{"id":1136,"date":"2026-04-24T07:40:27","date_gmt":"2026-04-24T07:40:27","guid":{"rendered":"https:\/\/rtooxidizer.com\/?post_type=product&p=1136"},"modified":"2026-04-24T08:08:42","modified_gmt":"2026-04-24T08:08:42","slug":"plate-crystallizer-pillow-plate-heater","status":"publish","type":"product","link":"https:\/\/rtooxidizer.com\/ar\/product\/plate-crystallizer-pillow-plate-heater\/","title":{"rendered":"Plate Crystallizer (Pillow Plate Heater)"},"content":{"rendered":"
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Ever-power Thermal Systems<\/div>\n

Plate Crystallizer (Pillow Plate Heater) for Industrial Thermal & Crystallisation Duties<\/span><\/p>\n

Laser-welded pillow plate technology built for Australian chemical, pharmaceutical, petrochemical, coating, dyeing and hazardous-waste operators. Up to 100 bar operating pressure, \u221230 \u00b0C to 800 \u00b0C service range, and heat transfer coefficients reaching 1500 W\/(m\u00b2\u00b7\u00b0C) \u2014 delivered with full material traceability and AS\/NZS-aligned documentation.<\/p>\n<\/div>\n

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What Is a Plate Crystallizer (Pillow Plate Heater)?<\/h2>\n

A plate crystallizer \u2014 also known as a pillow plate heat exchanger or pillow plate heater \u2014 is a laser-welded, inflated-plate thermal device used to evaporate, heat, cool or crystallise process fluids. Two thin metal sheets are laser-welded across their entire surface in a pre-set dot or line pattern, sealed at the edges by seam welding, then hydraulically inflated so that the unwelded zones deform plastically into the characteristic three-dimensional cushion surface.<\/p>\n

The result is a rigid, high-pressure, high-turbulence plate that outperforms conventional tubular and gasketed plate heat exchangers in saline, scaling and corrosive duties. For Australian operators running brine concentrators, solvent recovery columns, MVR evaporators, reboilers or ORC waste heat loops, pillow plates from Ever-power deliver measurable gains in energy recovery and uptime.<\/p>\n

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\"Laser-welded<\/p>\n

Pillow Plate \u2014 inflated cushion geometry<\/div>\n<\/div>\n
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\"\"Honeycomb Plate \u2014 dense weld-dot pattern<\/div>\n<\/div>\n<\/div>\n

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Core Advantages Over Tubular & Gasketed Plate Designs<\/h2>\n
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Multiple Material Options<\/h3>\n

304\/316L stainless steel, duplex 2205, super-duplex 2507, titanium Gr.1\/Gr.2, Hastelloy C-276, C-22, Nickel 200 and Monel 400 \u2014 matched to your stream chemistry.<\/p>\n<\/div>\n

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High Pressure Rating<\/h3>\n

Maximum operating pressure up to 100 bar on the plate side, validated by hydrostatic burst testing and documented per ASME VIII Div.1 equivalents.<\/p>\n<\/div>\n

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Wide Working Media<\/h3>\n

Steam, thermal oil, flue gas, cooling water, glycol, ammonia, CO\u2082 and hydrocarbon refrigerants \u2014 suitable for single-phase and two-phase service.<\/p>\n<\/div>\n

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High Turbulence<\/h3>\n

Weld-dot geometry forces the fluid into repeated directional changes, breaking the boundary layer and keeping Reynolds numbers high at modest flow rates.<\/p>\n<\/div>\n

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Low Pressure Loss<\/h3>\n

The inflated central channel on the jacket side minimises flow resistance, which cuts circulation pump duty and energy cost across the plant.<\/p>\n<\/div>\n

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Heat Transfer up to 1500 W\/(m\u00b2\u00b7\u00b0C)<\/h3>\n

Overall U-values 2\u20133 times higher than conventional jacketed vessels, shrinking the required heat transfer area and footprint.<\/p>\n<\/div>\n<\/div>\n

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How Ever-power Manufactures Pillow Plates<\/h2>\n

Every Ever-power plate crystallizer follows the same audited production path, which is what keeps warranty claims low across our Australian installed base.<\/p>\n

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1<\/div>\n

Material Inspection<\/strong><\/p>\n

Mill certificates verified, PMI test on every coil before cutting.<\/p>\n<\/div>\n

