Anatomy and Knowledge

Of Sondex Traditional Plate Heat Exchangers

This compendium contains basic knowledge and a description of the
anatomy of Sondex Traditional plate heat exchangers. It is meant to give
you an overview of the composition and working principle of the plate
heat exchangers, as well as some unique selling points and general
benefits of choosing a Sondex plate heat exchanger. Furthermore, you
will find an outline of the application areas and an explanation of the
importance of perfectly matching the thermal requirements of our
customers’ installations.

On the following page you will find an interactive table of contents with
clickable links that lead to the respective sections of the compendium.

2
Table of Contents

Anatomy of a Plate Heat Exchanger.......................................................................4

Plates.....................................................................................................................6
Main Plate Pattern.................................................................................................8
Gaskets..................................................................................................................9
Sonder Lock Gaskets.............................................................................................10
Sonder Guide Gaskets..........................................................................................10
Traditional Plate Heat Exchangers........................................................................11
Benefits................................................................................................................11
Applications.........................................................................................................13
Technical Specifications........................................................................................15
Working Principle.................................................................................................16
Plate Range That Covers All Duties.......................................................................17
Choosing the Right Heat Exchanger.....................................................................18
Sonder Safe Leakage Protection System..............................................................21

3
Anatomy of a Plate Heat Exchanger

Carrying Bar Column

Plate Pack

Plate Follower

Connections

Head

Tie Bolt

Guiding Bar
Flange Connections

Foundation Feet
A Sondex IS frame
Anatomy of a Sondex plate heat exchanger.

Frame Follower
It is important that the frame is strong, rigid, and durable, as it is The follower is equipped with a big roller, making it easy to
the foundation of any plate heat exchanger. slide the follower back and forth. This makes opening and
closing the plate heat exchanger an easy task, when service and
Sondex frames are designed according to prevalent rules and maintenance must be performed.
legislations and comply with international standards. By default,
our frame designs are developed according to the PED 2014/68/ Optional Features
EU (EN13445) and ASME sec VIII, Div. 1 construction standards. It is possible to install inspection holes that allow for easy
examination of the interior of the plate pack. This is particularly
Our frames are painted with a durable RAL 5010 blue colour, with useful when treating media that contain pulp or fibres, which
more colours available upon request. Several paint classifications have a tendency to cause fouling in the heat exchanger.
are available according to your specifications. Different paint
classifications are suitable for different conditions, such as the Sea water filters can also be installed in the plate heat exchanger.
installation environment or the media itself. This is particularly useful if the plate heat exchanger is going to be
used in the marine/offshore industry, aboard vessels or platforms.
Furthermore, our frames are designed to make assembly, and The filter will catch smaller particles, resulting in longer intervals
service and maintenance as easy as possible. between service and maintenance.

4
Head Plate Pack
By default, we design our plate heat exchangers as single-pass The heart of the plate heat exchanger is the plate pack, where the
solutions with all connections on the head side. heat transfer takes place. The plate pack consists of a number of
plates that feature state-of-the-art plate pattern design.
Having all connections on the head makes service and
maintenance work very easy, as you do not need to dismantle The combination of plate type and pattern determines the
the pipe installation in order to access the interior of the heat efficiency of the heat exchanger, and is calculated to match the
exchanger. thermal requirement of the duty.

The head and the column can be equipped with strong Each plate is fitted with a high-quality gasket, that seals the heat
foundation feet that make it easy to fixate the heat exchanger to exchanger, guides the flow, and aligns the plates.
the rest of the installation.

Connections Tie Bolts

Our Traditional plate heat exchangers have connections that Sondex tie bolts are designed to be tightened from the head side
range from DN25 to DN650 (1" to 26"), with threaded pipes and of the plate heat exchanger. This makes opening, closing, and
flange connections designed according to all standards available, tightening of the heat exchanger easier, as the ratchet spanner
thus eliminating the need for reducers in the piping system. does not need to be manoeuvred along the entire length of each
tie bolt, which significantly reduces labour effort and assembly
Our flange connections can be lined with rubber, or clad in the time.
same material the plates are made from, such as AISI 316 or
titanium, to protect against corrosion damages.

