Laser-welded dimple jacket integrated into process or bulk tanks
As laser-welded dimple jacket supplier with a customized experience in heat transfer calculations for more than a 100 years, we are mainly specialized in the manufacturing of dimple jacketed tanks and reactor plates for process or storage tanks and pressure vessels. Thermal heat exchange surfaces are utilized on vessels for controlling temperature and quality of the contents of the vessel. Heat exchange surfaces can be designed either for heating or cooling. Jacketed vessels are used in many industries and can be used to remove the elevated heat of reaction (heat reactor vessel) or reduce the viscosity of high viscous fluids.
Most noteworthy there is no more homogeneous tempering than demonstrably formed by a complete enclosure of the product with an entire heat transfer surface as dimple jacket. In comparison to compact external thermal heat exchangers, favorable temperature differences result in a significantly better efficiency. At the same time, the products, especially beverages, are treated very gently. Laser-welded dimple jackets are mainly used as process tank plates such as for milk tanks, wine tanks, beer tanks, reactor vessels and pharmaceutical tanks.
The large dimple jacketed surface ensures safe process control with controlled homogeneous temperature control. As result, the dimple jacket design as tank cooling jacket allows the temperature control of products during other process steps. This saves a separate thermal process stage and often increases productivity and product quality. Manufactured tanks out of laser-welded dimple jackets have also less weight, because of less stainless steel material. Tanks can be manufactured cheaper by even higher product quality.
Laser-welded dimple jacket method of operation
Single embossed laser-welded dimple jackets are made of two metal sheets of different thickness welded together by using laser or resistance welding. By a special inflation process, fluid channels are created between the metal sheets . Together with the fittings (e.g. pipes with welded ends, flanges or threaded socket ends) these channels form a pressure chamber, through which a fluid will pass to transfer heat transfer to/from the room enclosing the Single embossed laser-welded dimple jacket. If the Laser-welded dimple jacket enclosing chamber is also a pressure chamber (vacuum or pressure > 0,5 bar above ambient) this has been considered in the design.
Single embossed laser-welded dimple jackets are integrated into process tank cooling and heating steps. Individual design in measurement, shape and material allow flexible use in numerous industries and extend the normal standard. Single embossed laser-welded dimple jackets may be rolled to a cylindrical half-jacket and be clamped on to existing tanks retroactively or being welded to rings to build a tank.
Laser-welded dimple jacket advantages in comparison to half pipe or double wall manufacturing of process tanks
Especially for the price comparison of the three alternatives, double shell should not be discussed futher, because of too high wall thicknesses compared to competitive pricing. Pricewise, a half pipe welded process tank can be more than double as expensive compared to the laser-welded dimple jacket execution. Main price impacts for higher manufacturing prices with half pipes are higher wall thicknesses and welding times of the half pipes.
Assembly of Laser-welded dimple jackets
Laser-welded dimple jacket heat exchange plates have been designed, built and tested as a pressure equipment. They are supplied with a works certificate or if required by the European Pressure Equipment Directive 97/23/EC are certified by CE labelling and a declaration of conformity. If agreed additional certificates can be issued. Details about the design, dimensions connections and authorised operational conditions are part of our delivery content.
Connection to process of Laser-welded dimple jackets
Connection seams that have to be welded to the connections have to be carried out and checked in accordance with valid and authorised welding procedures.
The fluid connection to the aser-welded dimple jacket is either by flanges, welding nozzles or screw pipe connections. Please note that the projected flow direction for the heat transfer fluid has to be adhered to. In case of screw connections these should be re-tightened during operational conditions after a certain operational period. The heat exchange plates do not have any electric connection. During the operation of the laser-welded dimple jacket with liquids a venting facility for the plates, preferably above the upper piping, should be arranged, if the order related design does not include such a possibility. As per operation of the laser-welded dimple jacket with refrigerants an oil removal device should be installed via the lower pipe, if the refrigeration process makes this necessary and if the order related design of the plates had not considered such specification.
Laser-welded dimple jacket advantages
- No expensive double shell or half pipe construction.
- Less weight than half pipes.
- No surface damage on the inside of the tank due to the laser-welding process.
- No cost effective grinding or polishing of the tank inside.
- Homogenious and conciliatory tempering of products
Long lifetime due to individually choosen materials
Any design possible according to application criteria or demand.
Kind of weldings free programmable. Cut-outs for pipes, legs. etc.
Integration into vessels for mechanical and thermal doublefunction
Laser-welded dimple jacket technical data
- Sizes up to 14000 x 2000 mm
Cylinders made of one piece: diameter from 600 – 3800 mm
For conical, as well as for elliptical vessel heads
- Up to 50 bar operating pressure
- Wall thickness 0.8 – 1.5 mm with dimpled plates on the outer side
- Up to 12 mm groundplate with single embossed dimple plate profile on the inner side
Laser-welded dimple jacket specifications
- As a dimple jacket design for water, glycol, thermal oil or steam inside the dimple jacket
- As tank cooling dimple jacket in form of dimple plates for all refrigerants
used as pump- or gravity- or dry expansion system.
Channel design according to individual calculation by experienced engineers.
Carbon steel or stainless steel as: AISI 304, AISI 316L, AISI 316Ti up to titanium.
- Surfaces: stained, ground, polished
- Certificates according to TÜV , PED , TR CU (GOST) and ASME
Laser-welded dimple jacket applications and benefits
- Homogenious tempering of liquids in process tanks such as in milk tanks, wine tanks, beer tanks, reactor vessels and pharmaceutical tanks.
For over 50 years BUCO tank plates and pressure vessel walls.