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2<\/div>\n

Laser Spot Welding<\/strong><\/p>\n

CNC-guided fibre laser places weld dots to \u00b10.1 mm accuracy across the plate.<\/p>\n<\/div>\n

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3<\/div>\n

Edge Seam Welding<\/strong><\/p>\n

Continuous edge seal with automated TIG; ports left open for media inlet.<\/p>\n<\/div>\n

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4<\/div>\n

Hydraulic Inflation<\/strong><\/p>\n

Pressurised water forms the cushion; gap depth controlled by weld spacing.<\/p>\n<\/div>\n

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5<\/div>\n

Testing & Passivation<\/strong><\/p>\n

Hydrotest at 1.5\u00d7 design pressure, helium leak test, pickling and passivation.<\/p>\n<\/div>\n<\/div>\n

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Technical Specifications<\/h2>\n
\n\n\n\n\n\n\n\n\n\n\n\n\n\n
Parameter<\/th>\nStandard Range<\/th>\nCustom \/ Maximum<\/th>\n<\/tr>\n<\/thead>\n
Plate thickness<\/strong><\/td>\n0.8 \u2013 2.0 mm<\/td>\nup to 3.0 mm<\/td>\n<\/tr>\n
Plate dimensions (W \u00d7 L)<\/strong><\/td>\n800 \u00d7 2000 mm to 1500 \u00d7 4000 mm<\/td>\nup to 1800 \u00d7 6000 mm<\/td>\n<\/tr>\n
Working pressure<\/strong><\/td>\nup to 40 bar<\/td>\nup to 100 bar<\/td>\n<\/tr>\n
Working temperature<\/strong><\/td>\n\u221230 \u00b0C to +450 \u00b0C<\/td>\n\u2212196 \u00b0C to +800 \u00b0C<\/td>\n<\/tr>\n
Heat transfer coefficient<\/strong><\/td>\n600 \u2013 1200 W\/(m\u00b2\u00b7\u00b0C)<\/td>\nup to 1500 W\/(m\u00b2\u00b7\u00b0C)<\/td>\n<\/tr>\n
Plate pattern<\/strong><\/td>\nDot pattern (50\u201380 mm pitch)<\/td>\nLine pattern, honeycomb, custom<\/td>\n<\/tr>\n
Material<\/strong><\/td>\nSS 304 \/ 316L \/ 2205<\/td>\n2507, Ti Gr.2, Hastelloy C-276, Nickel 200<\/td>\n<\/tr>\n
Surface finish<\/strong><\/td>\n2B mill \/ pickled<\/td>\nElectropolished Ra \u2264 0.4 \u03bcm<\/td>\n<\/tr>\n
Design code<\/strong><\/td>\nGB 150 \/ EN 13445<\/td>\nASME VIII Div.1, PED 2014\/68\/EU<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

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Single-Embossed vs Double-Embossed Pillow Plates<\/h2>\n

Ever-power produces two geometries, selected according to whether the plate is bolted onto a vessel wall or immersed as a bundle inside a process vessel.<\/p>\n

\n\n\n\n\n\n\n\n\n\n
Feature<\/th>\nSingle-Embossed<\/th>\nDouble-Embossed<\/th>\n<\/tr>\n<\/thead>\n
Construction<\/td>\nThin top sheet on a thicker flat base<\/td>\nTwo symmetrical thin sheets inflated on both sides<\/td>\n<\/tr>\n
Typical use<\/td>\nVessel jackets, silo heating panels, reactor walls<\/td>\nImmersion bundles, falling film evaporators, crystallisers<\/td>\n<\/tr>\n
Flow path<\/td>\nSingle-side service fluid<\/td>\nProcess fluid outside, service fluid inside<\/td>\n<\/tr>\n
Cleaning<\/td>\nCIP possible<\/td>\nEasy bundle lift-out for mechanical cleaning<\/td>\n<\/tr>\n
Preferred service<\/td>\nLow-shear batch reactors<\/td>\nScaling brines, slurries, mother liquor<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

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Typical Applications in Australian Industry<\/h2>\n
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Evaporative Crystallisation<\/h3>\n

Sodium sulphate, ammonium chloride, sodium chloride, lithium carbonate and battery-grade salt recovery.<\/p>\n<\/div>\n

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ORC Waste Heat Recovery<\/h3>\n

