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 Application: Heat a large volume of 30% sulfuric acid from ambient to elevated temperatures for vanadium recovery.
Technical Requirements:
- Use of all-plastic heat exchanger components, specifically PVDF, to withstand aggressive acids.
- Reliable operation under continuous flow and elevated temperature conditions.
- Design must minimize pressure drop and avoid metallic contact with the process fluid.
- Integration with skid-mounted systems and existing plant piping for ease of installation and maintenance.
Solution
CALORPLAST PVDF Tube Plate Heat Exchangers, designed to deliver the required thermal transfer while maintaining process safety.
Key Technical Features
PVDF Tube Plate Design: All wetted surfaces constructed from PVDF, offering superior resistance to 30% sulfuric acid at elevated temperatures.
Parallel Operation: Multiple heat exchangers installed in parallel to maximize heat transfer efficiency and enable process flexibility.
Custom Manifolds & Skid Mounting: Integrated manifolds and skid system using polypropylene and PTFE components for structural integrity and chemical compatibility.
Process Control: Expansion joints and isolation valves allow for safe operation and simplified maintenance, even under demanding process conditions.
Performance Focus: System sized for high flow rates, consistent acid heating, and controlled pressure drop to ensure reliable, repeatable extraction results.
Result
- Efficient, uniform acid heating ensured optimum conditions for vanadium extraction, improving process yield and throughput.
- Long-term reliability: All-plastic construction eliminated corrosion issues, reducing maintenance and total cost of ownership.
- Operator and plant safety: Engineered safeguards and pressure management features supported safe, continuous operation.
- Quick installation: Skid-mounted and custom manifolding simplified field integration, minimizing production downtime.
By utilizing CALORPLAST PVDF heat exchangers, the facility achieved a durable, efficient, and maintenance-friendly heating solution for its critical extraction process.
