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Case Study
Heat exchangers are prone to corrosion and incrustation, reducing performance and raising costs. Photo courtesy of SÄKAPHEN GmbH.
risk of scaling and corrosion, while the high-pressure steam requires robust protection to prevent material degradation over time. Ensuring long-term resistance to these challenging conditions was a key priority in selecting the appropriate protective coatings.
Solution 1. Excellent application skills Jiangsu Simijia Tank Container Service was SÄKAPHEN’ s authorized applicator that took this project in charge. It has been one of our trusted partners since 2014 when we teamed up to provide the Chinese market with application services using our renowned linings. As always with SÄKAPHEN, the heat exchanger treatment process included the following steps:
• Preliminary analysis and technical consultancy
• Surface preparation( grit blasting and cleaning)
• Coating application until the achievement of the ideal DFT( dry film thickness) and curing
• QC, testing, and preparation of the required documentation.
Chemical processing industry relies on heat exchangers to maintain efficiency and durability under extreme conditions. Photo courtesy of SÄKAPHEN GmbH.
2. Ideal coatings SÄKAPHEN offers a wide range of coatings and linings to protect the surfaces of heat exchangers, condensers and coolers from the most varied industries( including power generation, chemical processing, petrochemical, refineries, natural gas processing and others) against corrosion, incrustation and fouling. Two cold-cured linings were selected in this case: HR 60 Extra TG and SÄKATONIT K 80 LS. The key goal was protecting the heat exchangers’ tube sheets with their protruding tube ends. SÄKAPHEN HR 60 Extra TG is a two-pack epoxy lining formulated to be chemically resistant to various acidic and strongly alkaline substances from inorganic salts and solutions, acidic aqueous liquids and all types of water including brackish, river and sea water up to 100 ° C in permanent immersion. The lining is also resistant to water vapor diffusion( ΔT 85 ° C). SÄKAPHEN SÄKATONIT K 80 LS is also a two-pack epoxy coating system resistant to all types of water in addition to various substances, including sour to strong alkaline, inorganic salts and their solutions. It also has outstanding hydrophobic properties and is resistant to temperature fluctuations. It can be used as a primer, putty, or a top coat, and it can be thinned down or thickened up depending on each application’ s need, which also ensures cost reduction and waste minimization for more sustainable operations.
Final results The customer was very pleased with the project’ s results, as the applied coatings provided durable and effective protection for the heat exchangers, ensuring optimal performance in demanding conditions. The key benefits included:
• Excellent overall protection of the surfaces of the heat exchangers’ tube sheets and water boxes, preventing premature wear and extending equipment lifespan.
• Optimal prevention of caking, fouling, and incrustation, reducing the risk of blockages and maintaining efficient heat transfer rates.
• Long-term plant efficiency and reliability, minimizing unplanned maintenance and costly downtime.
• Outstanding ROI( return on investment), as the enhanced durability and performance of the coated surfaces reduced operational and maintenance costs over time.
• High-level corrosion prevention, safeguarding the integrity of critical components against aggressive environmental and process-related factors.
• Maximum operational safety, ensuring that the heat exchangers function without risk of leaks, failures, or efficiency loss, contributing to a stable and secure plant operation.
This project once again demonstrated the effectiveness of advanced cold-cured linings in protecting industrial heat exchangers, delivering a long-lasting solution tailored to the customer’ s specific needs. For more visual representation, view the video on the case study version here.
38 Heat Exchanger World April 2025 www. heat-exchanger-world. com