from your coolants.

Applications: Cleaning of water-basedcoolants and water de-oiling.

Alfie 200 Mobile Separation SystemSpecially designed to remove contaminantsfrom coolant in smaller systems, Alfie 200is a compact unit that is permanentlymounted on the coolant tank.

Application: Cleaning of water-basedcoolant.

DecantersAn efficient solution for dewatering sludgefrom, for example, painting lines, decantersreduce waste to a minimum and the watercan be recirculated. Decanters are alsosuitable for removing sludge from liquids,such as waste oil, prior to cleaning incentrifugal separators, and for variousduties in surface treatment applications.

Applications: Dewatering of paint waste.Removal of sludge from liquids in surfacetreatment and waste oil applications.

AlfaPure Cleaning Module

Emmie Separation System

Alfie 400 Separation System

Alfie 200 Separation System

Decanter

Alfa Heavy Duty Basket Centrifuge

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Surface treatment

Accurate temperature control for French phosphatizing lineSimpson Technipart, near Lyon, France,manufactures vibration absorptioncomponents for the automotive industry.For accurate temperature control in itsnew phosphatizing line, the companychose Alfa Laval plate heat exchangers.

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Part of the global Metaldyne Group,headquartered in Michigan, USA,Simpson Technipart in France has 300employees engaged in the manufactureof rubber dampers, isolation pulleys andother vibration absorption componentsfor the automotive sector. Customersinclude major players such as Renault,Ford and Peugeot.

New phosphatizing lineSome months ago, the workshopinstalled a new phosphatizing line forsurface treatment of the componentsprior to delivery. An Alfa Laval Platelec®

V8 electrical plate heat exchanger withan output of 280 kW was installed as aboiler in the primary heating circuit.

After being heated to 80°C by thePlatelec boiler, the water enters thesecondary circuit incorporating three Alfa Laval M3 FM Plate Heat

Exchangers. These units heat thesolutions in the degreasing, pickling,phosphatizing and rinsing baths.

Compact designs, low maintenance Franck Laramée, the Metaldyne tech-nician responsible for the washing pro-cess, explains that Alfa Laval heatexchange components were chosen fortheir compact designs and low main-tenance requirements. “The Platelectakes up little space and gives uscontinuous efficient performance withlow energy consumption. The conven-tional Alfa Laval Plate Heat Exchangersperform well and are very reliable. Theentire system is operating efficiently.”

Cleaning no problemFranck Laramée is pleased with the low maintenance requirements of the Alfa Laval heat exchangers. “We intendto clean the Platelec once a year as a

preventive measure. For the other plateheat exchangers we have an Alfa LavalCleaning in Place unit that we can movearound the line. We don’t need to dis-mantle the units, so cleaning them is very easy.”

What does Franck Laramée think of Alfa Laval as a supplier? “We get goodservice from Alfa Laval and they give us a fast response. In our business, workingas a sub-supplier to the automotiveindustry, this is essential.”

Franck Laramée, responsible for the washing process: “Alfa Laval plate heat exchangersgive us continuous efficientperformance with low energyconsumption.”

PHEs for surface treatment

Alfa Laval Plate Heat Exchangers aresuitable for controlling processtemperatures in the following surfacetreatment applications: Degreasing,pickling, rinsing, phosphatizing,passivating, anodizing, copper plating,nickel plating.

Imel uses Alfa Laval Plate HeatExchangers as heaters for the chemicaltreatment baths in its plants. Highturbulence over the plate surfacesprovides constant stirring of processfluids and minimizes fouling.

Lucio Grillo: “We choose Alfa Laval Plate Heat Exchangers for their qualityand because they give us no problems.Also, Alfa Laval is a familiar name inmany parts of the world. As a largeamount of our production goes forexport, it is good for our image to haveglobal sub-suppliers.”

Located near Udine, in Northern Italy,Imel SpA is a leading manufacturerand supplier of surface treatmentplants to customers in the manu-facturing industries. The company has40 employees and an annual turnoverof 10 M Euro.

