Spiral heat exchanger in Industrial Zinc Sulphate Heating System Upgrade
A chemical processing plant located in Peru, specializing in the production of zinc sulphate (ZnSO₄), required a reliable heating solution for one of its critical production processes.
During operation, the zinc sulphate solution must be heated from 70°C (158°F) to 95°C (203°F) using saturated steam. This heating stage plays a crucial role in preparing the solution for subsequent concentration and crystallization processes.
Process Challenges
After several years of operation in a corrosive chemical environment, the existing heat exchanger began experiencing multiple issues that impacted process stability and maintenance costs.
- Corrosion caused by acidic zinc sulphate solution
- Internal fouling and mineral deposition
- Reduced heat transfer efficiency
- Increased pressure drop in the process circuit
- Risk of leakage and production downtime
HEXNOVAS Solution
A HEXNOVAS Spiral Plate Heat Exchanger was selected as the optimal replacement solution. The unit was custom engineered to match the original installation footprint, allowing seamless integration into the existing process system.
- Matching nozzle orientation
- Compatible connection sizes
- No modification required for existing piping
- Rapid installation and commissioning
Engineering Improvements
Compared with conventional heat exchangers, the HEXNOVAS spiral plate design incorporates several performance improvements specifically suited for chemical process applications.
- Optimized spiral flow channel design improving turbulence and reducing fouling
- Corrosion-resistant materials suitable for acidic process media
- Enhanced heat transfer efficiency through optimized geometry
- Lower pressure drop across steam and process sides
Results & Benefits
After commissioning the new HEXNOVAS spiral plate heat exchanger, the plant achieved significant operational improvements.
- Stable process temperature reaching 95°C (203°F)
- Improved heat transfer efficiency
- Reduced fouling and maintenance frequency
- Lower energy consumption
- Improved system reliability
Conclusion
This project demonstrates the effectiveness of spiral plate heat exchangers in demanding chemical processing environments. With optimized flow design, corrosion-resistant materials, and robust welded construction, the HEXNOVAS solution provides reliable long-term performance for zinc sulphate heating applications.
For chemical plants seeking to upgrade aging equipment or improve process efficiency, spiral plate heat exchangers offer a durable and high-performance solution for harsh industrial environments.
