Cross flow HP units: A combination of various units

Cross flow HP units:  A combination of various units

Gas to Air Unit, Automotive, Aluminium Furnace, USA 2008

Gas to Air Unit, Automotive, Aluminium Furnace, USA 2008

  Econotherm® GA 360 smooth pipe heat exchanger

•  500 kW combustion air pre-heater

•  High particulate matter exhaust from furnace

•  Low fouling, easy cleaning and maintenance, high reliability

•  Unit positioned outside main factory premises

Specification of unit:

Exhaust Temp In/Out :             400/266 Deg C

Air Temp In/Out         :              30 /289 Deg C

Exhaust / Air mass     :              12,000/6374 kg/hr

Flow

Energy Recovered     :               528 Kw

Recovered Energy     :               155 K p/a

Project  Cost               :              150  K

Payback Period           :               16 Months

  

Econotherm receives ISO9001 certification

   
                 Econotherm receives ISO9001 certification




The ISO9001 is a quality assurance on all Econotherm products for the 'Design, manufacture and supply of a heat pipe heat exchanger and heat pipes for use in industrial heat recovery'. 

This certification was conducted by SGS UK Ltd. who were very impressed with the procedures and methods already in place at Econotherm.

ECONOTHERM COMPANY PROFILE

Company Profile

Econotherm (UK) was formed in 2007 in order to develop, design, manufacture and deliver heat pipe waste heat recovery units for industrial applications. The company acquired the intellectual property of Dr Dumitru Fetcu and Transterm which is the culmination of 25 years extensive research and development in the heat pipe field.

In this relatively short period Econotherm has demonstrated the viability and significant technical advantages of heat pipe units over conventional heat exchange technology.

With over 200 successful implementations behind it Econotherm has built up an enviable list of blue chip references. Econotherm equipment now operates in 12 countries and 8 industrial sectors and ranges in size from 10KW to many MW..

Alongside production and within its new dedicated research facility Econotherm has continued to develop the heat pipe technology and is currently working on 5 major R&D projects with the UK government and other international partners.

Econotherm works closely with the UK government Carbon Trust and is currently developing industrial heat recovery solutions for various manufacturing sectors in the UK and Europe.

Econotherm has developed international partnerships for heat pipe recovery unit manufacture and its products are now available in India and Italy through local licensing arrangements. The company is recognised internationally for its expertise in the field. It has also been recognised with green technology awards from Shell Oil and the Carbon Trust in recent years.

Econotherm operates to ISO 9001 and its products are CE compliant where applicable.

Application Type –

Gas to Gas/Air

1.       Aisin Automotive, Kentucky, USA – Contact - Phill Cranny – 001 (843) 883 3533

3 X 528 KW Gas to Air furnace Pre-Heaters – (2005 -2008)

2.       Spirax Sarco, Italy – Contact Gianmarco Ronco, Via per Cinisello 18, 20054 Nova Milanese   +39 (0)362 4917547

3.      
1 X 320KW and 1 X 195KW furnace exhaust gas combustion air Pre-heater - (2009)

4.       Schering Plough, Co Wicklow Ireland –Contact - David Johnson –  (0) 28 9188 3875  

820 KW Gas to Gas Pre-Cooler/Re-Heater – (2009)

5.       Saint Gobain, British Gypsum, UK – Contact - Derek Dacre – (0)7929 461776

1 X 391KW Gas to Air Pre-Heater on gypsum kettle exhaust –(2011)

6.       Trinec, Ostrava, Czech Republic – Contact - Dr Pavel Sturcz – (0) 597 305 808      

520 X 7.5Mtr finned gas to air pre-heater heat pipes – (2010)

7.       Antique & Somany Ceramics, India – Contact – Chander Kamra – 0091 9819536221

1 X 445 KW Gas to Air Pre-Heater with integrated moving plate cleaning system - (2011)
1 X 540 KW Gas to Air Pre-Heater with integrated moving plate cleaning system (2013)

