Alfa Laval's Integrity Test detects internal leaks, enables smart recycling of brazed heat exchangers

A customer producing biofuel in Belgium faced a potential internal leak in a brazed heat exchanger. The challenge was that these units are fully welded. The team quickly identified the leak, replaced the heat exchanger and even added real financial value by deducting the cost of the recycled metals when the customer purchased new equipment according to the Re-Made to Matter programme.

A Belgium-based international producer of food, agricultural and industrial products contacted Alfa Laval regarding a possible internal leak on one of their brazed heat exchangers. Testing for leaks on these types of heat exchangers has traditionally been difficult as they are fully welded.




Integrity Tests – answers in fifteen minutes
Experts carried out an Alfa Laval Integrity Test on this fully welded unit and confirmed that there was a high level of internal leakage, 1,900 ppm at 5 bar pressure, which meant the equipment needed replacing. Integrity Tests on a heat exchanger take less than 15 minutes per section and are a cost-effective way to efficiently identify leaks, giving a complete picture of the condition of the plate packs in heat exchangers.

A sustainable way to replace heat exchangers
The heat exchanger was replaced by an identical unit. The old unit was recycled in the Re-Made to Matter programme that recovers valuable materials and promotes sustainability. The 8% financial gain from the recycled material was deducted from the purchase price of the replacement unit – a win for the customer and a win for a more circular future.




About the Re-Made to Matter programme
The Re-Made to Matter programme encourages the replacement of less energy-efficient plate heat exchangers with modern products, saving on energy and reducing CO2 emissions in customers’ processes. The programme also recycles and reuses the large amounts of valuable metals in Alfa Laval heat exchangers. Partnering with Stena Recycling, the goal is to recycle and regenerate 100% of the metals in the heat exchangers. The partnership is a first step towards a circular approach to Alfa Laval's product portfolio, and an important part of its commitment to become carbon neutral by 2030.

How Integrity Tests work
A non-toxic, non-flammable mix of hydrogen and nitrogen is pumped through the heat exchanger revealing any micro scopic cracks, corrosion or material fatigue. The precision sensors pick up any discharge of gas and identify the type of flaw – micro-cracks, corrosion, gasket failure and more. With this test, experts detect cracks in the unit’s plates and external leakages on gaskets to evaluate the risk of media cross-contamination.

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