Following a call with the team and a briefing to describe what was required, our engineering team got together to design a solution. Time was critical and we quickly realised the solution had to use readily available piping components to build the elevator autoclave.

The AC75 elevators connect to the bottom of the rudder at the back of the boat.  They control the boat pitch and need to be really strong, so they’re made from a fast curing pre-impregnated carbon fibre laminate. The autoclave increases both the temperature and pressure during the carbon fibre curing process.  The result is that the consolidated laminates ensure the highest quality and strongest uniform elevator blades.

Our specialty autoclave design called for a cylinder with flanged, removable covers for ease of operator access during lamination. Within a week, we built and tested the autoclave at our Auckland factory before we delivered it down to Emirates Team New Zealand’s workshop facility.

Team NZ appreciated the fast turnaround, design skill and quality product.  Just a few weeks after delivering the elevator autoclave they contracted us again, this time to test and certify the hydraulic tank used on board Te Rehuai.  These system critical components are crucial to the efficient working of the boat.  The systems worked without a glitch and we were all greatly relieved when the Americas Cup was locked back in its case at the Yacht Squadron in Westhaven for another few years!

We’re pleased to have had the opportunity to work with Emirates Team New Zealand and be involved, in even a small way, to making their defence a success.

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Our thermal design team analysed the rocket exhaust process data and then designed a specialty heat exchanger to meet the Rocket Lab design brief.  As result, Pressure Worx specially developed a number of notable features for the exhaust condenser.  We included a condensate impingement separator and collection sump within the exhaust outlet bonnet.  “We had to analyse over 29 different and complex rocket operating cases to come up with a heat exchange solution that would meet all of them”, said Rowntree.

Exhaust gas from the rocket enters the stainless flange at the right of the exhaust condenser

Following the successful design and delivery of the Rocket Exhaust Condenser, Rocket Lab asked us to design and supply a Spray Chamber Vessel, also fitted to the exhaust.  This vessel saturates the exhaust and cools the stream prior to the rocket exhaust condenser.  Furthermore, it works under vacuum and was fabricated entirely from stainless steel.

“We loved working with the engineers from Rocket Lab and its awesome to be involved in just a small way with helping develop their test facility to enhance their rocket performance for future missions into space. They are an innovative and exciting company, proud of their New Zealand origin”.

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We manufacture replacement upgrades of older units including legacy Flotech and Greenlane Technology units for which we have historic project information and direct replacement units available. The direct replacements are dimensionally equivalent and can slide straight in with no changes to the existing piping. Our specialist thermodynamics designers can also replace existing fixed tubesheet designs to floating tubesheet, bellows or U-tube designs, to better accommodate the thermal expansion often seen in hot water and CIP heat exchanger applications.  Construction materials are typically stainless steel 316 or Duplex (SAF2205) and we can provide hygenic design for food grade applications. Stainless steel heat exchangers are finished with electro-polishing.

For difficult site layouts, we customise our standard designs, tailoring the layout, orientations and connection sizes to suit the particular site installation requirements. We stock key components and can offer rapid delivery when required.

Pressure Worx provides the most energy efficient, robust and cost effective heat transfer solutions for our clients. Please contact our sales team on sales@pressureworx.co.nz  to discuss your hot water and CIP heat exchangers requirements.

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Different products and processes require different types of CIP systems. Single use and dump systems are often installed where there is a large amount of fouling due to product deposits and high chemical oxygen demand (COD) levels make them unsuitable for re-use systems. Reuse CIP systems typically have a dilute chemical supply tank and a post rinse recovery tank used for the next pre-rinse. Both types of systems require critical temperature control to prevent product spoilage and to increase its dirt removal efficiency.

At Pressure Worx, we understand both the process of CIP systems and the requirements of the heating systems for CIP temperature control for water and cleaning agents. We custom design heat exchangers and heating systems with either an in-line heater for each cleaning circuit or a re-circulated kidney type heater for each chemical supply tank or water recovery tank. In both cases, the cleaning agents will be heated to the proper temperature.

Capacity and pressure requirements in CIP systems vary dramatically, so we custom design heat exchangers for your specific CIP system requirements. Whether a single pass heat exchanger with a fixed tubesheet, a multi-pass design with a floating tubeplate, or u-bundle design, we can provide the most economical and reliable heat exchanger design to meet your CIP systems requirements.

For more information on how we can help with your CIP systems, please don’t hesitate to contact us at sales@pressureworx.co.nz

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Hydrogen Sulphide (H₂S), more commonly known as ‘rotten egg gas’ is an essential gas used in the production of Nickel. The gas is produced by reacting molten liquid sulphur with hydrogen in a reactor. The refinery produces 225 tonnes per day of H₂S for its Nickel production.

“Pressure Worx won a contract to design and supply the H₂S Cooler in Madagascar, having considerable experience and reputation in the design and supply of similar heat exchangers for Nickel plants around the world”, said Steve Rowntree, director at Pressure Worx.

The H₂S cooler, cools the gas down in the shell of the unit. Residual sulphur within the gas solidifies on the outside of the water cooled U-tubes during the cooling process. Over time this results in a restriction of the gas flow and a reduction in cooling performance. “The Pressure Worx design incorporates a special shell jacket, that periodically allows the operators to inject low pressure steam around the outside of the shell, melting the sulphur build up which then drains to a separate blow down vessel, allowing the performance of the cooler to return to new” reported Rowntree.

The H₂S cooler was designed by Pressure Worx in Auckland. High temperature stainless steel grade SS310s was used for the tube bundle design, providing excellent resistance to corrosion and oxidation at elevated temperatures. Non-destructive testing (NDT) including both X-rays and dye pen testing was carried out on all welds in direct contact with the H₂S gas due to ensure their integrity with the highly toxic gas. Fabrication, testing and certification of the unit was carried out in Auckland.

“It’s great to see that NZ companies can still compete globally on the world stage with clever design, IP and competitive specialist fabrication” said Rowntree. “We are currently developing other specialised heat exchange equipment designs as well as a range of biogas and landfill gas conditioning systems to improve the efficiency and reliability of renewable gas power gensets around the world.”

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Each SS316L cooler was fabricated in Auckland weighing in at approximately 2500 kg each. The coolers were TEMA ‘AEM’ design incorporating removable heads and end plates with purpose build davits to assist in removal for cleaning.

The contract was completed on time and budget with the quality of the final products produced to the highest standard.

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Phase 2 of the project is the delivery of larger 3x 1MW Transformer Oil Coolers. These are also in stainless steel, with the coolers weighing in at around 2500kg each. The transformer coolers will be completed and delivered to site during November.

“Pressure Worx was responsible for doing the complete thermal and mechanical design of each cooler type during the tender process to match the clients process requirements”, said Steve Rowntree, Director at Pressure Worx. “We specialise in non-standard niche applications, requiring thermodynamic and mechanical design expertise. Fabrication and testing of the heat exchangers is done locally in New Zealand, supporting NZ businesses.”

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