Refinery FAQ

Below you will find a number of common questions along with answers from Alfa Laval’s experts. Don’t see your question here? Contact us to get a personal response from our experienced team.

General questions

Questions about Compablocs​

Questions about Spiral heat exchangers

Questions about Packinox

Questions about OLMI Process shell and tube Heat exchangers

Questions about OLMI Finned tube air Heat exchangers

1. What solutions does Alfa Laval offer for crude oil refineries?

Alfa Laval provides a wide range of solutions aimed at improving profitability, reliability, and product quality in crude oil refineries. These include high-efficiency heat exchangers, separation technologies, and process optimization services.​

2. How can Alfa Laval's solutions help improve refinery operations?

Alfa Laval's solutions can increase capacity, improve product yield and quality, reduce CAPEX, maximize energy efficiency, reduce emissions, and lower water requirements. They also enhance reliability and increase uptime.​

3. What types of refinery processes does Alfa Laval support? Alfa Laval supports various refinery processes, including:​

Atmospheric distillation ​

Vacuum distillation ​

Crude oil desalting ​

Naphtha & kero hydrotreatment ​

Catalytic reforming ​

Isomerization ​

Diesel hydrotreatment ​

Fluid catalytic cracking ​

4. How can Alfa Laval assist with process optimization in refineries?

Alfa Laval leverages its extensive experience with high-efficiency exchangers to optimize process design. Early involvement in projects can improve economics, increase the chances of project approval, avoid expensive redesigns, and speed up implementation.

5. What are some examples of Alfa Laval's successful implementations in refineries?

Alfa Laval has delivered over 10,000 units to various refinery processes worldwide. The solutions have been implemented in numerous refineries, providing benefits such as reduced energy consumption, lower CO₂ emissions, and increased production capacity.

1. What determines the right size for a Compabloc heat exchanger?​

The sizing depends on allowed pressure drops, approach temperature, and plate material—not just thermal duty in kW—especially since many duties involve low NTU (number of transfer units) ​

2. How does Compabloc compare to traditional shell‑and‑tube exchangers?​

Compabloc offers higher heat transfer efficiency, lower fouling, and a compact footprint—thanks to corrugated plates that increase turbulence and thermal performance ​

3. What materials and plating configurations are available for Compabloc?​

You can select from materials like stainless steel, titanium, and high alloys. Plate patterns and materials are customized based on corrosion resistance and thermal requirements.​

4. What gives Compabloc the edge in severe fouling crude pre‑heat duties?​

With its aggressively corrugated plates and high‑velocity flow paths, Compabloc effortlessly processes heavy, fouling feeds; think atmospheric bottoms or vacuum residues, eliminating the stagnant pockets and flow bottlenecks ​

5. Really interested in meeting your refinery’s decarbonization targets? Then go for a pilot sooner. ​

A real case, by replacing shell‑and‑tube preheaters with two Compabloc units, Petronas Kerteh Refinery squeezed an extra 0.0051 GJ of heat per barrel, a 9.2 % energy saving. That shift prevents 8,000 tonnes of CO₂ emissions annually, enough clean heat to power a small town. ​

Learn more about Compablocs

1. How does the self-cleaning effect work?​

SHEs use single-channel geometry: if fouling occurs, the channel narrows, increasing fluid velocity and scouring away deposits—this is Alfa Laval’s patented SelfClean™ design ​

2. Which applications are ideal for spiral heat exchangers?​

They excel in handling sludges, emulsions, slurries, fibers, particle‑laden or viscous media. Common industries include oil refining, pulp & paper, petrochemicals, wastewater treatment, and vegetable oil refining (industry specific)​

3. What design features let a Spiral exchanger hold a tight 2 °C approach when heating high‑salinity desalter wash‑water?​

Spiral’s self‑cleaning 1–1.5 mm channels force high‑velocity centrifugal flow to purge salt deposits; its counter‑current floe configuration and corrosion‑resistant alloys then lock in a 2 °C approach at high salinities.​

4. What design types and flow configurations are available?​

Key models include SpiralPro (liquid–liquid) and SpiralCond (condensing/vapor duties). Flow can be counter-current, cross‑flow, or mixed—specialized versions handle vapors, condensate, or vacuum applications ​

5. What sizes and thermal capacities are typical?​

Alfa Laval Spiral can withstand up to 125 barg as max design pressure (depending of T design and of material and of Spiral model). ​

It can also reach a max design temperature = 550°C (depending of T design and of material and of Spiral model), and range from 1 m² to 2,000 m²

Learn more about spiral heat exchangers

1. What efficiency boost and decarbonization impact did Packinox deliver compared to shell‑and‑tube heat exchanger?​

Packinox utilizes a fully welded plate pack inside a pressure shell. The counter‑current flow through corrugated plates enables thermal efficiency above 95% and hot approach temperatures as low as ~25 °C, while drastically reducing utility use and CO₂ emissions.​

In real case, replacing seven shell‑and‑tube units with a Packinox feed/effluent and stripper‑bottoms exchanger cut charge‑heater duty by 80% (18 MW) and compressor load by 41% (1.5 MW), saving US$ 3.3 million per year and 48 t/day of fuel gas.​

2. Can Packinox handle multiple streams and asymmetric flow conditions?​

Yes. With FlexFlow and multi-stream configurations, Packinox + supports optimized channel gaps for different fluids, enabling efficient handling of asymmetrical flow duties like feed/recycle gas and effluent streams​

3. What pressure and temperature conditions can Packinox withstand?​

The plate bundle operates at differential pressures up to ~70 bar, with total vessel design pressures reaching 100–140 bar. Typical operating temperatures go up to 550 °C (with some units reaching 650 °C), ideal for demanding refinery and chemical service ​

