Flue Gas Heat Recovery Study
Every 20C heat recovered from Flue Gases translates to ~1% improvement in Boiler efficiency.
For flue gases with SOx and/or sooty, particulate material
Conventional heat exchangers suffer from cold spot and SOx condensation corrosion due to cold spots. Also, sooty flue gases offer challenges with respect to cleaning and maintenance in conventional exchangers.
HPHE operates at isothermal conditions and hence does not suffer from cold spot formation. Flue gases can be cooled close to the condensation temperature allowing higher heat recovery. Automated or manual in-situ cleaning of HPHE makes it an ideal exchanger for sooty flue gases.
This study focuses on a boiler producing 6 t/h saturated steam at 10 bars. Two fuel cases have been considered for this study, Briquettes and Natural Gas.
Briquette fired boiler
The flue gases will contain a high amount of particulate/soot. The evaporator section of the HPHE for this case has non finned smooth heat pipes and is fitted with an Ultra-Sonic soot blower.
The graph on the right shows the Cost Saved per year and HPHE CAPEX for 60, 80, 100, 120 �°C heat recovered from flue gases, assuming the flue gas exits the boiler at 200�°C.
Savings is calculated based cost of steam @ Rs 2.3/kg
Savings is calculated based cost of steam @ Rs 4.2/kg
Natural Gas fired boiler
The HPHE for this case will have fins in the evaporator section to improve the overall heat transfer. In case there is SOx in the flue gas, the gases can be cooled to a temperature close to the dew point at the stack exit.
The graph on the left shows the Cost Saved per year and HPHE CAPEX for 60, 80, 100, 120 �°C heat recovered from flue gases, assuming the flue gas exits the boiler at 200�°C.
The shown Savings and CAPEX figures are estimated values. Connect with us to find our the exact cost savings and HPHE CAPEX for your project.
We supply specialized  manufactured Shell amp Tube Heat Exchangers amp Pressure Vessels Delivering superior quality products in minimum delivery time MOC we can supply in copper brass carbon steels stainless steels like SS304 SS310 SS316L copper alloys such as cupro nickel Admiralty amp Aluminum Brass and many other materials We can supply Heat Exchangers amp Pressure Vessels up to 40 Tons The product range includes the proprietary plate fin tube heat exchanger oil coolers inter coolers after coolers marine heat exchangers oil cooling systems condensers chillers economizers super feed heat exchangers receivers and surge drums This products are extensively used in oil and gas refineries air separation plants chemical steel refineries pharmaceutical industries air conditioning amprefrigeration plants heat treatment shops marine engines amp gear boxes induction furnaces machine tools diesel engine generating sets compressors power plant installations transformers hydraulic power packs food processing vegetable oil refining amp sugar industry etc We are supplying this with certifications such as U R amp NB Stamp from ASME ISO 90012008 quality certificates from LRQA and certifications from DGQA IRS NSIC etc This are all manufactured in Nondestructive testing such as Visual Inspection Liquid penetrant testing Radiographic testing Tube to Tube sheet Weld radiography Ultrasonic testing for raw material and welds Helium leak testing Bubble Leak testing Magnetic particle testing
Welcome to A.S Engineers & Fabricators, where innovation meets excellence. We are thrilled to introduce our latest breakthrough: the Heat Exchanger. Engineered with precision and crafted with care, our Heat Exchanger is poised to redefine the standards of heat transfer efficiency in diverse industrial applications. In today's dynamic industrial landscape, optimizing heat transfer is essential for enhancing productivity, reducing energy consumption, and ensuring the reliability of critical processes. With this in mind, our team at A.S Engineers & Fabricators has developed a state-of-the-art Heat Exchanger that promises unmatched performance and reliability. MOC:- SS304,SS316,SS316l,Carbon Steel Strategies by heat Exchanger Fluid Selection: Choose the right fluids based on their thermal conductivity and heat capacity to maximize heat transfer efficiency. Matching the properties of the fluids to the application ensures optimal performance. Flow Control: Implement proper flow control mechanisms to regulate the movement of fluids within the Heat Exchanger. This ensures uniform heat distribution and prevents the formation of hot spots or cold spots, enhancing overall efficiency. Temperature Monitoring: Utilize advanced temperature monitoring systems to continuously monitor the temperature of the fluids entering and exiting the Heat Exchanger. This allows for real-time adjustments to optimize heat transfer performance and maintain desired operating conditions Efficient Heat Transfer Our heat exchanger ensures efficient transfer of heat between two fluids, allowing you to maintain optimal temperatures in your processes Cost-Effective Solution By effectively utilizing heat exchange principles, our product helps you save on energy costs, making it a cost-effective solution for your operations Enhanced Performance With improved heat transfer efficiency, our heat exchanger boosts the performance of your equipment and processes, leading to increased productivity Customizable Designs We offer customizable designs tailored to your specific requirements, ensuring that our heat exchanger seamlessly integrates into your existing systems Durable Construction Built with high-quality materials and precision engineering, our heat exchanger is durable and reliable, providing long-lasting performance in demanding industrial environments Easy Maintenance Designed for easy maintenance and servicing, our heat exchanger minimizes downtime and ensures smooth operation, allowing you to focus on your core business activities
