This large air-to-liquid high temperature intercooler, used in the orange juice making process, was severely corroded after years of use.
Operating temperatures are consistently between 180°F and 220°F with occasional spikes to 250°F.
A replacement unit had a delivery lead time of nine months and a cost of $45,000. Without this unit online, the facility’s production would be severely decreased.
The local ENECON Field Engineering Specialist recommended rebuilding the internal diameter of each 24” flange with DurAlloy. Then a vertical boring mill was used to machine the cured DurAlloy to proper internal dimensions.
Lastly, the internal flow channels were coated with Ceramalloy HTL to provide corrosion protection and restore thermal efficiency. The customer saved $30,000 and was able to cancel the replacement intercooler order.