Gas to Water

8.       Empower, UK – Contact,   - Gordon Hiscock – (0)1225 791099

10 X 118 KW Gas to Water oil tank Pre-heaters- 2008

9.       Vitkovice, Ostrava, Czech Republic – Contact - Dr Pavel Sturcz – (0) 597 305 808        

564 KW Gas to water building heater - - (2008)

10.   Honeywell Process Solutions, UK -  Contact - Chris Bayliss – (0) 7715 008722

5 X  488 KW – 650 KW Gas to Water boiler Pre-Heaters – (2008)

11.   Kawan, Ipoh, Malaysia – Contact - W K Wong – (0) 605-2913840

Various gas to water boiler Pre-heater –(2009)

12.   Spirax Sarco, Milan, Italy – Contact – Matteo Palena

Various gas to water boiler Pre-heaters – (2010)

13.   CCC, Abhu Dhabi – Contact – Idries Dudokh, e-mail - idudokh@ccc.ae

Various gas to water – Genset exhaust to water heaters – (2009)

14.   Quebrada, Chile – Contact – Alberto Gonzalez, e-mail – alberto.gonzalez@teck.com

2 X 2MW gas to water genset process water heater – (2011)

15.   Maralto, Canada – Contact – Marlin Romeo, e-mail – maralto@telus.net, cell – 001 780-305-9555

1 X 1.9 MW high temperature (815C) gas to water fracking water heater (2012)

16.   Conoco Phillips – Contact – Mark Mckay, e-mail – mark.mckay@conocophillips.com, cell 001 615-4364

1 X  1.1 MW gas to water genset utility water heater – (2013)

Gas to Oil

17.   Qinetiq,  UK, – Contact – Chris Bayliss – (0) 7715 008722

 2 X 550WK incinerator exhaust  to thermal oil heater for ORC – delivered to US Military, multiple re-orders – (2009)

18.   Spirax Sarco,  Italy, – Contact – Antonio Cavadini –  (+39) 0362 4917531

Various gas to oil units – (2010-2011)

Steam to Water

19.   Western Proteins, Ireland – Contact – Liam Flynn – liam.flynn@crowleycarbon.co.uk –(2011)

SOMANY CERAMICS HEAT PIPE HEAT RECOVERY

HEAT PIPES BASED SOLUTIONS FOR CHALLENGING

WASTE HEAT RECOVERY APPLICATIONS

                   

          
                       ECONOTHERM FACILITY IN UK

Challenging waste heat recovery scenarios

           Many industrial processes
generate highly difficult exhaust
conditions that can be
characterised as follows:
                             1. High temperatures /
                                 mass flows
                             2. High particulate content
                                 that is abrasive and / or
                                 can cause fouling
                            3. Highly corrosive, acidic
                                content SO2, SO3, NO2,
                                etc.








Heat pipes can manage

these difficult conditions!

  What Does The Solution Consist Off?

Why Does The HP Solution Work Where Conventional Units Don’t?

1. HP metal temperature can be kept above the acid dew point.
2. Eliminates any localised acid condensation (cold spots).
3. Easy to clean.
4. The risk profile on pipe failure is minimised due to the multiple
redundancy.

                                     “Heat Pipes”

                                     What are they?               

Multiple Redundancy
Each pipe operates independently so unit is not vulnerable to a single pipe failure
This prevents cross contamination each heat pipe acts as an additional

buffer between the two fluids

Low Fouling
Use of smooth pipes allows exchangers to be used in high particulate or oily

applications

Ease of Cleaning & Maintenance
Can be maintained in situ (no uninstall) Manual/automated cleaning systems

Isothermal Operation – no hot or cold spots
Eliminates cold corners and condensation
Allows greater energy recovery
Better longevity for thermal oil

Robust Materials and Long Life
Design allows pipes to freely expand and
contract, thus no thermal stress on structure

