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Case Study #13: Acid Recovery Systems Initial situation Industrial acid recovery systems are essential for reducing chemical waste and operating costs in metal finishing and pickling lines. These systems operate under highly corrosive conditions, handling sulfuric acid or hydrochloric acid at varying temperatures. Historically, metallic heat exchangers failed quickly due to corrosion, leading to costly…
Case Study #9: Plastic Heat Exchangers in Galvanizing Initial situation Galvanizing operations demand precise temperature control in their acid pickling tanks, particularly during the colder winter months. Traditional metallic heat exchangers often exposed to aggressive hydrochloric acid require frequent replacement due to corrosion and scale buildup, leading to costly downtime and maintenance headaches. The customer…
Case Study #19: Sulphuric Acid Heating Initial situation A US-based metals producer sought a solution for heating concentrated sulfuric acid to support vanadium extraction. The process required a robust system capable of handling both the corrosive properties of sulfuric acid and elevated operating temperatures, while delivering consistent thermal performance for improved extraction efficiency. Challenge Process…
Case Study #20: Sulfuric Acid Dilution in Battery Production Initial situation In battery manufacturing, sulfuric acid (H₂SO₄) is a key electrolyte. While it’s delivered in highly concentrated form, it must be diluted before bottling and use. However, the dilution process releases significant heat (dilution enthalpy), which can cause the temperature of the mixture to…
Case Study #19: Vanadium Redox Flow Batteries Initial situation In vanadium redox flow batteries, vanadium dissolved in sulfuric acid cycles through four distinct oxidation states. Positive and negative electrolytes are stored separately and pumped into a galvanic cell divided by a membrane. During charging and discharging, chemical redox reactions occur in the cell, where…
Case Study #18: Jewelry Electroplating Initial situation A decorative electroplating facility in California needed to replace its existing electrically heated tanks due to updated fire safety regulations. Although retaining the current tanks was required, electric heaters could no longer be utilized. Additionally, maintaining high-quality finishes and precise temperature control was critical due to the high…
Case Study #17: Phosphating Application Initial situation In phosphating processes, tanks require precise temperature control to treat base materials effectively. During phosphating, intense crystallization reactions typically occur directly on the heat exchanger surfaces. External stainless steel heat exchangers for bath heating or cooling often aren’t practical because of these deposits. Internal heat exchangers, however, also…
Case Study #16: Plating om Plastics (PoP) Initial situation Although surface coatings in electroplating are usually associated with the treatment of metallic parts, metallic coating processes can also be used with great success on non-electrically conductive surfaces. The application of a metallic coating can greatly improve the functionality, look and feel of plastic surfaces…
Case Study #15: Strip Pickling Initial situation Strip pickling is commonly used in the electroplating of wire or thin metal strips. In this continuous process, metal materials are pulled over rollers and sprayed with reactive chemicals. Excess solution flows into a shallow collection basin beneath the belts, where precise temperature control of the chemical…
Case Study #14: AquaZoo Initial situation In public aquariums, many species of fish and anemones are highly sensitive to metal ions in their environment. Meanwhile, lighting and water circulation systems continuously add heat to the tanks. To maintain healthy aquatic conditions, both freshwater and saltwater systems must be carefully temperature-controlled, without introducing corrosive or toxic…
Case Study #13: Biogas Desulfurization Initial situation Biogas production generates hydrogen sulfide (H₂S), a highly toxic and corrosive gas formed in the fermenter. If not removed, this contaminant leads to increased operating costs in combined heat and power (CHP) units due to accelerated wear on spark plugs, oil degradation, and corrosion-related maintenance. Additionally, combustion of…
Case Study #12: Biogas Drying for a Brewery – Exhaust Air Purification Initial situation Biogas is a renewable by-product generated from organic waste in industries like agriculture, brewing, food processing, ethanol, paper, and palm oil production. It typically contains 50–70% methane (CH₄), 30–50% carbon dioxide (CO₂), and 0.1–3% hydrogen sulfide (H₂S). When biogas is used…
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