Evaporators and condensers for organic Rankine cycle loops, working with R245fa, R1233zd and hydrocarbon refrigerants.<\/p>\n<\/div>\n

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Reboiler Service<\/h3>\n

Kettle and thermosyphon reboilers for distillation columns in solvent recovery and petrochemical duties.<\/p>\n<\/div>\n

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Zero Liquid Discharge (ZLD)<\/h3>\n

MVR and multi-effect evaporators for coating, electroplating and dyeing wastewater \u2014 replacement of shell-and-tube falling film units.<\/p>\n<\/div>\n

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Pharmaceutical Jackets<\/h3>\n

Reactor and silo jackets for API synthesis, with electropolished surfaces meeting GMP cleaning requirements.<\/p>\n<\/div>\n

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Hazardous Waste Centres<\/h3>\n

Flue gas heat recovery, thermal oil heaters and quench condensers downstream of incineration lines.<\/p>\n<\/div>\n<\/div>\n

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Why Australian Operators Choose Ever-power<\/h2>\n
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18+ Years, 600+ Projects<\/strong><\/p>\n

In-house laser welding since 2007 and a delivered base in 34 countries, including active sites across Victoria, New South Wales and Western Australia. Full company background on our company page<\/a>.<\/p>\n<\/div>\n

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Thermal Design in 72 Hours<\/strong><\/p>\n

Send your process data sheet and our chartered engineers return a sized drawing, U-value calculation and budgetary quote within three working days.<\/p>\n<\/div>\n

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Documented Material Traceability<\/strong><\/p>\n

EN 10204 3.1 mill certificates, weld maps, NDT reports and hydro-test records provided per unit \u2014 audit-ready for clients in regulated Australian industries.<\/p>\n<\/div>\n

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FOB-Melbourne \/ Sydney Logistics<\/strong><\/p>\n

Sea-freight optimisation through Port of Melbourne and Port Botany, with 20-ft and 40-ft HQ loading plans reviewed before cutting steel.<\/p>\n<\/div>\n

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Replacement of Imported OEM Units<\/strong><\/p>\n

Drop-in replacement fabrication of pillow plate bundles for legacy European and North American crystallisers \u2014 cut lead time from 9 months to 10\u201312 weeks.<\/p>\n<\/div>\n

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Commissioning Support<\/strong><\/p>\n

Remote start-up supervision via video link included on every order; on-site supervision from a dedicated project engineer available on request.<\/p>\n<\/div>\n<\/div>\n

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Australian Project References<\/h2>\n
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Case Study 01 \u2014 Western Australia<\/div>\n

Lithium Brine Concentration \u2014 Goldfields Region<\/h3>\n

A mining service contractor required a titanium Gr.2 double-embossed pillow plate bundle to replace a corroded shell-and-tube evaporator handling chloride-rich brine at 70 \u00b0C and 2.2 bar.<\/p>\n

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Heat area<\/strong>
\n186 m\u00b2<\/div>\n
U-value<\/strong>
\n1320 W\/(m\u00b2\u00b7\u00b0C)<\/div>\n
Energy saved<\/strong>
\n2.1 GJ\/h<\/div>\n
Payback<\/strong>
\n14 months<\/div>\n<\/div>\n<\/div>\n
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Case Study 02 \u2014 Victoria<\/div>\n

ZLD Evaporator for a Dyeing Plant \u2014 Dandenong<\/h3>\n

A textile finisher needed to cut trade waste discharge volumes by 95 %. Ever-power supplied a 2-effect MVR system with 316L double-embossed pillow plate crystallisers producing 380 kg\/h of mixed-salt cake.<\/p>\n

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Feed rate<\/strong>
\n4.2 t\/h<\/div>\n
Steam saving<\/strong>
\n62 % vs MEE<\/div>\n
Uptime<\/strong>
\n8300 h\/year<\/div>\n
Downtime<\/strong>
\n2 short clean cycles \/ yr<\/div>\n<\/div>\n<\/div>\n<\/div>\n

