Case study: heat exchanger protection even at high temperatures

03.2025

HR 60 Extra TG & SÄKATONIT K 80 LS

SÄKAPHEN’s coatings and application processes prevent corrosion, protect heat exchanger surfaces and ensure long-term reliability and safety.

Any company operating heat exchangersknows it: these systems run a high risk of corrosion and incrustation, which may cause a loss or drop in performance and lead to increased operating or investment costs.

SÄKAPHEN and one of its trusted authorized applicators have recently completed another interesting project in this field, which proved once again that our cold-cured linings are among the best in class to safeguard thermal exchange equipment. This time, our coatings were required right across the world from our headquarters, as two Chinese heat exchanger manufacturers needed a high-performance product to be applied on their systems.

Project specifications
End user: Samsung E&A for a Baltic chemical company

HE manufacturers: Jiangsu JBPV Intelligent Equipment Co., Ltd and Wuxi Chemical Equipment Co., Ltd
Items to be coated: respectively, 27 shell and tube heat exchangers and 5 sets of floating-head heat exchangers. Lengths ranging from approx. 12 to 9 m, diameters from approx. 1.5 to 1.75 m
Medium in contact: cooling water of inconsistent quality at 60 °C on the tube side and high-pressure steam on the shell side (temperature of condensation: approx. 200 °C)

SÄKAPHEN’s solution

1. Excellent application skills

JiangsuSimijia Tank Service Co. Ltd was SÄKAPHEN’s authorized applicator that took this project in charge. It has been one of our trusted partners since 2014 when we teamed up to provide the Chinese market with application services using our renowned linings.

As always with SÄKAPHEN, the heat exchanger treatment process included the following steps:

Preliminary analysis and technical consultancy
Surface preparation (grit blasting and cleaning)
Coating application until the achievement of the ideal DFT (dry film thickness) and curing
QC, testing, and preparation of the required documentation.

2. Ideal coatings

SÄKAPHEN offers a wide range of coatings and linings to protect the surfaces of heat exchangers, condensers and coolers from the most varied industries (including power generation, chemical processing, petrochemical, refineries, natural gas processing and others) against corrosion, incrustation and fouling.

Two cold-cured linings were selected in this case: HR 60 Extra TG and SÄKATONIT K 80 LS. The key goal was protecting the heat exchangers’ tube sheets with their protruding tube ends.

SÄKAPHEN HR 60 Extra TG is a two-pack epoxy lining formulated to be chemically resistant to various acidic and strongly alkaline substances from inorganic salts and solutions, acidic aqueous liquids and all types of water including brackish, river and sea water up to 100 °C in permanent immersion. The lining is also resistant to water vapor diffusion (ΔT 85 °C).

SÄKAPHEN SÄKATONIT K 80 LS is also a two-pack epoxy coating system resistant to all types of water in addition to various substances, including sour to strong alkaline, inorganic salts and their solutions. It also has outstanding hydrophobic properties and is resistant to temperature fluctuations. It can be used as a primer, putty, or a top coat, and it can be thinned down or thickened up depending on each application’s need, which also ensures cost reduction andwaste minimization for more sustainable operations.

Final results
The customer was very pleased with the project’s results. These included as follows:

Excellent overall protection of the surfaces of the heat exchangers’ tube sheets and water boxes
Optimal prevention of caking, fouling and incrustation
Long-term plant efficiency and reliability
Outstanding ROI (return on investment)
High-level corrosion prevention
Maximum operational safety.

SÄKAPHEN: your ideal partner for corrosion protection
We work alongside our customers worldwide to provide the best solutions to all their corrosion protection challenges, ensuring reduced maintenance costs and increased operational efficiency.