Surface/Volume Ratio > 1000ft2/ft3
Compact Footprint for Process Intensification
Higher Energy Efficiency Resulting in Lower OpEx and CapEX
Customized Flow Passages for Optimal Performance
Numerous Channel Designs with Scalable Width and Height
Multiple Layers - Core Blocks - Assemblies
High Temperature and Pressure Applications
Experienced Manufacturing Partner: Robinson Metal
FinRex®: Brazed Plate Fin Technology
ShimRex®: Diffusion Bonded Technology
The CompRex compact heat exchangers and compact heat exchange reactors can be manufactured using any of a number of manufacturing methods, the most common two being Metal Brazing and Diffusion Bonding.
Brazed Plate-Fin Technology
Each fluid layer is constructed out of pressed metal sheets forming the plate-fin design. A partition sheet is placed between each layer, resulting in a separation between the process and utility streams. This alternating structure between the streams is repeated, resulting in short heat path distances and sufficient surface area for heat transfer to occur.
Brazed material is integrated into the unit and serves to hold the CompRex unit together after curing the unit in a braze furnace.
The dimensions and materials for the fins for each stream is custom picked to provide the strength and heat transfer properties required for the application.Fins can be designed from a variety of shape options such as straight, serrated, and wavy fins; each shape having its own set of properties of heat transfer and pressure drop.
Straight fins are especially useful for reactors where catalyst packing is required.Small catalyst particles are packed into the channels, converting the CompRex unit into a Fixed Bed Compact Heat Exchange Reactor.Such a reactor has the ease of operation of a shell-and-tube reactor, but with a superior heat transfer coefficient that allows it to be used in applications where S&T reactors had failed.
Diffusion Bonded Technology
Another manufacturing method used for CompRex reactors and heat exchangers is diffusion bonding, where high temperature and pressure are used to fuse the reactor parts into one extra strong single-piece reactor block.
Thin sheets of metal are chemically etched to produce custom designed intricate and precise dimensioned channels.These sheets of metal are then stacked to produce a single stream layer.Layers of different streams are separated by a thin solid sheet of metal.All the sheets of the reactor are properly stacked before being placed into a high temperature furnace.With sufficient pressure applied to the layers, the metal of the separate sheets are fused together, producing a reactor made of a single metal block.This reactor can be designed to withstand extreme operational temperatures and pressures that most other heat-exchange reactors cannot withstand.
The flexible design of each sheet of metal allows for a wide flexibility in the reactor performance, including highly tortuous flow patterns to improve mass and heat transfer, intermittent injection of reactants or fluid catalyst at multiple points within the reactor block, and incorporation of other features into the reactor such as metal membranes.