Sales Manager Lucio Grillo has been withImel for 32 years. He explains that Imelhas long experience of surface treatmentplants for spraying or dipping. “Imel hasthe know-how and technology to designplants for all kinds of surface treatment.As well as painting lines we supply plantsfor degreasing, pickling, phosphatizingand other chemical treatments.”

‘Alfa Laval PHEs are an efficient solution’

Part of the global Otefal Group,Otefal Ingegneria is located inCologne, Italy. The companyproduces plants for paintingaluminium coils and profiles,metal plating and anodizing.

Otefal Ingegneria has installed Alfa Laval Plate Heat Exchangers inits plants for many years. ManagingDirector Mr Di Massimo explains thatthey are an efficient solution for con-trolling process temperatures in, forinstance, electrolytic baths and tanksused for metal plating and anodizing.

“Correct process temperatures arevery important to the efficiency of our plants,” says Mr Di Massimo. “Alfa Laval Plate Heat Exchangers do the job and they are reliable.”

Pasquale Vitiello, Alfa Laval Italy,explains that Alfa Laval also suppliesgraphite plate heat exchangers. “OurDiabon PHEs (see photo below) withgraphite plates and corrosion-resistantgaskets can handle virtually all galvanic baths, including the hightemperature types that are extremelycorrosive towards metal plates. Thismakes them the perfect solution forheavy duty anodizing and othertough duties.”

Surface treatment

Surface treatment

‘We choose a quality name’

Imel designs plants for degreasing,pickling, phosphatizing and otherchemical treatment processes. Alfa Laval Plate Heat Exchangersare installed as heaters in thechemical treatment baths.

Plate heat exchangers are an efficientsolution for controlling process temperaturesin surface treatment, metal plating andanodizing plants in the metal-working,automotive and other heavy engineeringindustries.

Compact in design, Alfa Laval Plate HeatExchangers (PHEs) are to a large extent self-cleaning. Tank volumes can be reducedsince, unlike submerged coils, they do notsteal tank space. Alfa Laval PHEs can besimply adapted for new duties by adding or removing plates.

Where correct process temperatures are crucial

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Cleaning service fluids by centrifugal separation

Boosting productivity forthe automotive industryAn increasing number of vehicle manufacturers and theirsuppliers are taking advantage of Alfa Laval’s extensiveapplication know-how in the field of cleaning and maintainingservice fluids. Higher productivity, lower operating costs andthe capability to meet stringent environmental regulations are some of the benefits offered by Alfa Laval.

Plug-and-play systemsAlfa Laval supplies a complete range ofcompact, dedicated, plug-and-playseparation modules for cleaning servicefluids. Many are mobile and can bewheeled from station to station. Theseparators are often installed in bypasssystems. The result is a drastic reductionin filter consumption.

Short payback timesBo Grauers, Regional Sales Manager,Fluids & Utility Equipment, Alfa Laval,explains that although centrifugal separ-ation systems involve a higher initialinvestment, payback times are short.

“Most automotive plants run three-shiftproduction with high service levels for theequipment. With our systems installed,the number of rejects is drastically re-uced, downtime due to failure of serviceliquids is eliminated and productivityincreases.

“A feasibility study conducted by Alfa Laval at one of America’s big threeautomakers showed that by installingcentrifugal separation systems to clean

service fluids, the plant could eliminatenearly all unplanned production stop-pages, reduce overtime and raise prod-uctivity by 30%,” relates Bo Grauers. “Theentire investment would pay for itself injust four months.”

Meeting environmentalstandards

Environmental regulations governingrecycling and disposal of industrial fluidsin factories get tougher every year.

ISO 14000 limits the release of contam-inants into the external environment bystipulating a permitted minimum level ofrecirculation.

Preferred technologyThe design centres of major vehicle manufacturers are increasingly specifying Alfa Laval separators to achieve a higherdegree of recirculation in their coolant and wash liquid systems.

“Using Alfa Laval cleaning systems it ispossible to extend the life of wash liquidsby up to six times,” says Bo Grauers.