Our connection sizes match any duty, which means that there
is no change in the velocity of the flow during operation. This
reduces the wear and tear of the pipe installation, and means
lower maintenance costs and better, more stable installations.

5
Carrying Bar Guiding Bar
Our carrying bars are designed to be strong enough to prevent The guiding bar is a very important part of the frame that is often
distortion or slumping from the weight of the plate pack - even overlooked when designing the frame. The bar helps prevent
after many years of operation. misalignment, or “snaking” of the plate pack by supporting the
plates during assembly, or when opening the heat exchanger for
Furthermore, the carrying bar is designed to allow the plates to service.
easily slide along the bar. The length of the bar is designed to
provide enough room for cleaning the plates without having to The bar must be designed to be strong enough to withstand the
remove them from the frame. This saves time and money during side load of the powerful tightening forces when assembling the
service of the heat exchanger. heat exchanger.

Additionally, the carrying bar on our IS frames is designed to

allow extraction of a single plate, without having to remove all
the other plates.

Plates
Hanging System

Inlets

Drain Zone

Distribution Area

Heat Transmission Area

and Main Plate Pattern

Gasket

Traditional Plate Free Flow Plate Semi-Welded Plate

Anatomy of Sondex plates.

The plates are commonly made of AISI 304/316 or titanium, but can The choice of plate pattern depends on the type of media that is
also be made from other pressable and exotic materials. The type of treated in the heat exchanger. We offer a large variety of different
material depends on the treated media and their temperatures. plate patterns, from fishbone patterns in varying pressing depths and
angles, to Free Flow patterns that allow media containing particles
The plates form the plate pack, which is held firmly between the head and fibres to pass through the heat exchanger unimpeded.
and the follower of the frame. The corrugated pattern on the plates
ensures a turbulent flow in the entire heat transmission area, and is
designed to eliminate “dead zones”.

6
Heat Transmission Area
The heat transmission area is the “main” part of the plate, and this Distribution Area
is where the primary heat transfer takes place. Our many years of The distribution area on Sondex plates is designed to prevent
experience with thermal design and plate pressing techniques “dead zones”, and features angled guiding channels that ensure
is our greatest strength, and our plate design is based on this an even distribution of the media across the entire plate.
knowledge.
Furthermore, the pressure drop in the distribution area is minimal
Through our expertise we have maximized the heat transmission and is used on the heat transmission area instead, which results
area of each plate. This improves the thermal efficiency of the in better heat transmission efficiency.
entire plate pack in Sondex plate heat exchangers.

The size of the heat transmission area depends, of course, on the

size of the plate.

We have the process knowledge that enables us to develop heat

transmission areas that perfectly match the requirements of
your duty, and deliver a plate size that is optimized for maximum
efficiency in your installation.

Edge Reinforcement
Sondex plates feature reinforced edges in order to strengthen
the gasket groove and provide optimal support for the plates.
The reinforcement is made by pressing the plates on both sides
of the gasket groove, which fixes the gasket securely in place.
Furthermore, this provides a solid foundation for the adjacent
Hanging System plates to rest upon.

Sondex plates feature a unique, reinforced hanging system.

The plate is securely suspended from the carrying bar on the heat
exchanger and is perfectly aligned by the guiding bar.

Furthermore, the reinforced hanging system is very important

during assembly or service of the plate pack, as it helps the
plates withstand the powerful tightening forces, and prevents
misalignment, or “snaking” of the plates.

If the hanging system is not reinforced, there is great risk of the

plate corners collapsing, which will cause the plate pack to leak.
The faulty plate would then have to be replaced.
Gasket Safety
This makes Sondex plates a solid investment, as the lifetime of
the plates is increased and service intervals are reduced. Sondex plates and gaskets are designed with a special “drain
zone” to prevent damage in the unlikely event of a leakage. The
two media cannot mix, as this safety feature forces the media to
leak externally in case of gasket defects, or if the gasket has been
misaligned due to the impact of pressure surges.

7
Main Plate Pattern

A small selection of our available plate patterns.