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Pillow Plate vs Shell-and-Tube vs Gasketed Plate<\/h2>\n
\n\n\n\n\n\n\n\n\n\n\n\n
Criteria<\/th>\nPillow Plate (Ever-power)<\/th>\nShell-and-Tube<\/th>\nGasketed Plate<\/th>\n<\/tr>\n<\/thead>\n
Footprint per m\u00b2<\/td>\nCompact<\/td>\nLarge<\/td>\nCompact<\/td>\n<\/tr>\n
Max pressure<\/td>\n100 bar<\/td>\n>200 bar<\/td>\n25 bar<\/td>\n<\/tr>\n
Max temperature<\/td>\n800 \u00b0C<\/td>\n>600 \u00b0C<\/td>\n180 \u00b0C<\/td>\n<\/tr>\n
Fouling tolerance<\/td>\nVery high<\/td>\nMedium<\/td>\nLow<\/td>\n<\/tr>\n
Exotic alloy cost<\/td>\nLow \u2014 thin sheet<\/td>\nHigh \u2014 heavy tube wall<\/td>\nMedium<\/td>\n<\/tr>\n
Gasket failure risk<\/td>\nNone (fully welded)<\/td>\nMinor (flange only)<\/td>\nHigh<\/td>\n<\/tr>\n
Heat transfer U<\/td>\nUp to 1500 W\/(m\u00b2\u00b7\u00b0C)<\/td>\n300\u2013800 W\/(m\u00b2\u00b7\u00b0C)<\/td>\nUp to 6000 W\/(m\u00b2\u00b7\u00b0C) clean<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

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Frequently Asked Questions<\/h2>\n
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How long does a pillow plate heat exchanger last in scaling brine duty?<\/h3>\n

A correctly specified duplex 2205 or Hastelloy C-276 plate crystallizer regularly reaches 8\u201312 years of continuous service before re-plating. Service life depends on chloride concentration, chloride-to-sulphate ratio, temperature and the cleaning cycle. We recommend a CIP regime every 2500\u20134000 operating hours for chloride-rich brines.<\/p>\n<\/div>\n

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What data does Ever-power need to size a plate crystallizer?<\/h3>\n

Feed composition, mass flow, inlet and outlet temperatures, required evaporation or crystallisation rate, service fluid (steam, thermal oil or refrigerant), design pressure, and a preferred material. A populated data sheet is usually enough; a full P&ID is welcome but not required at the budgetary stage.<\/p>\n<\/div>\n

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Can you match ASME Section VIII and AS 1210 requirements?<\/h3>\n

Yes. Ever-power pressure vessels and pillow plate bundles are available with ASME U-stamp, PED CE marking, and documentation compatible with AS 1210. Certified third-party inspection \u2014 BV, T\u00dcV, SGS or Lloyd’s \u2014 is arranged on request.<\/p>\n<\/div>\n

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What is the typical lead time to Australia?<\/h3>\n

Standard 316L plates with a production slot ship in 8\u201310 weeks. Titanium or Hastelloy units are 12\u201314 weeks due to raw material procurement. Sea freight from Shanghai or Ningbo to Melbourne or Sydney adds 18\u201324 days.<\/p>\n<\/div>\n

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Can pillow plates handle slurries without clogging?<\/h3>\n

Yes, when correctly oriented. Double-embossed bundles with 6\u20138 mm inter-plate gaps and vertical orientation allow solids-laden mother liquor to drop through under gravity. For slurries above 20 % w\/w, Ever-power recommends forced circulation with a low-shear axial pump.<\/p>\n<\/div>\n

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Is on-site repair possible if a weld dot fails?<\/h3>\n

Individual weld-dot failures are rare and almost always traceable to over-pressure upsets. If one occurs, the affected plate can be isolated, drained, and repaired by TIG plug weld. Ever-power supplies a repair procedure with every order and trains client maintenance teams during commissioning.<\/p>\n<\/div>\n

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Do you supply complete evaporation or crystallisation skids?<\/h3>\n

Yes. Ever-power delivers complete MVR, forced-circulation and DTB crystallisation systems including vapour-liquid separators, circulation pumps, centrifuges, instrumentation and control panels, wired on a modular skid ready for site connection.<\/p>\n<\/div>\n

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Ready to Specify Your Plate Crystallizer?<\/h2>\n

Share your process data sheet and receive a sized drawing, thermal calculation and budgetary quotation within 72 hours. Direct factory pricing, full traceability, delivered to any Australian port.<\/p>\n

Email sales@rtooxidizer.com<\/a>
\nContact Our Engineers<\/a>
\nView All Products<\/a><\/div>\n<\/div>\n<\/div>\n


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