Maximum uptime

For the automotive industry worldwide,being competitive means cutting costsand increasing productivity. Vehicle assem-bly plants, engine builders, componentmanufacturers and other suppliers to theindustry all rely on service fluids to keepproduction running smoothly.

When contaminated, coolants, hydraulicoils, lubricating oils and wash liquidscannot fulfill their intended functions. Thismeans headaches for the plant managerin the form of rejects on the productionline, unplanned downtime, and highcosts for fluid disposal and replacement.

Know-how and technologyAlfa Laval offers extensive applicationknow-how in this field. The company’sinnovative technology, based on centri-fugal separation, has proved to be by farthe most efficient method of cleaningindustrial fluids. Compared with compet-ing technologies such as filters, vacuumpurifiers and skimmers, centrifugal separ-ation can extend the life of service fluidsin a plant many times over.

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Uni Boring machines engine blocksand other components for major auto-makers. Service Manager SteveBrodersen remembers the old days.“Problems with the coolant filtrationsystems often meant that someonehad to climb into the system to cleanout the fine solids and oils that hadcoated the filter.”

Since installing Alfie 400 and AlfaPuresystems, Steve Brodersen says he’s rested better at night because Uni Boring now has cleaner coolant.“You can tell the difference inside the machine tools. We’ve had noproblems. That’s the goal.”

One AlfaPure saves USD 145,000By efficiently cleaning the coolant, and thus extending its useful life, one of the AlfaPure modules savesabout USD 145,000 a year, says

Dennis Russ, Uni Boring’s vicepresident of manufacturing.

Tramp oil disposal costs reducedCleaner, longer-lasting coolant extendsthe life of machine tools and cuttingtools and reduces downtime. Thecompany also saves money throughlower costs for tramp oil disposal.

Last year Uni Boring invested in anAlfaPure 2000 wash liquid module forcleaning post-machining wash liquid.Dennis Russ is happy with its perfor-mance. Once each head is bored, itmust be cleaned of any remainingcoolant, oils and shavings. “The watergets dirty quickly in the wash cycle,”he said.

“The Alfa Laval centrifuges haveeliminated some headaches for us.”concludes Steve Brodersen.

Coolant and wash liquid cleaning

Alfa Laval prolongs coolant and tool life at Uni Boring

In the US Alfie 400 and AlfaPure coolant cleaningsystems are saving Uni Boring money by extendingthe life of the coolant, the machine tools and thecutting tools. Uni Boring also spends less on trampoil disposal.

“The life of cutting fluids can be pro-longed indefinitely – losses must bereplaced but it’s not necessary to replacethe liquid completely.”

Recycling means major savingsBy recycling, a large automotive plant innorthern Europe has reduced its annualconsumption of cutting oil by 25 m3 andachieved considerable savings in terms ofoil disposal and replacement costs.

Handling paint wasteAlfa Laval also supplies a centrifugaldecanter system for paint waste. Thepaint sludge is dosed with polymers anddewatered in the decanter. Most of thewater is removed and can be recircula-ted in the system. The paint sludge isreduced to 40-50% dry solids, providinga major reduction in disposal costs.

‘Nonstop performance’Alfa Laval is a global company. Wherevervehicles or components are manufact-ured, Alfa Laval is there, striving to reachits overall goal: “nonstop performance”for automotive customers.

Preventive maintenance plays a key role.Alfa Laval offers comprehensive partsand service agreements covering all Alfa Laval systems in the factory. Theseeliminate the risk of downtime due tofailure of service fluids, providing peaceof mind for plant management personnel.

Global partnerBo Grauers sees a bright future for Alfa Laval as a global partner to theautomotive industry. “Demand for ourcentrifugal separation systems is growingin pace with the introduction of increas-ingly stringent environmental regulationsfor recycling and waste management.The industry knows our products canhandle the job,” he concludes.