Thick pipe walls resist erosion/corrosion

Intermediate Pipe Working -Temperature
Allows higher exhaust temperature

limits on some applications

Highly Scalable, Customisable & Configurable
Modular design allows on site assembly
Can be designed for future expansion,
to meet specific application or operational needs

Reactivity
Fast reaction time, 
offers different
control options and suitable for sensitive

apparatus: does not require preheating

Typical geometries of heat pipe based waste heat recovery systems

A schematic of a typical heat pipe unit

Heat pipe units: typical configurations
      
        Standard cross flow HP heat exchangers  


Air preheaters
Gas to water
Gas to thermal oil
Steam generators 
       Modular cross flow HP heat exchangers Gas to water

 Gas to water

 Gas to thermal oil

       Throughflow HP heat exchangers

Cross flow HP units: Gas to air

Hot stove blast furnace gas to air heat recovery 

Cross flow HP units: Gas to air ( Ceramics )

Gas to air heat recovery at ceramics kiln

FICCI Technical Meet On Industrial Waste Heat Recovery

Antique Ceramics Case Study

Client: Antique Ceramics 

Product Application: Ceramic Kiln Exhaust to Dryer Air Pre-heater

Location: Morbi, Gujarat, India

Date of Installation: 2008

The Challenge:

Exhaust Inlet:                       316°C

Exhaust Mass Flow:              9800 Kg/h

Recovery Media Inlet:          35°C

Recovery Media Mass Flow: 12000 Kg/h

Fuel Type:                             Gas

The Client:

Much of India’s ceramics industry is located in Morbi, Gujarat; an estimated 75% of all India’s tile output is said to derive from this one region. Antique Ceramics is one of circa 300 local factories operating in a highly competitive sector both nationally in India and globally. Any competitive advantage that can be derived may make the difference between profitability and survival or loss making and potential closure.

Project Circumstances:

The technology used by Antique Ceramics (and many of their competitors) is roller kiln whereby the tiles are pressed as they pass through. The kilns contain multiple burners that generate a known waste heat but is largely considered unusable due to the aggressive dust particulate with high sulphur content. Several attempts had been made with conventional heat exchange technologies but none had been successful prior to the installation of the Econotherm unit.

Why Econotherm Heat Pipe Technology?:

Econotherm  waste heat recovery technology proved ideal for Anrique Ceramic’s needs for a number of reasons:

• Econotherm heat pipe technology was sufficiently robust and reliable to withstand the aggressive particulate in the exhaust
• An automatic cleaning system was incorporated that enabled continuous operation without need for frequent maintenance stoppages
• Avoidance of corrosion due to isothermal properties and heat pipe temperatures higher than dew-point

       The Solution: Carbon Steel Heat Pipes Unit

       Configuration: Cross-Flow

Working Fluid: Distilled water

Access Panels: Yes

Automated Cleaning: Yes

Project Cost: 59,000 GBP

ROI Period: 6 months

       Factors of Success: 

       In addition to the long-term reliability and robustness of the Econotherm unit the ability to clean and maintain the performance of the unit without disrupting the manufacturing process were critical to the clients’ needs and expectations.

       Client / Project Feedback

       Following the installation and commissioning of this unit Econotherm have received a performance certificate from the client  testifying that the Econotherm unit has delivered  on expectations in terms of recovering waste heat energy in extremely challenging circumstances.

Heat Pipe Heat Recovery

I am an associate of ECONOTHERM UK

ECONOTHERM® is a leading UK based manufacturer of Heat Pipe Waste Heat Recuperators, Economisers, Pre-Heaters and Steam Condensers 

ECONOTHERM® heat pipe exchangers are used to recover waste heat from furnace, boiler, oven, thermal oxidiser, engine & incinerator exhaust. The recovered heat is converted to useable hot air, water or thermal oil for use in process, space heating and electrical generation to significantly reduce the clients fuel costs and corresponding CO₂ emissions.

You can reach me at

Econotherm India

Chander Kamra
Telephone: +91 9819536221 
E-mail:       chander.kamra@econotherm.eu
Skype ID:   chanderprakashkamra