Heat Exchanger Retrofit
Modernise existing heat exchanger systems with PPS-GR tubes:
Technoform’s corrosion-resistant PPS-GR tubes can be used to replace specific sections of existing heat transfer surfaces. Depending on the design, existing system components may still be reused. Together, we will assess whether PPS-GR is suitable for the fluids, temperatures, pressures and installation conditions of your system.
When heat exchanger tubes become a maintenance issue
Corrosion, damaged coatings, glass breakage or recurring tube damage can impair the availability of a heat exchanger and significantly increase maintenance costs.
Particularly aggressive condensates and operation at or below the acid dew point place high demands on the heat transfer surfaces. Corrosion, damaged coatings or recurring tube damage can significantly increase maintenance costs.
Typical damage and operating conditions:
- Corrosion on heat exchanger tubes
- Damaged or ageing coatings
- Recurring glass breakage or other tube damage
- High maintenance and repair costs
- Corrosive condensates
- Operation at or below the acid dew point
Possible consequences include more frequent repairs, reduced plant availability and unplanned downtime.
Corrosion-resistant material
In coated systems, corrosion protection depends on a protective layer that remains intact over time, as well as on the quality of its transitions and joints. Temperature fluctuations, cleaning or localised damage can lead to weak points in these areas.
With PPS-GR, corrosion resistance and thermal conductivity are inherent properties of the pipe material itself – without the need for a separate functional protective layer.
Retrofit at the waste-to-energy plant
The South-East Bavaria Waste Management Association (ZAS) has been operating a waste-to-energy plant for the thermal treatment of waste since 1994.
As part of the overhaul of the gas-to-gas heat exchangers on both combustion lines, the glass tubes previously in use were replaced with PPS-GR tubes. The glass tubes had repeatedly suffered from tube ruptures and leaks due to vibration and high-temperature HF corrosion, which led to emission spikes and operational restrictions. Thanks to close support during the overhauls and swift coordination, the replacement was carried out quickly and without disrupting plant operations. Since commissioning, the heat exchangers have been operating reliably and stably. Subsequent inspections have revealed only minor damage.
The number of pipe bursts has been reduced almost entirely, thereby avoiding unplanned shutdowns and improving process reliability. Furthermore, a sustained improvement in the emissions situation has been achieved. The daily average HCl values in continuous monitoring are well below 1.0 mg/Nm³. This confirms the integrity and efficiency of the flue gas system.
Does your plant have retrofit potential?
As a plant operator, you know that every application is different. Temperature, process media, pressure, dew point, and the existing system design determine whether PPS-GR is a suitable material for your plant.
We would be happy to advise you.
