SPWAVE Heat Exchanger Delivers a Smart Retrofit Solution for Zinc Sulphate Heating
SPWAVE Spiral Plate Heat Exchanger Replaces Aging Alfa Laval Unit for Zinc Sulphate Preheating in Peru
A chemical plant located in Peru, specializing in the production of zinc sulphate (ZnSO₄), had long relied on an Alfa Laval spiral plate heat exchanger for one of its critical thermal processes. In this process, a zinc sulphate solution is preheated from 158°F (70°C) to 203°F (95°C) using saturated steam as the heating medium. This heat exchange step plays a vital role in preparing the solution for subsequent concentration or crystallization steps.
However, after several years of continuous operation under harsh chemical conditions, the original Alfa Laval unit began to suffer from corrosion, internal fouling, and eventual leakage. The deterioration in mechanical integrity and rising maintenance costs posed serious operational and safety risks. Additionally, the degraded heat transfer efficiency began to impact downstream production quality.
To address this issue, the plant operators began searching for a reliable replacement that could not only match the original design specifications but also offer improved durability and thermal performance.
Solution: SPWAVE Spiral Plate Heat Exchanger by SHINEHEAT TECH
SHINEHEAT TECH, a specialist in welded heat exchanger solutions, proposed its SPWAVE Spiral Plate Heat Exchanger as a direct replacement for the aging Alfa Laval unit. The SPWAVE unit was custom-engineered to fit the original installation footprint—including nozzle orientation, connection sizes, and mounting dimensions—allowing for plug-and-play installation without requiring modification to the existing piping or structural supports.
Beyond simple replacement, the SHINEHEAT TECH engineering team introduced several key design enhancements:
- Optimized internal flow channel design for the zinc sulphate side, improving turbulence while reducing risk of fouling or solid buildup.
- Corrosion-resistant stainless steel material selection, tailored to withstand the acidic and mineral-rich nature of the zinc sulphate solution.
- Enhanced thermal efficiency through improved plate spacing and optimized spiral geometry.
- Lower pressure drop across both steam and process sides, reducing overall system energy consumption.
Results & Benefits
Since commissioning the new SPWAVE spiral plate heat exchanger, the plant has achieved stable and efficient heating performance, with the zinc sulphate solution consistently reaching the target temperature of 203°F without fluctuations. The elimination of leakage and rust-related contamination has significantly improved product quality and reduced unplanned maintenance shutdowns.
Additionally, operators reported that the lower pressure loss across the SPWAVE unit has led to energy savings and more stable flow control on the process side. This contributes to long-term operational cost reduction.
Conclusion
This retrofit project in Peru demonstrates the versatility and performance of SHINEHEAT TECH’s SPWAVE Spiral Plate Heat Exchanger in replacing aging heat exchanger infrastructure. With customizable dimensions, durable welded construction, and superior thermal design, SPWAVE provides an ideal upgrade solution for harsh chemical processes like zinc sulphate heating.
Whether for new installations or legacy system replacements, SHINEHEAT TECH continues to deliver engineered solutions that extend equipment lifespan, enhance reliability, and lower total cost of ownership.
