What is Pillow Plate Heat Exchanger?

What is a Pillow Plate?

Pillow plates are an innovative engineering solution created through an inflation process. This process involves welding two stainless steel or mild steel sheets together over their entire surface using laser or resistance welding techniques. Once the edges of the plates are sealed, except for the connecting ports, hydraulic fluid is used to pressurize the gap between the sheets, causing them to form a distinctive wavy surface with a custom circle weld pattern. This process highlights the advancements in modern technology and engineering.

When it comes to pillow plate technology for exchange panels, there are two main types: single-embossed and double-embossed. Single-embossed pillow plates are typically used as dimple jackets, while double-embossed plates are mostly employed in exchanger units as exchanger plates. These plates are designed with a thicker base panel and a thinner top panel, resulting in the deformation of the top panel while the base panel remains unaffected. This allows manufacturers to easily create specialized exchange panels. Industries striving for maximum efficiency increasingly use these innovative exchangers, which feature "pillow" seam weldings that provide targeted flow guidance within the panels. These weldings are particularly useful in situations where fluid velocity or distribution is a concern, enhancing the performance and efficiency of heat exchangers and reducing costs.

What Are Pillow Plate Heat Exchangers?

As industries seek to optimize their processes, pillow plates are becoming a highly desirable solution. Although relatively new compared to traditional heat exchanger plates, their unique "pillow-shaped" design offers greater flexibility and efficiency in heating and cooling systems for energy exchangers. They can serve as both panel-type heat exchangers and jackets for vessels, making them increasingly popular in the process industry. Pillow plates represent a versatile technology that is transforming various industries. A single or double-inflated panel offers flexibility in design, surface, and mechanical requirements for heating or cooling. Their volume is considerably smaller than comparable tubular exchangers, depending on the weld seam distance and pressure height. With the right expertise, manufacturers can ensure optimal heat transfer solutions for their customers.

How Does a Pillow Plate Heat Exchanger Work?

To prevent damage due to thermal and mechanical expansion, the connecting pipework to the single and double plates must be properly supported. Expansion bends or joints are recommended if not included in the delivery. Connection seams must be welded and checked according to authorized procedures. For transferring large amounts of heat or ensuring uniform temperature distribution inside a tank, it is advisable to install double-profiled panels directly inside the tank. In tanks with agitators, double-inflated panels also act as guide surfaces for the flow, aiding in optimal mixing and homogeneous heating or cooling. Pillow plates offer unmatched reliability and durability in energy transfer equipment. Their hermetic seal withstands pressures over 100 MPa while maintaining structural stability. They can operate at temperatures up to 800°C, making them suitable for demanding industrial processes. Their highly automated manufacturing process adds flexibility, making them ideal for various applications.

Pillow Plate Heat Exchange Panel Welding Contours in Any Shape

Pillow panels are gaining popularity as industries look for new ways to optimize their processes. Their unique "pillow-shaped" design, created by laser welding two sheets, mostly nickel alloys, provides greater flexibility and efficiency in heating and cooling systems. They can serve as both panel-type exchangers and jackets for vessels, making them increasingly used in the process industry. These exchangers represent versatile technology with reduced deposition, customizable to almost any geometry through spot or seam welding for targeted energy transfer. Applications include cooling pipes in thermal processes, battery packs, and electric motors in the automotive industry, and falling film use cases.

Advantages of Pillow Plate Heat Exchangers

1. Customizable Designs: Single and double-side pillow panel exchangers can be tailored in size, shape, and material using a CNC laser welding system.

2. Efficient Space Usage: Small thermoshelf spacing of up to 2mm provides a large exchange surface in a compact area.

3. High Efficiency: Favorable flow routing (counterflow and crossflow) enhances efficiency.

4. Low Pressure Loss: Flat parallel ducts and thin-walled plates reduce pressure loss in the shell space.

5. Reduced Operating Costs: Smaller quantities of cooling or heating medium are needed in the small volumes of pillow-plates.

6. Ease of Cleaning: Flat surfaces make pillow plates easier to clean, even with contaminated media, compared to pipes or mounted panels.

By leveraging these advantages, pillow plates offer an optimal solution for industries looking to enhance their heat transfer processes and reduce operational costs.