Pattern Properties Pattern Development and Innovation

Each pattern has different properties, and is developed to handle We constantly improve our plate patterns and develop new technical
specific duties, as well as meet individual requirements. The allowed solutions, as we are determined to provide our customers with quality
pressure drop for the media being treated in the heat exchanger installations, tailored to individual thermal duties, across all market
correlates with the size of the heat exchanger. The sized of the needed segments.
heat transmission area can be reduced if a higher amount of the
pressure drop is used. This makes it important to use the allowed We have many years of experience with pressing tool design, which
pressure drop to the fullest. allows for greater, uniform plate deformation.

Some patterns only use a low pressure drop, but offer a lower level of Our plates feature state-of-the-art plate pattern design and are
turbulence, while others offer high turbulence in exchange for a high developed using the latest pressing technology. This technology
pressure drop. Other patterns have very deep channels, making them allows us to increase the heat transmission area, making better use of
suitable for high-viscosity media and media that cause fouling. Some the plate sheet, meaning that Sondex plates are very efficient, while
patterns combine multiple channel depths in a single plate to handle maintaining their strength.
the flow rate and thermal requirements for different media in a single
heat exchanger.

Having a large variety of patterns for each plate size, as well as an

extensive plate range, guarantees the best possible technical solution
for your specific application of the heat exchanger.

8
Gaskets

In-House Gasket Production Materials

We are proud to have our own in-house gasket production and The quality of a gasket is directly tied to the gasket design and the
testing facilities around the world to ensure an uncompromising materials used in its production. The composition of the rubber
quality of our gaskets. compound not only determines the lifetime of the gasket and its
ability to maintain elasticity, but also its areas of application. Some
The gasket is a very essential part of the plate heat exchangers. gaskets are better suited for aggressive media than others, so it is
Without a proper, high-quality gasket that fits the plate perfectly and important to choose the right gasket for the right duty.
provides tight sealing, the performance and lifetime of the plate heat
exchanger is significantly reduced. Furthermore, the unique design and low compression gives the gasket
a long lifetime. We use an assortment of rubber compounds from
Sondex gaskets are designed and developed according to the latest nitrile, EPDM, and Viton, to chloroprene, Hypalon, and butyl to cover all
standards in rubber technology and gasket design. We provide our possible duties.
customers with gaskets that meet all requirements of the thermal
duty, and are well-suited for the media that are being treated in the
heat exchangers.

The result is superior heat exchangers that perform exceedingly well

due to the perfect interaction between the plate and the gasket.

9
Sonder Lock Gaskets
Sondex Traditional plate heat exchangers are fitted with the unique
Sonder Lock system, which “locks” the plates together and perfectly
aligns the plate packs. The alignment of the plates is possible due to
the strong rubber buttons on the Sonder Lock gaskets that fit perfectly
into the back of the adjacent plate. This keeps the plates in place and
prevents misalignment, or “snaking” of the plate pack.

1: A Sonder Lock rubber button.

2: The buttons lock the plates together. Sonder Lock rubber buttons are evenly spread out across
the gasket, ensuring easy assembly and maintenance.

Sonder Guide Gaskets

Sondex Semi-Welded plate heat exchangers are fitted with the unique
Sonder Guide system that guides the plates together using a closed
gasket groove. This keeps the plates in place and prevents “snaking” of
the plate pack when assembling the heat exchanger.

Furthermore, this gasket design is particularly well-suited for high

working pressures and vacuum applications, as the pressure inside
the gasketed area helps keep the gasket in place. The Sonder Guide
system is used in all our semi-welded plate heat exchangers, as well as
in our condensers and evaporators.

The gaskets guide the plates during assembly. The gaskets

fit perfectly into the empty gasket groove on the back of
each plate, making the process easy and problem free.

The pressure from the flow area of the plate keeps the gasket in place. This
makes this type of gasket well-suited for high-pressure installations.

10
Traditional Plate Heat Exchangers

LARGEST
PLATES IN THE WORLD

BIGGEST
PLATE LENGTHS:
25cm - 5m

SELECTION OF PLATES
CUSTOMIZED SOLUTIONS
CONNECTIONS:
DN25 - DN650
The Sondex Traditional series is a top-of-the-line, single-pass plate
heat exchanger range that can be fully customized to meet your
requirements. We perfectly match the individual thermal requirements
of any duty, and we have developed a plate programme that is
second-to-none.
FLOW VOLUME:
By upgrading to a Sondex product you will receive a service-friendly,
easy-to-install solution that is designed specifically for your thermal 50 l/h -
duty, and provides reliable, unmatched performance while lowering 7,200 m3/h
your energy consumption.

