Case Study #1: Corrosion-Free Heat Exchanger for Landfill Leachate Treatment
Initial situation
At a landfill leachate treatment facility operated by the Neuwied district administration, the incoming seepage water (leachate) must be tempered before entering the biological treatment stage. While the leachate itself is not highly corrosive, it causes persistent scaling and mineral deposits on the heat exchanger surfaces. These deposits must be removed with diluted hydrochloric acid.
Previously, a stainless steel shell-and-tube heat exchanger was used. Although it tolerated the leachate, repeated acid cleaning caused corrosion damage and premature failure of the equipment.
Challenge
The objective was to replace the failing stainless steel unit with a fully corrosion-resistant heat exchanger that:
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Withstands repeated acidic cleaning cycles
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Maintains thermal performance over time
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Fits into the existing piping and process layout
Solution
Calorplast provided a custom-designed shell-and-tube heat exchanger made entirely from polyethylene (PE). This material is 100% corrosion-resistant and capable of withstanding both the physical demands of wastewater treatment and the chemical stresses from routine acid cleaning.
Each unit is engineered to match the site’s specific flow rate, pressure, and temperature conditions, ensuring seamless system integration.
Result
The polyethylene heat exchanger was successfully installed and has been operating reliably. Regular acid cleaning can now be performed without degrading the unit, preserving both system uptime and thermal efficiency.
According to the customer:
“The CALORPLAST tube bundle heat exchanger has been installed and has been in operation for 10 days. Conclusion: good / very good. Kudos to your calculation! The planned heat output characteristic curve is met exactly in practice.”