Shell and Tube Heat Exchanger
A double pipe heat exchanger is a sort of heat exchanger which includes concentric pipes parted through a mechanical closure. The name of this heat exchanger indicates that it makes use of pipes to exchange heat among fluids. One pipe has hot fluid whilst the opposite pipe has cold fluid. These two fluids do not mix with each other as they are separated by pipes. This heat exchanger is likewise known as a jacketed u-tube, jacketed tube, hairpin, and pipe-in-pipe heat exchanger. The double pipe heat exchanger has a small pipe this is surrounded by some other huge pipes. One fluid glide withinside the small pipe, and the opposite fluid acts through the annulus among the 2 pipes. The internal wall of the small pipe is the heat switch surface. The complete warmness switch system takes vicinity withinside the huge tube. In this way, the internal pipe works as a conductive barrier. The outside facet consists of fluid gliding thru the tube facet or inside. This heat exchanger might also additionally have one pipe or a package deal of pipes (however decrease than 30 pipes). The huge pipe has decreased by 2 hundred mm in diameter. In a few conditions, the internal pipe has vertical fins to enhance the heat switch coefficient among operating fluids. Double pipe heat exchangers are used for small heat switch areas (e.g., 14 m2). The collection connection to elevate the heat switch place wishes greater area and greater accessories, which results in a better strain loss. In addition, it isnâ??t always viable to boom the number of fluid passages on each side. This heat exchanger isnâ??t always exceptionally appropriate for grimy drinks due to the fact the grimy liquid will clog it, and the cleansing of this exchanger could be very hard. The essential benefit of the double pipe warmness exchanger is that it has a smooth operation and easy design.
Shell & Tube Heat Exchangers Air Cooled Heat Exchanger Finned Tube Heat Exchangers Plate Heat Exchangers Oil Coolers Tube Bundles Inter Coolers After Coolers Centac Air Cooler Chillers & Condensors Air Receiver & Pressure Vessels Tank & Coils / Sample Coolers U-Tube Heat Exchanger Kettle Type Heat Exchanger Hairpin Heat Exchanger / Double Pipe Heat Exchanger Reactor Vessel Distillation Columns Storage Tank
Precision Equipments is the leading Shell and Tube heat exchanger manufacturer. A shell and tube exchanger consists of a number of tubes inter-connected inside in a cylindrical shell. This shell and tube exchanger heat through the tubes. there are two fluids cab exchange heat from one place to another. One tubes flows over the outside and other one flows through the tubes. Whether it is a liquid or gas can transfer easily. These tubes are aligned in parallel or cross arrangement. we are using Standard Quality raw material to manufacture of our products.
Shell types Heat Exchanger are classified into fixed and floating type Heat Exchangers. Fixed type Heat Exchangers are used where there are absolutely no chances for inter mixing of two fluids. In this type, the tube sheets are completely welded to the shell and acted as shell flanges. The Floating type Heat Exchangers has the advantages of removability of tube bundle and access for cleaning both inner and outer side of tubes and shell. BEU heat exchanger are shell and tube exchangers with tube bundle consisting of 'U' shaped tubes fixed by mechanical rolling to only one tube sheet. This type of heat exchangers is designed and built with removable shell and tube to allow easy maintenance.
A heat exchanger is a system used to transfer heat between a source and a working fluid. Heat exchangers are used in both cooling and heating processes. The fluids may be separated by a solid wall to prevent mixing, or they may be in direct contact. Classification of heat exchangers: 1. Classification according to construction: Tubular heat exchangers. Plate heat exchangers. Extended surface heat exchangers. Regenerative heat exchangers. Pipe in pipe heat exchangers: Hairpin heat exchangers (often also referred to as â??double pipesâ??) are characterized by a construction form which imparts a U shaped appearance to the heat exchanger. In its classical sense, the term double pipe refers to a heat exchanger consisting of a pipe within a pipe, usually of a straight-leg construction with no bends. However, due to the need for removable bundle construction and the ability to handle differential thermal expansion while avoiding the use of expansion joints (often the weak point of the exchanger), the current U-shaped configuration has become the standard in the industry.
Murphy plate finned tube heat exchanger has some obvious advantages in operation, especially in the field of air to air heat transfer, especially in the field of ultra-high temperature air to air heat transfer. To a certain extent, it has become the upgrading product of the tube, heat pipe and finned tube heat exchanger. The main characteristics of Murphy plate finned tube heat exchanger: the finned tube heat exchanger can be designed with elastic structure, which can effectively solve the problem of its thermal expansion; there are rich test and actual operation data as support, through constant correction of the calculation formula, the calculation error is within 5%, and more than 95% of the equipment operation can reach the design parameters.