4. How does Packinox master the toughest paraffin dehydrogenation challenges like low ΔP, two‑phase flow and catalyst fines?​

Its fully‑welded, low‑resistance plate pack uses patented spray‑bars to ensure uniform, counter‑current two‑phase distribution, while generous 5 mm channel gaps let catalyst fines pass harmlessly, delivering minimal pressure drop and trouble‑free operation without the overdesign shell‑and‑tube rigs need.​

5. Does Packinox offer active process control and digital monitoring?​

Yes. The Lifting Controller (in feed/recycle duties) optimizes flow conditions to prevent liquid hold-up, while Packinox Performa (ALOnline) provides real-time monitoring and diagnostics. Onsite support is available via Alfa Laval’s global services network​

6. Can Packinox be cleaned during operation?​

Yes, Packinox heat exchangers can be cleaned during operation. The PlateWash system removes any fouling as soon as it starts to accumulate, all while the plant is in operation. No need for cleaning stops. This online cleaning capability is particularly valuable in refinery applications like hydrodesulfurization (HDS) units where Packinox heat exchangers are commonly used, as it helps maximize plant uptime and maintain consistent performance throughout the operating cycle.​

7. How did cutting pressure drop in Shell’s Berre‑l’Étang Packinox retrofit drive payback and performance? ​

Replacing 12 shell and tube exchangers with one Packinox slashed ΔP from 4 bar to 1.5 bar, boosted capacity by 33% and tightened hot‑side approach from 60 °C to 25 °C, delivering €4.3 million in annual savings and a 12‑month payback.

Learn more about Packinox

1. What sets Alfa Laval Olmi exchangers apart in demanding process applications?​

Each unit is fully custom-engineered for your specific duty—pressure, temperature, corrosion, fouling—and built using advanced thermal design and exotic metallurgy. This ensures maximum reliability, high energy recovery, and minimal service needs in critical petrochemical, refinery, and power applications ​

2. What operating ranges do Olmi exchangers cover?​

They are engineered to handle temperatures from –150 °C to over 1,000 °C, and pressures from vacuum to ~300 bar (4,350 psi)—covering applications like feed/effluent preheaters, hydrotreating, hydrocracking, and quench duties ​

3. What materials are available for challenging chemistries?​

Olmi exchangers offer a wide range of materials—carbon and stainless steel, duplex, titanium, zirconium, high-nickel alloys, and copper alloys—selected by Alfa Laval’s metallurgy experts to optimize long-term cost and corrosion performance ​

4. How does Alfa Laval ensure weld and structural quality?​

All units undergo rigorous NDE testing—ultrasonic, X-ray/gamma, hydrostatic, helium leak, and dye penetrant inspections. Welding teams are EN and ASME certified to meet the highest standards ​

5. What innovations enhance durability under erosion and thermal stress?​

Olmi’s OptiForm tubesheet design places weld joints in the cooling medium, protects against erosion, and includes Inconel overlay plating. Their quench exchangers use a ProShield inlet, reducing coke damage, thermal fatigue, and deposit build-up in ethylene plants.​

6. What service and lifecycle support does Alfa Laval provide?​

Services include commissioning, audits, repairs/refurbishment, materials supply, testing, operator training, and upgrade solutions—even for non‑Alfa Laval equipment. The global ALOnsite network provides fast access to qualified support and spare parts

Learn more about OLMI Shell and Tube Heat Exchangers

1. How are Olmi air‑cooled heat exchangers customized for different applications?​

Olmi units are engineered‑to‑order to meet specific process requirements—matching temperature, pressure, ambient conditions, flow capacity, and materials (e.g. carbon steel, stainless, duplex, nickel alloys, titanium)—ensuring reliable performance with low CAPEX and OPEX ​

2. What temperature and pressure ranges do Olmi air coolers support?​

Olmi air‑cooled units can handle up to 400 °C and pressures as high as 613–700 bar, meeting stringent industry requirements like API 661 ​

3. What design configurations are available?​

Models like Olmi Model G (modular), ACE API 661 (engineered-to-order), and other variants support vertical, horizontal, or sloped tube sections, forced-draft or induced-draft fans, and 1–5 fan setups—all configurable to site layout and service requirements. ​

4. What thermal performance enhancements do Olmi units offer?​

The HyperFin slitted fin design breaks up stagnant airflow layers, boosting heat transfer efficiency while keeping pressure drop and fan power low—leading to a smaller footprint and reduced operating costs ​

5. Which draft configurations are supported, and what are their trade‑offs?​

Forced‑draft: Fans push air before tubes—benefiting from cooler inlet air, longer fan life, and lower energy use.​

Induced‑draft: Fans pull air after exiting tubes—promoting even airflow distribution and reducing exhaust recirculation risk ​

6. How does Alfa Laval ensure quality and maintainability in Olmi units?​

Units feature header box designs with SealTight leak protection, modular construction (e.g. Olmi Model G) for easy transport and installation, full pre‑assembly, adherence to API 661 standards, and ULN compliance where needed. ​

7. What additional features improve reliability and operation?​

Optional enhancements include Vspeed variable-frequency fan drives for optimized power use, HybridCool technology for wetlands/dry hybrid cooling with minimal water use, winterization louvers, low-noise fans with dampening panels, and vibration-resistant design with spectral analysis testing​

8. Who supports Olmi air-coolers over their service life?​

Alfa Laval provides full lifecycle support—including engineering, fabrication, installation supervision, maintenance, spare parts, upgrades, and field services—through its global ALOnsite network and field service engineers

Learn more about Finned tube air heat exchangers