Alfa Laval in the automotive industry

Cleaning systems for:• Coolants• Hydraulic oils• Lubrication and other oils• Wash liquid• Paint wastePlate heat exchangers forheating/cooling of service fluids.

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Process Automation International Ltd., PAL, Hong Kong,designs and supplies equipment for manufacturing semi-conductors, printed circuit boards and various electroplatingapplications. PAL has chosen to integrate Alfa Laval PlateHeat Exchangers into its systems since the mid-eighties.Chemical Engineer Peter Young explains why.

With subsidiaries and associated com-panies in key locations throughout theworld, Process Automation InternationalLtd. supplies machines to manufacturersof power chips and high-density printedcircuit boards. These electronic com-ponents are used for everyday applica-tions ranging from vehicle airbags tocomputer disc drives.

Sensitive processFormer PAL employee Peter Young nowhas his own consultancy, ILEX Projects,and works closely with PAL. He empha-sizes that the manufacture of semi-conductors is a highly sensitive process.“Product quality depends to a largeextent on accurate temperature control

of process water and the solution usedto deposit metal on the substrate. “Forthis reason PAL often purchases PHEsfrom Alfa Laval with plates in non-standard steel alloys, supplied withgaskets in chemical-resistant materials.Recently, Alfa Laval has supplied PALwith a large number of M6MFL plate heat exchangers with corrosion-resistanttitanium plates.

Clean plates crucial“Alfa Laval provides good technicalassistance,” says Peter Young. “PALsupplies the chemical specifications forthe process and Alfa Laval recommendsa material for the heat exchanger platesthat will ensure reliability and a long

service lifetime. The plates must also stayclean because any contaminationreduces the heat transfer coefficient.”

The herringbone pattern on the plates inAlfa Laval plate heat exchangers createsa high level of turbulence over the heattransfer surfaces. This in turn ensures ahigh heat transfer coefficient and reducesfouling to a minimum.

Tighter temperature specificationsPeter Young points out that PAL’scustomers and their chemistry providersdemand ever tighter temperaturespecifications. “In the past we usedcooling coils which were not so accurate.Nowadays, you get a high intensity

Production of semi-conductors and printed circuit boards

Accurate temperature control, a crucial factor

process in a small body of liquid, andcontrol parameters are much closer. Thehigh heat transfer coefficient of Alfa LavalPlate Heat Exchangers is very importantin this respect.”

Compact designs importantAnother important factor for PAL is thefootprint of its machines. “You cansupply the best machine in the world butif it takes up too much space no one isgoing to buy it. The compact designs ofAlfa Laval Plate Heat Exchangers allowPAL to integrate them easily into themachines.”

Peter Young says that PAL’s aim is todeliver machines that work. He agreesthat the quality of Alfa Laval equipmentaligns well with PAL’s overall objective: “To strive continuously to provide ourcustomers worldwide with qualitysystems and services that meet orexceed their requirements.”

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PAL – a global operation

Process Automation International Ltd.’s

modern headquarters are located in Hong

Kong. The company’s main manufacturing

operation is situated in a 170,000 sq. ft.

facility in Shenzhen, near Hong Kong.

Other operations include IML, Taiwan, which

builds horizontal processing and handling

equipment, and Beijing Golden PAL, building

plating lines for the northern China market.

PAL has service centres in the USA, the

UK, Singapore/Malaysia, the Philippines,

Thailand, Taiwan, Shanghai and various

cities in China, in addition to the Hong Kong

headquarters.

Customers include: Motorola, Ericsson, IBM,

Hitachi, Via Systems, Multek, Wus PCB.

Alfa Laval PHEs installed in PAL’s semi-conductormanufacturing operation in Shenzhen, near Hong Kong.

Transporting oil in a cold climatecan be tricky. At an oil terminal inKazakhstan, oil heaters incor-porating Alfa Laval Plate HeatExchangers solve the problem.

The problem arises during unloading.At –10°C, oil becomes a stiff, non-fluid medium. This is the case inKazakhstan, where Alfa Laval PlateHeat Exchangers have beeninstalled.