Benefits

Customized Solutions That Match Your Single-Pass Solutions With All

Requirements Connections on the Head
Our large selection of plates, plate patterns, and pressing depths By default, we design all of our plate heat exchangers as single-
enables us to cover all thermal duties with solutions that match pass solutions that have all connections on the head.
the requirements perfectly compared to other plate heat
exchanger designs. Our designs are superior to multi-pass solutions, as we require
fewer plates to perform the thermal duty efficiently. The
The efficiency of an installation depends on how well the heat increased efficiency equals a greatly reduced footprint, and also
exchangers match the thermal requirements of the duty. We means a lower purchase price, as fewer materials are needed to
have specialized in developing a plate range that covers all construct the heat exchanger.
duties and is second to none!
With all connections on the head, maintenance and cleaning of
Sondex design engineers are always in direct contact with our single-pass solutions is also much easier, as opening the plate
customers to ensure that our products match the requirements heat exchangers do not interfere with the pipe installation.
and remain state-of-the-art.
Our heat exchangers are designed to be efficient enough to
The single-pass solution of Sondex heat exchangers is very easy reduce the media volumes needed for operation. This greatly
to further customize and upgrade. diminishes the dangers associated with accidents when
operating with chemical substances.
During an upgrade, no changes need to be made to the pipe
installation due to the accessible design of our single-pass plate
heat exchangers.

11
 Lower Purchase and Operational Costs Localized Service and Maintenance
Available Near You
The plate technology used in Sondex plate heat exchangers
results in a much higher heat transfer coefficient compared Sondex Traditional single-pass plate heat exchangers are
to tubular heat exchangers and other plate heat exchanger designed to have all connections on the head of the heat
designs. exchanger, which is very advantageous during service work, or if
the capacity needs an upgrade.
Consequently, the required heat transmission area is reduced,
which results in less material needed for each plate, thus making We offer service work across the globe from our local Sondex
the heat exchanger less expensive. subsidiaries or through our local, well-educated agents and
partners.
Additionally, the savings on material costs are even greater
when using exotic material types, such as SMO Steel, Hastelloy We provide on-site service work on all brands of plate heat
C-276, titanium or other materials that are required when exchangers, including repairs, leak detection, as well as gasket
treating aggressive media in the heat exchanger. and plate replacement.

Furthermore, high-efficiency plate heat exchangers equal less

energy consumption, which means that the operational costs
are reduced in the long run.

Premium Protection Against Leaks Maximum Turbulence, Less Fouling

Sonder Safe plate heat exchangers offer important measures The right velocity and turbulence greatly reduces the risk of
to minimize damage caused by leaks by preventing the media fouling. This is achieved with the specially designed corrugated
from mixing. fishbone pattern and the right choice of plate heat exchanger
from our extensive range.
In the unlikely event of a leakage, the Sonder Safe plate design
makes the leaks visible from outside the plate heat exchanger. The result is longer intervals between service, more reliable
operation, and reduced maintenance costs.
The single-pass heat exchanger can quickly be disabled for
service and resume operation within a short time frame.

12
Applications

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Our Industry Matrix provides you with a quick overview of the
A a r ir g g a s f r lp a in t r e
HV M Da Su Bio W Re Pu He M Pe Ch

applications of our entire product portfolio, as well as the industries Traditional Plate Heat Exchangers

Sanitary Plate Heat Exchangers

we cover.
Semi-Welded Plate Heat Exchangers

Free Flow Plate Heat Exchangers

All of our products are developed in close cooperation with our Condensers
customers to ensure that we can perfectly match their requirements. Evaporators

Deep Process Knowledge All-Welded Plate Heat Exchangers

SondBlock Heat Exchangers

Having deep process knowledge of the different market segments is Plate & Shell Heat Exchangers

essential for choosing the right plate heat exchanger. Sondex design Spiral Heat Exchangers

engineers are always in direct contact with our customers to ensure Brazed Heat Exchangers

that the requirements of the media are taken into account when Freshwater Distillers

designing the heat exchanger.

