MECS® Fully-Welded Plate Heat Exchanger
MECS-ThermoZ™ is among the most energy-efficient air preheating and heat exchanging technologies available for the fertilizer, refining, non-ferrous metals, general chemicals, coal gasification, and other industries. Our customized solutions maximize thermal efficiency and process savings.
The MECS-ThermoZ™ Fully-Welded Plate Heat Exchanger recovers waste heat from hot gas streams, which may otherwise be stack-vented to the atmosphere. Recovered heat is then used within the plant to heat or preheat another gas stream for use in other processes. Plant energy and process efficiency is optimized, for significant savings and improved cost-effectiveness.
Backed by our decades of process experience, dedicated MECS engineers can custom-design and furnish a MECS-ThermoZ™ gas-to-gas solution to meet your organization’s application needs, yielding optimum performance and energy efficiency.
A Modular Design for Robust Performance
All MECS® gas-to-gas heat exchangers — including MECS-ThermoZ™ — feature a compact, modular design and long service life. The units are shop-fabricated to ensure quality, and trucked as individual blocks or complete modules. With their compact size and weight, installation and field setup are much simpler than with conventional shell and tube heat exchangers. And because the MECS-ThermoZ™ Fully-Welded Plate Heat Exchanger has no moving parts, it requires virtually no maintenance.
The MECS-ThermoZ™ Fully-Welded Plate Heat Exchanger is available in both cross-flow and counter-flow configurations. Our modular approach enables us to offer one of the most flexible and efficient flow arrangements available, as well as the flexibility to expand to accommodate future increases in capacity. This modular approach also enables significant design and operational customization, including the freedom to select distinct materials of construction for each heat transfer zone. Each module can be fabricated from a variety of heavy-gauge carbon steel and stainless steel plates, including COR-TEN®, 304L, 316L, and 309S. Heavy-duty MECS-ThermoZ™ units, built with robust materials, can deliver reliable and efficient performance in the most demanding, corrosive, and high-temperature applications, up to 1500°F (816°C).
Thanks to our heavy-duty design, robust fabrication, and the proper selection of construction materials, MECS-ThermoZ™ is delivering highly reliable performance in demanding applications like these:
- Fired heaters
- Air preheating
- Gas coolers
Unique Design Features and Outstanding Efficiency
Our distinctive units feature a unique plate dimple design that achieves outstanding heat transfer efficiency. The MECS-ThermoZ™ Fully-Welded Plate Heat Exchanger consists of a series of stacked, parallel plates that provide a smooth, continuous gas flow path, for minimum air resistance and very low pressure drop. The heat transfer plates are completely seam-welded, to prevent cross-contamination. Spacing is achieved with a combination of raised and depressed conical dimples, which enable a uniform plate pitch and an improved heat transfer coefficient. The height of these dimples can be varied during shop fabrication to establish the desired plate spacing necessary to meet your specific performance parameters. Prior to shipment, each module is leak-tested and rated for 0.05% maximum leakage at the design differential pressure, ensuring straightforward start-up and long service life. The rigid, heavy-duty frame assemblies may be parallel-bundled for additional capacity, and are easy to lift and install.
The MECS-ThermoZ™ Fully-Welded Plate Heat Exchanger design offers additional advantages over conventional exchangers:
- Generous plate clearances allow for ease of inspection
- Ability to inspect and clean both sides of the exchanger
- Outstanding heat exchange efficiency due to plate dimple design
- No tubes to vibrate or to cause acoustic resonance
- Lower surface area requirements than traditional shell and tube heat exchanger designs
- Rigid heavy-duty frame assembly for long service life
Optimum-h™ Technology to Prevent Corrosion
When gas temperatures and dew point conditions require maximum corrosion protection from cold spots, the Optimum-h™ System can raise the minimum metal temperature near condensing applications and allow for less expensive materials of construction. Unlike most other attempts to reduce cold spots in heat exchangers, the Optimum-h™ System does not increase the resistance to heat flow through the gas separation plates, and thus does not reduce the overall effectiveness of the heat exchanger.
INFORMATION & IDEAS
Hydrogen Safety: Sulfuric Acid Today
Feature on hydrogen safety in the sulfuric acid industry in Sulfuric Acid Today by James W. Dougherty, Process Engineer, Mosaic Fertilizer LLC.
Clean Technologies Best Practices Workshop
DuPont hosts an annual Best Practices Workshop highlighting the STRATCO® Alkylation and MECS® Sulfuric Acid Regeneration Technologies. We had a great turnout for our 2014 Best Practices Workshop in September 2014 in Coeur d’Alene, Idaho, USA! Our 2015 Best Practices Workshop is in the planning stages, so be on the lookout for more information!
DynaWave® Application: Cement Kilns
To get more information on improving removal efficiency and protection against corrosion in cement kilns, please read the full bulletin on DynaWave® wet gas scrubber applications.
DynaWave® Reverse Jet Scrubber
Read the short brochure to learn more about the application, features and benefits of using our DynaWave® Reverse Jet Scrubbers.
Zecor® Piping System Information
MECS® ZeCor®-Z piping systems set the leading standard on prevention of leaks. The ultra-low corrosion rate of ZeCor-Z results in reduced maintenance costs. Read the brochure to learn more.
MECS® UniFlo® Technical Bulletin
Read the MECS® UniFlo® acid distributor technical bulletin to learn more about the uses and benefits of our ZeCor®-Z and ZeCor®-310M corrosion-resistant family of alloys in this application.
Acid Coolers Technical Brochure
Download the MECS® engineered alloy products technical bulletin to get more information on the benefits and uses of our innovative FilmGARD®-5 Anodic Protection System offering.
ZeCor® Alloy Packing Brochure
Read the product and offering brochure to learn more about the features and benefits of using our ZeCor® Alloy packing support system.
ZeCor® Alloy Brochure
Download the ZeCor® Alloy technical bulletin to get more information on the benefits and uses of our corrosion-resistant and high-performance metals.
Mild hydrocracking is catalytic cracking in the presence of hydrogen and operating at ‘mild’ hydrogen partial pressures. IsoTherming® technology limits the temperature rise across the reactor to minimize undesirable side reactions.
IsoTherming® for Diesel Hydrotreaters
Read the DuPont Sustainable Solutions (DSS) article on revamping diesel hydrotreaters with IsoTherming® clean fuel technology.
IsoTherming® Clean Fuel Technology
Read the DuPont Sustainable Solutions (DSS) brochure on IsoTherming® hydroprocessing technology for cleaner fuel.
USES AND APPLICATIONS
MECS® Brink® Packaged Mist Elimination Systems
Discover how our mist elimination systems meet emission regulations in fuming acid, organic, asphalt and metalworking mist and oil smoke applications.
Brink® TowerGARD® Mesh Pads
See how TowerGARD® Mesh Pads from MECS® yield 50% turndown ratios or higher for sulfuric acid plants, significantly boosting corrosion resistance.
- MECS® UniFlo® Acid Distributors for Sulfuric Acid Plants
- MECS® WavePak™ Tower Packing for Sulfuric Acid Plants
- Process Hazard and Consequence Analysis PSM Workshop
DUPONT PRODUCTS & SERVICES
- MECS® Sulfuric Acid and Environmental Technologies
DuPont Operator Training Simulators (OTS)
We combine our technical expertise and owner/operator experience with our world-class safety culture to deliver a high-impact training program for your operators and engineers. By leveraging the power of DuPont’s high-fidelity dynamic process simulators students learn valuable troubleshooting and response skills in a realistic environment that models “cause and effect” relationships across the entire.