The system was built for the oilterminal by Polarteknik PMC Oy,which designs modular oil heatersfor crude and heavy fuel oil. Theheaters are specially constructed forunloading cold oil from railwaywagons.

Oil heating

Beating the coldin Kazakhstan

For the electronics sector Alfa Laval also supplies:

• Nickel brazed heat exchangers forcooling demineralized water for lasers, x-ray units and computers

• PHEs for cooling ultra-purewater (UPW)

• Separators for cleaning of wash liquid in wafer production

• PHEs for electroplating

Contaminants in the lubrication oil atFundia Dalsbruk steel mill, Finlandwere costing large sums ofmoney in downtime andreplacement oil. Theinstallation of anAlfaPure modulesolved the problem.

Jan-Henrik Sundqvist isresponsible for rolling millmaintenance at FundiaDalsbruk, Finland. Here steelbillets weighing more than 1,400 kg areprocessed into rolls of wire up to severalkilometres in length.

Water and lye in the oilA serious problem at the mill wascontaminants, such as lye, entering theoil which lubricates the gearboxes androllers. “We use lye in the cleaning

system to check the pH values of thewater,” explains Jan-Henrik, “and water

from the cooling systemsplashes into the oil as it

cools the gearboxes.” Thelye enters and contamin-ates the oil system. If notremoved, it quicklydestroys the bearings.

“We have 17,000 litres of oilin circulation which should

normally need replacing aboutevery five years. But the amount ofwater and contaminants in the oil is sohigh that we have had to replace it everytwelve months.”

AlfaPure solved the problemThe solution was an AlfaPure oil cleaningmodule capable of removing water andparticles between 2 µm and 5 µm. “The

system has been running problem-freesince the day it was installed,” says Jan-Henrik. “It runs 24 hours a day andremoves all dirt and water from the oil.”

The separator bowl is a solids retainingtype. It is cleaned on average every twoweeks. “We remove between 400 and700 grams of lye and other contamin-ants. That shows how much lye hasbeen fouling the oil system and destroy-ing the bearings. The savings in time andmoney have been considerable!”

Cleaning of lubricating oil

No more oil contaminationproblems at Fundia Dalsbruk

By using Emmie to cleanthe oil in its hydraulicpump units, Inter-nordisk Spännarmeringhas cut filter consump-tion, and oil disposaland replacement costs.

Typical products for InternordiskSpännarmering are large-scale bridgemodules, which are pressed together byarmoured cables to withstand high loads. The tensioning of the cables isachieved by means of large hydraulicpumps and the company has more than

100 pump units onconstruction sitesthroughout Scandinavia.Years ago, condensationwas a major problem.Hydraulic pump units in

operation outdoors wouldsoon have their oils mixed

with water. Even worse, in lowtemperatures ice would form in the oil.

Dirt particles were another problem. Thecompany had to spend considerablesums on frequent oil filter changes, andwas throwing away large amounts ofcontaminated oil.

Emmie to the rescue!To solve these problems, the companypurchased an Emmie hydraulic oilcleaning system. Emmie is a plug-and-play, trolley mounted centrifugalseparation system that can easily bewheeled from tank to tank.

Emmie removes all dirt particles andreduces the amount of water. A typicalsituation: after cleaning with Emmie forjust one hour, the water content of thehydraulic oil is reduced from 4% to just 58 ppm.

Cleaning of hydraulic oil

Small separator – big contribution!

“The AlfaPure cleaningmodule has been runningproblem-free since theday it was installed,” saysJan-Henrik Sundqvist.

Inaugurated on July 1, 2000,the Øresund Bridge linkingSweden with Denmark is 7.8kilometres in length. The totalvolume of cement usedduring construction was320,000 m3.

P H O T O : B E R T I L H A G B E R G / P R E S S E N S B I L D

Yudigar SA manufactures fittings andshelving made of sheet metal. One of themost important stages in the process iscleaning the fittings prior to painting andfinishing.