Unit Solutions

© Copyright Sondex A/S 2016

We have many years of experience across numerous market segments,

affording us great knowledge and insight into the industrial processes
High-Quality Materials
and their thermal requirements.
The right choice of plate and gasket material is extremely important
Armed with this knowledge, we provide customized heat exchangers for the life time of the entire installation. We offer many high-quality
that perfectly handle each individual thermal duty, across all options for plate and gasket materials depending on the requirements
segments. of the thermal duty to ensure an efficient, lasting solution.

Extensive Plate Portfolio Products for All Applications and Thermal Duties
Sondex plate heat exchangers can be used in a large number of If our Traditional plate heat exchangers are unable to handle a given
applications, as our product range covers all thinkable flow rates, application or thermal duty, the right solution might be one of our
from the lowest to the highest. We are able to cover all thermal other products – each one is specially developed to handle different
requirements with our extensive plate range that includes short plates thermal and process specifications.
for low thermal requirements and long, slim plates for high thermal
requirements. All of our plates are available with different patterns and Use our Industry Matrix to get an overview of all our products, as well
pressing depths for each plate size. as the industries they are suited for.

13
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HV M Da Su Bio W Re Pu He M Pe Ch

Traditional Plate Heat Exchangers

Sanitary Plate Heat Exchangers

Semi-Welded Plate Heat Exchangers

Free Flow Plate Heat Exchangers

Condensers

Evaporators

All-Welded Plate Heat Exchangers

SondBlock Heat Exchangers

Plate & Shell Heat Exchangers

Spiral Heat Exchangers

Brazed Heat Exchangers

Freshwater Distillers

Unit Solutions

© Copyright Sondex A/S 2016

14
Technical Specifications

Frame Gasket Materials

Painted frame, colour RAL 5010. NBR, EPDM and Viton.
(Also available in other colours). Other materials are available on request.
The frame is equipped with tie bolts placed around the edge of Performance Certificates
the frame. AHRI (LLHE)

Design Pressure Construction Standard

0.6/1.0/1.6/2.5/3.0 MPa PED 2014/68/EU (EN13445).
(87/145/232/363/435 psi). ASME sec VIII, Div. 1.
Other design pressures are available on request.
Classification Societies
Connections ABS / BV / CCS
From DN25 up to DN650 (1" up to 26”) flanges in carbon steel, DNV-GL / LRS / NKK
rubber lined, or clad with AISI 316 or titanium. According to all RINA / RMRS / CR
known standards. CSC BPV

Plate Material Extra Equipment

AISI 304/316 and titanium. Safety cover in stainless steel.
Other materials are available on request. Insulating jacket.
Assembling spanner.
Gaskets Foundation feet.
The plates are fitted with the unique Sonder Lock system, which Instrument flange.
“locks” the plates together and perfectly aligns the plate pack. Thermometer and manometer.
The alignment of the plates is possible due to the strong rubber
buttons on the Sonder Lock gasket, that fit perfectly into the
back of the adjacent plate.

15
Working Principle
Behind the Scenes of Plate Heat Exchangers

WARM MEDIA
COLD MEDIA

Working principle of a Sondex Traditional plate heat exchanger.

Heat Transfer
Passing energy from one media to another in order to either heat up
or cool down the media, is the basis of heat transfer. This can be done
by treating the media in a heat exchanger.

Sondex plate heat exchangers use highly efficient flow plates to

achieve the heat transfer, and are superior to tubular heat exchangers
and other plate heat exchanger designs in terms of heat transfer
efficiency, space requirements and ease of maintenance.

Distribution of the Media

The media are circulated in a counter-current flow within the plate
heat exchanger and are introduced into the system via the inlets. From
the inlets, the media cascade through the distribution area which is Distribution area of a plate.
specially designed to eliminate “dead zones” and ensure an optimal,
even distribution of the media across the heat transmission area of the
plates.

