Metalforms, Inc. - ROD baffle Technology

Rod Baffle Technology

Metalforms has been an industry leader in the application, design and fabrication of exchangers utilizing Phillips Petroleum Rod Baffle Technology, having been licensed by Phillips for fifteen years to provide this product and service. Please read the following information on Rod Baffle technology and see if it's right for you.

Plate Baffle Example Rod Baffle Example

The Rod Baffle heat exchanger concept was conceived by Phillips engineers as a means of eliminating destructive, flow-induced tube vibrations which existed in three conventional, double-segmental, plate-baffle heat exchangers at a Butadiene Plant in Borger, Texas. Although originally designed to solve tube vibration problems, Rod Baffle exchangers are increasingly being used to enhance thermal-hydraulic performance, improve flow field uniformity, reduce shell side fouling deposition, and increase critical process reliability. The Rod baffle design provides more
effective shell-side turbulence at a lower pressure drop compared to a conventional segmented baffle design.

Since licensing of Rod Baffle technology was begun in 1978, over 2,000 Rod Baffle heat exchangers with a market value of over $150,000,000 have been placed in commercial service. Rod Baffle exchangers have been utilized worldwide by over 50 major petrochemical companies in all phases of upstream and downstream operations.

Commercial Rod Baffle exchangers have been fabricated in a wide range of sizes, with shell diameters ranging from 12 inches (305 mm) to 180 inches (4572 mm) and tube lengths extending to 80 feet (24.4 m). Rod Baffle exchangers have been manufactured in a wide variety of shell and tube sheet configurations, using all common materials of construction, and utilizing both bare and low-finned tubes.

Rod Baffle Technology

The flow dynamics through the shell side of the Rod Baffle exchanger illustrate that there are no stagnation areas so the entire heat-transfer area is effective. The alternating rods provide positive 4-point confinement of the tube to eliminate tube vibration and possible tube failure. The improved flow dynamics also result in lower pressure drop, low fouling and easier cleaning.

Elimination of Tube Vibration Failure

The Rod Baffle bundle is vibration free, and features two major design innovations:
(1) Positive 4-point containment of the tubes, and
(2) Minimum, Convex Point contact between rods and tubes.
These innovations eliminate tube vibration failures, providing a high integrity bundle for longer on-stream performance.

Rod Baffles - Metalforms Inc.

Energy Savings

The uniform, free-flowing turbulence created by tube-support rods absorbs very little energy, minimizing pressure drop across the shell side of the exchanger. The pressure drop through a Rod Baffle exchanger can be 50% less than the pressure drop through a typical plate baffle exchanger. When used in compression services, the lower pressure drop in the Rod Baffle exchanger requires less energy, resulting in major dollar savings.

Rod baffle Uniform Flow Pattern - Metalforms Inc.
Plate Baffle Flow Reversal Pattern

Improved On-Stream Performance

The Rod Baffle concept eliminates dead or low flow areas in the bundle, making 100% of the heat transfer area effective. The absence of low flow areas minimizes fouling, resulting in longer on-stream performance, less maintenance and faster cleaning, with substantial reductions in costly labor and downtime.

Design and Construction Flexibility

In many applications, when compared to a plate baffled bundle, the Rod Baffle bundle will provide the required duty at a lower pressure drop with a smaller diameter exchanger which reduces weight and cost. When additional exchanger capacity is required, a Rod Baffle replacement bundle will often yield an increase in throughput of up to 30%. This may eliminate the need for additional exchangers and related design/installation costs.

Proven Performance

There are over 2,000 Rod Baffle heat exchangers of varying sizes and types, on-stream in a multitude of petroleum and petrochemical processing operations. Twenty years of day-to-day operating experience has provided in-plant verification of the operating characteristics and benefits of the Rod Baffle design.

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