The company’s old cleaning system hada capacity of 14,000 litres of wash liquid.The liquid was so full of contaminantsthat it had to be changed every threemonths and transported to a wastewater company for disposal. Also, thecompany did not meet the strict require-ments of the European Union relating todischarge of contaminated water.

Mobile moduleYudigar solved the problem by installingan AlfaPure 2000 mobile separatormodule to clean the water and removethe old oil and sludge. At the same time,cleaning capacity was doubled by instal-ling a second cleaning system with acapacity of 16,000 litres.

Although the total volume of wash liquidin the plant has doubled to 30,000 litres,the AlfaPure module has doubled theservice life of the wash liquid to sixmonths.

Fernando Ibort, head of maintenanceand general installations for the factory:“Our AlfaPure 2000 enables us to complywith ISO 14000 and we no longer pay to have the wash liquid removed fromthe premises.

“The separator is self-cleaning. It flushesthe sludge into one tank and the oil intoanother. In the first year, it removedseven tons of sludge and 2.5 m3 of oil.The oil is sent to an incineration plantand the water is discharged as effluent in the normal manner.”

Two systems in parallelYudigar runs the old and the newwashing systems in parallel. As soon

as the level of contaminants starts torise, the separator is connected to thesystem and run for two days. When it’stime to clean the liquid in the othersystem, the AlfaPure 2000 is simplywheeled from one system to another andplugged in.

“We clean the module once a week and have a maintenance agreement with Alfa Laval for servicing and repairs,”concludes Fernando Ibort.

Cleaning of wash liquid

Twice the volume, double the service life

AlfaPure 2000

• A complete module, simple to install,easy to use.

• Requires less than 1 m2 of floor space.

• Handles tank volumes up to 100 m3.

• Removes all traces of contaminatingoil, grease and solid particles fromwash liquids and coolants.

Fernando Ibort (left), head of maintenance andgeneral installations for the factory: “In the firstyear, the AlfaPure removed seven tons of sludgeand 2.5 m3 of oil!”

Yudigar SA, one of Spain’s largest producers ofshopfittings, solved its problems with contaminatedwash liquids by installing an AlfaPure 2000 module.The AlfaPure has doubled the service life of thewash liquid and saved the company considerablesums in disposal costs.

Barcelona, Spain. Located in Zaragoza, inthe east, Yudigar SA, supplies sheet metalshopfittings to customers throughoutsouthern Europe.

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“I was particularly interested in thefeatures that facilitate the integration ofthe oil cooler with the rest of the hyd-raulic system,” says Benny Jonasson.Managing Director of BEAX Hydraulik,Sweden.

No more damaged connections“For me, the DOC’s most importantfeature is the stainless steel mountingblock brazed onto the cover plate. Withmany conventional BHEs the oil andwater connections can be damaged byapplying too much torque. With DOCunits all connections are made to astainless steel block, that allows a goodspanner grip and high tightening torqueto be applied when installing the unit.”

Vibration minimized Benny Jonasson also appreciates theshelf-type support bracket. “In con-junction with the two tapped holes in the stainless steel mounting block, the bracket can be used to hold theDOC firmly in position on the hydraulicsystem or an adjacent wall. This feature minimizes vibration which cancause metal cracks or splits over thelong term.”

The DOC series also offers optional in-line control of temperature and pres-sure. Nipples brazed onto the back platepermit periodic performance checking,without interrupting operation of theequipment.

Hydraulic oil cooling

DOC™ – developedwith our customers

“A simple yet effective way of savingtime and effort,” points out Benny. “Ifthere are no nipples, it can take us half aday to attach measuring instruments tocheck the performance of the hydraulicsystem. With a DOC unit fitted withnipples we can attach the instrumentsdirectly.”

‘A well thought-out product’“All in all, DOC is a well thought-outproduct and it gives me personalsatisfaction to have contributed to its development.”

The innovative design of the Dedicated Oil Cooler,DOC™, is partly due to Alfa Laval’s close relationshipwith its customers. Benny Jonasson contributed hisexperience of building hydraulic systems to the development of this unique brazed heat exchanger.