Heat Transmission Area

The heat transmission area is the most important part of the plate
when it comes to the heat transfer itself. The warm media transfers
its energy through the plate, to cold media on the opposing side of
the plate. The plates act as “separators” that prevent the media from
mixing.
Heat transmission area of a plate.
Plate Pattern
The media flow through the channels of the pattern that is pressed
into the heat transmission area of each plate. The patterns are available
in numerous types, each with its own unique properties and purpose.
As such, the patterns have great impact on the heat transfer efficiency
of the heat exchanger and must be carefully chosen to accommodate
the specific requirements of each thermal duty.

A small selection of plate patterns.

16
Plate Range That Covers All Duties
Plates In All Sizes

DN25 DN50 DN65 DN100 DN125 DN150

DN200 DN250 DN300 DN350 DN400 DN500 DN650

Sondex offers the largest selection of traditional plate heat exchangers

in the world. We have specialized in developing plate heat exchangers
in close cooperation with our customers. We can perfectly match your
individual requirements because we understand the process behind
your applications.

Using the right plate for each individual duty is very important, as
it greatly impacts the efficiency of the entire installation. Several
aspects define what plate is right, such as the plate pattern, plate and
connection sizes, and plate material.

Plates in All Sizes

Sondex Common
We feature plates with lengths up to 5 m (16.4 ft) and a large number
of different patterns for each heat exchanger type. It is important
Plate Plate
to match the length of the plates and the type of pattern to the Range Range
individual thermal duty - some installations might require small plates,
while others require long plates.

Covering Most Duties

We cover most duties up to 7,200 m3/h (31,700 gpm) in a single-pass
solution. It is beneficial to reduce the number of passes in a plate heat We cover all thermal duties with plates of all sizes - including plates that
exchanger to a single pass, as it improves the efficiency of the heat lie outside the commonly manufactured plate sizes, to ensure that we can
transfer, and reduces the footprint of the heat exchanger. However, perfectly match any thermal requirements.
in order to do this, it is necessary to use plates and connections that
match the size defined by the thermal requirements.

Optimal Solutions
Our extensive plate programme ensures that we can provide the
perfect plate and connection size for any duty. No application is too
small or too big for us - we provide the optimal technical solution
every time.

17
Choosing the Right Heat Exchanger
Why So Many Plates?
∆TA - ∆TB ∆TA - ∆TB Nu = hL / k
LMTD = = gβ ∆TL3

( NTU = UA / Cmin Gr =
Our customers span a large number of market segments that all have
ln
∆TA ( ln ∆TA - ln ∆TB
v2
different process and application requirements. The one thing they all ∆TB
have in common is the need for highly efficient heat exchangers that
match these requirements perfectly.
+ +
There are several key aspects that decide what plate size and what
pattern is the right choice for the duty. One of the most deciding
factors is the temperature profile that the plate heat exchanger is + +
designed for. For this reason the design of the plates is very important.
ƒ = ∆ p / (L / D) (0.5 ρU 2) h Nu Pr = v / α = cp µ / k τw
St = = cƒ=
Thermal Requirement Re = UL / v j = St Pr 2/3 ρ U cp Re Pr c ƒ = τ w / 0.5 ρU 2
0.5 ρU 2

The NTU value (Number of Heat Transfer Units) describes the thermal
requirement of the duty. Generally speaking, the desire to reach a
closer temperature approach results in higher thermal requirements.
NTU (Number of Heat Transfer Units)
In other words, the closer the input and output temperatures have to
be to each other; the more efficient the heat exchanger has to be. =
The efficiency of the heat exchanger is determined by how closely
it matches the thermal requirements of the duty. Higher thermal Warm Temperature In - Warm Temperature Out
requirements need longer plates and lower thermal requirements
need shorter plates.
LMTD (Logarithmic Mean Temperature Difference)

High Thermal Requirement Low Thermal Requirement

100°
100°
50°
T (°C) T (°C)
LMTD 50°
90° LMTD 10°

10° 50°

0° 0°

50
90 NTU = =1
NTU = =9 50
10

100˚

90˚

100˚

50˚

10˚ 50˚
0˚ 0˚

The closer the input and output temperatures of the two media have to be to each other; the longer the plates must be.
18
Number of Passes
Multi-pass solutions are rarely an efficient choice, as they are more
space demanding and require more plates for effective heat transfer.
Our plate range is developed to ensure that we have plates that match
each individual NTU requirement.

