PTFE Heat Exchanger for an Automotive Parts Manufacturer
When one of the world’s leading automotive parts manufacturers faced corrosion issues with their metal heat exchangers, they turned to Empire Pumps for a solution.
PTFE Heat Exchanger for an Automotive Parts Manufacturer
Customer: Automotive Parts Manufacturer
Application: Passivate tank for zinc plating
Equipment Supplied: PTFE Heat Exchanger

Details of Equipment Supplied
Description: Immersion PTFE Heat Exchanger
Model: EPX-V5-K-PP-DN40
Material: Fluoropolymer with a polypropylene (PP) frame bracket
Heating Surface Area: 5m²
Dimensions: Length 2000mm x Width 500mm x Thickness 80mm
Heat Exchanger Design: Bottom of tank installation
Connection: DN40 Stainless Steel Flange
Enquiry
Empire Pumps was approached by a world-leading automotive parts manufacturer who had been facing issues with their existing metal heat exchangers. After the chemical supplier updated the formulas in their zinc plating process, the client observed bubbles forming on the surface of the tank solution. Upon draining the tank, they found holes in the metal heat exchangers due to corrosion caused by the updated chemicals.
Key Challenges
- Tank Configuration: The client required the heat exchanger to be installed at the bottom of the tank rather than on the tank wall.
- Limited Space: The tank’s interior was highly crowded, necessitating special arms for installation and maintenance.
- Chemical Resistance: The process used strong acids, making standard metal heating equipment unsuitable due to corrosion risks.
Solutions
Our technical team performed in-depth calculations to determine the heating surface area needed based on the tank volume, required heat-up time, and the operational conditions at the client’s site. We recommended a 5m² PTFE heat exchanger custom-built with a frame optimized to maximize heating performance.
Onsite Survey and Design Customization
After the initial proposal, the client invited us for an onsite survey to ensure the heat exchanger would fit both the tank and its operational environment. Our engineer visited the facility to discuss all details, including:
- Tank depth
- Existing pipes and connections
- Steam pipe locations
Custom Solution
To address the crowded tank environment, we designed the heat exchanger with 1.3m rigid arms, enabling easy installation at the bottom of the tank for homogeneous heating. The arms were equipped with specially designed hinge connections that allowed them to be easily folded for straightforward installation and maintenance.


Empire Pumps custom design of Heat Exchanger
Superior Materials and Durability
The PTFE tubes used in the heat exchanger were of the highest fluoropolymer rating, capable of withstanding up to 4 bar pressure and providing exceptional resistance to strong acids. Empire Pumps is the only supplier in the UK capable of manufacturing PTFE heat exchangers of this size and specification, ensuring both durability and performance in highly corrosive environments.
Results
The custom-built PTFE heat exchanger was successfully installed and has since provided reliable, efficient heating for the client’s passivate tank, without any of the corrosion issues they experienced with metal heat exchangers. By implementing our engineering expertise and the use of high-quality materials, Empire Pumps delivered a tailored solution that addressed the client’s specific challenges and improved their process efficiency.
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