Continental Tyres, Gislaved, Sweden produces about 4 million tyres per year, 80%of which are exported. Installing BEAX Hydraulik equipment enabled Continental toachieve a substantial increase in production. Right: Benny Jonasson, ManagingDirector, BEAX Hydraulik, Sweden.

DOC – state-of-the-art oil cooling for:

• Hydraulic and lubrication systems

• Power packs and filter cooling units

• Heavy gears and other transmissionequipment

• Pressing machines

• Compressors

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Steam heating

‘A world-first product’UK-based Spirax Sarco is the world leader in steamtechnology and sales. Its compact steam heater,Easiheat™, is arousing keen interest in the Germanmanufacturing industries. At the heart of the unit isAlfa Laval’s TS6M plate heat exchanger.

Dean Tomlinson, GroupBusiness Manager, HeatExchange Packages,Spirax Sarco, explains

that his company has theknow-how and experience

to add value to Alfa Laval’s heatexchange components.

A world-first product!“Alfa Laval’s TS6M heat exchanger is agood example. It is the only plate heatexchanger designed specifically forsteam use and, as such, is a unique,world-first product. It is the corecomponent of our successful range ofsteam heat exchange packages.

“We have integrated the TS6M withSpirax Sarco steam and condensatecontrol equipment to form a completeunit for the control and efficient use ofsteam. It’s a combination of perfectlymatched components.”

Arousing interest in GermanyEasiheat™ is arousing keen interest in

the German market. KeithG. East, GeneralManager, Spirax SarcoGmbH, Konstanz,

points out that peopleoften underestimate the

role of steam as a heating medium.

“Most manufacturing processes needheat and the most efficient way oftransporting heat around a system is steam.”

He sees Easiheat™ as a breakthrough.“In the past, for steam you used shell &tube heat exchangers. Plate heat ex-changers have traditionally utilized thefluid-to-fluid principle. The TS6M allowsus to compete with shell & tube techno-logy using steam heaters one-third thesize and less expensive.”

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Easiheat™, Spirax Sarco’s compact steam heater, is arousing keen interest.

Water heating using industrial steam

The TS6M from Alfa Laval is the onlyplate heat exchanger designed speci-fically for use with steam. Equipped withheat seal gaskets, the TS6M handlestemperatures up to 180°C.

Based in Cheltenham, England, since1937, Spirax Sarco is the world leader in steam trap technology and sales. The company employs 3,500 people in 35 companies around the world.

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Thermocontroller

Precise temperature controlfor a perfect end-productFor the plastics industry, precise process temperaturecontrol means shorter production cycles, higherproductivity and a perfect end-product. French systembuilder Parmilleux designs and manufactures thermo-controllers incorporating Platelec®, a high-performanceelectrical plate heat exchanger from Alfa Laval.

Configured as a thermocontroller, Plateleccan both heat and cool fluids. It com-prises an electrical block, a channel forthe heat transfer fluid and a channel forthe coolant, one after the other.

100% thermal efficiencySince the turbulent flow in the unit in-creases the heat exchange coefficientand makes it possible to reduce thetemperature of the wall, thermal efficiency is 100%.

A true Alfa Laval partnerParmilleux, with 23 employees, is locat-ed in Vaulx en Velin, near Lyon. Thecompany has incorporated Platelec heatexchangers in its thermocontrollers formore than five years, using the V2 size

with EPDM and Viton gaskets – watercontrolled (90°C and 140°C) and oilcontrolled (180°C).

Precise temperature controlWhy does Parmilleux choose Platelec?Mr. M. Schroeder, General Manager ofParmilleux says: “The very smalltemperature difference between thePlatelec blocks and the fluid to betreated means precise temperaturecontrol and gentle treatment for fluids.”

Compact designPlatelec’s size is another important factor.“Incorporating Platelec, we design com-pact thermocontrollers that can be locatedclose to presses and moulds,” explainsMr. Schroeder. “Also, maintenance is

simple, which is a benefit for our end-customers. The plates can be accessed by removing the tightening bolts.”