Having plates that match the exact NTU value required in a process,
is essential for the efficiency of the plate heat exchanger and enables
us to provide our customers with single-pass solutions that have all
connections on the head of the plate heat exchanger.

When the plates of a solution do not match the thermal requirements

of the duty, you must use more passes within the heat exchanger to
artificially extend the thermal length of the plates.

Hypothetically, a two-pass solution is equivalent to stacking two plate

heat exchangers on top of each other, thus combining the length
of two plates. However, a multi-pass solution needs a much larger
number of plates to achieve the desired output compared to a single-
pass solution that matches the thermal requirements.

The drawback of using more plates is the additional distribution areas

that do not transfer heat as efficiently as the main heat transmission
area. This makes multi-pass solutions inferior to single-pass solutions
by default.
To the left: A multi-pass solution with connections on the follower and the head.
To the right: A single-pass solution with all connections on the head.

Wasted Area

Comparison of the effective heat transmission areas

in a multi-pass solution vs. a single-pass solution.

19
Consequences of Not Having the Right Plates Always the Efficient Choice
Not having the right plate for the thermal duty greatly reduces the We aim to design all our plate heat exchangers as single-pass
efficiency of the plate heat exchanger. solutions, with all connections on the head of the heat exchanger
for easy installation and maintenance. Single-pass solutions are the
For example, if you do not have long, slim plates for a duty with high optimal, preferred choice for almost all duties, both in terms of energy
thermal requirements, the plate heat exchanger must be built as a consumption, but also in regards to the plate material needed.
multi-pass solution to handle the thermal duty.

Another example would be over-dimensioning the heat exchanger.

By not having plates that perfectly match a duty with low thermal
requirements, the purchase price of the plate heat exchanger
becomes much too expensive. The reason for this, is the unnecessary
amount of materials needed for construction. Furthermore, an over-
dimensioned plate heat exchanger is difficult to control, making it
extremely hard to achieve efficient operation in the entire system.

PER
F
MA ECT
TCH

PER
F
MA ECT
TCH

Our plate programme is developed to perfectly match most thermal duties and
our goal is to provide our customers with the optimal technical solution.

20
Sonder Safe Leakage Protection System
Ultimate Safety - Detect Leaks Before They Cause Damage

Sonder Safe Double Plate

WARM MEDIA
COLD MEDIA
LEAKAGE

Sondex Sonder Safe flow. Click to see the full-sized image.

Sondex Sonder Safe plates are the ultimate safety measure. On the
off chance that the plates get damaged, the Sonder Safe system
eliminates the risk of mixing the media being treated in the heat
exchanger.

A Sonder Safe plate is made by pressing two identical plates together

and laser welding all four inlet holes in order to form a “double plate”.
This creates a tiny pocket within each “double plate” that will allow
leaking media to escape. Due to our optimized design, Sonder
Safe plates are able to maintain the high heat transfer efficiency of
conventional plates while providing additional safety.

Leakage Detection
The “double plate” Sonder Safe system is designed to make any
leakage, however unlikely, visible from outside the plate heat
exchanger. This means that leaks caused by corrosion damages or
cracks in the Sonder Safe plates will identify the malfunctioning plates. Sondex Sonder Safe plate.
Consequently, the heat exchanger can be taken out of service until it The “double plate” inlets are welded together.
has been repaired.

Premium Protection
Because all leaks are external instead of internal, the media will never
mix. This makes Sonder Safe plates the ideal solution when the heat
exchangers utilize media that must not be allowed to mix at any cost.

There can be several reasons as to why it is crucial that the media do

not mix: the media may be ruined, they can be hazardous, or pose an
environmental threat.

Additionally, all Sondex plates and gaskets are designed with a special
“drain zone” to further prevent damage in the unlikely event of a
leakage. The two media cannot mix, as this safety feature forces the
media to leak externally in case of gasket defects, or if the gasket has
been misaligned due to the impact of pressure surges.

Drain Zone.
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