Parmilleux also manufactures steamgenerators incorporating the Platelec V8version. “The key factor is high thermalperformance,” concludes Mr. Schroeder.

Mr. M. Schroeder, General Manager ofParmilleux: “Incorporating Platelec, wedesign compact thermocontrollers that canbe located close to presses and moulds.”

Alfa Laval in the plastics industry

• BHE, DOC and PHE for thermocontrollersand mould cooling

• BHE, DOC and PHE for oil cooling inhydraulic presses

• Emmie separators and larger separationmodules for cleaning hydraulic oil

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Sarkuysan Electrolytic Copper and Tradeis one of Europe’s giants in the pro-duction of copper wire. About 110,000tonnes are produced annually in state-of-the-art workshops near Istanbul. Keycomponents are plate heat exchangers,PHEs, from Alfa Laval that continuouslyremove excess heat from the process.

Cooling crucial“Our manufacturing process generateshuge amounts of excess heat, and it iscrucial to cool our production lines in a

reliable, cost-effective way,” says HuseyinGencay, Plant Manager at Sarkuysan.

An annealed wire rod of up to 8 mm indiameter is used in the production ofcopper wire. The wire is then drawnthrough numerous dies, each step re-ducing the cross sectional area by about 20%.

The dies are submerged in a water andoil emulsion, which is circulated throughthe Alfa Laval Plat Heat Exchangers.

Industrial cooling

Efficient process cooling for Turkish wire producerCopper wire producer, Sarkuysan Electrolytic Copper and Trade, Turkey, has 90 Alfa Laval Plate HeatExchangers providing crucial cooling for the company’ssophisticated production process.

This sophisticated production methodenables the wire to be drawn down to0.05 mm in diameter.

Strong local support“We have more than 90 Alfa Laval PHEsin operation today. They are high tech-nology products performing optimally.Combined with strong local technicalsupport, they give us peace of mindwhen it comes to cooling our machineryand thus securing maximum quality,”says Huseyin Gencay.

Plate heat exchangers from Alfa Laval continuously remove excess heat from the process at Sarkuysan, Turkey.

Your partner in Nonstop Performance

As your business partner, we are dedicated to securingNonstop Performance for your operation. We achievethis by offering outstanding service combined withunique knowledge and experience of your process and applications.

It goes without saying that our global parts and service organization provides service, repairs and spare parts around the clock. But for us service has a wider perspective.

Covered by a Performance Agreement, our “full house”of service offerings allows us to tailor an individualservice package that will fit your requirements like aglove. Or we help you choose your solution from ourstandard range.

This advanced customer support concept ensures that your processes run more efficiently. It raises yourcompetitiveness, and it improves your bottom line.

• Genuine Alfa Laval parts at short notice

• Repairs and reconditioning at our Service Centres worldwide

• On-site service

• Preventive maintenance that eliminates unforeseen breakdowns

• Technical advice and trouble-shooting

• Reconditioning service for plate heat exchangers

• Tools, Cleaning Chemicals and Cleaning in Placeequipment

• Personnel training

• Performance Agreements

P H O T O : C O R B I S

Upgrading Consulting Audits Monitoring

Recon-ditioning

Training ExchangeUnits

MaintenanceTools

GenuineSpare Parts Global Network Local Service

Performance Agreement

Alfa Laval’s “full house” of service offerings

P H O T O : B R I A N P O U L S E N

Alfa Laval in briefAlfa Laval is a leading global provider ofspecialized products and engineeringsolutions.

Our equipment, systems and servicesare dedicated to assisting customers in optimizing the performance of theirprocesses. Time and time again. We help them heat, cool, separate andtransport products such as oil, water,chemicals, beverages, foodstuff, starchand pharmaceuticals.

Our worldwide organization worksclosely with customers in almost 100countries to help them stay ahead.

How to contact Alfa LavalContact details for all countries are continually updated on our website. Please visit www.alfalaval.com to access the information.IB

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