over-heat

FOOD & BEVERAGE

Biogas (co-)firing

Food & Beverage companies are frontrunners with respect to energy efficiency. Many convert their organic waste into biogas, which is subsequently used in co-firing steam boilers or CHP-systems (Combined Heat Power). Flue gas originating from biogas firing is acidic and becomes corrosive at wall temperatures below 130 °C, leading to rapid corrosion, significant maintenance cost and unrecovered energy.

The HeatMatrix polymer air preheater is a new generation air preheater that enables heat recovery from corrosive and/or fouling flue gas streams. This exchanger contains polymer tube bundles that are corrosion resistant to concentrated sulphuric acid. A typical application for this exchanger is preheating of combustion air using waste heat from acidic flue gas from a biogas co-fired steam boiler. See Case study

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Other sources of waste heat in the Food & Beverage industry are:

  • Flue gas from oil fired indirect air heaters
  • Flue gas from CHP-units
  • Off-gas from dryers

See also the following links to:
A HeatMatrix polymer heat exchanger
Business Case Calculator

(PETRO) CHEMICAL & REFINERY

In the search for energy efficiency waste heat recovery from flue gas is one of the most interesting sources of hidden energy to improve efficiency and reduce cost. Because:

  1. At a ‘stack location” significant amounts of primary energy are converted into heat at one single location.
  2. Flue gas is discharged into the atmosphere at relatively high temperatures between 150 and 250 °C.
  3. The outlet for recovered waste heat is nearby. Combustion air has a sufficient low temperature to absorb the currently discharged waste heat.

However, metal air preheaters are designed for a minimum flue gas exit temperature of approximately 160 °C in order to prevent corrosion and subsequent high maintenance cost. The HeatMatrix polymer air preheater is a new generation air preheater that enables heat recovery from corrosive and/or fouling flue gas streams. A combination between a metal and a polymer air preheater combines the best of both worlds. See Case study.

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BIOGAS, BIOMASS

Biogas and biomass are new emerging fuels for heat production in order to reduce carbon emission. These fuels frequently contain sulphur, which is converted into corrosive flue gas during combustion. The energy efficiency of biomass fired boilers or biogas fired CHP units can be improved significantly via integration of waste heat from hot flue gas by pre heating combustion air or cold water.

HeatMatrix offers robust polymer heat exchangers for these types of applications. See our Products for more information.

UTILITY

Boilers fired by: (Bio)gas, Refinery gas, Oil, Biomass, Coal

Industrial heat is distributed using steam or hot water as energy carrier. The conversion of primary fuels takes place in a (steam) boiler via a combustion process. The exit temperature of the flue gas is proportional to the amount of heat lost and the loss of efficiency of the combustion process. Frequently, over 5% of the fuel is lost via hot flue gas.

Preheating combustion air with hot flue gas is a simple way to improve the boiler efficiency in a cost effective way. For corrosive flue gas the HeatMatrix polymer air preheater enables heat recovery over a large temperature range and prevents high maintenance cost as result of corrosion problems.

See also the following links to:
A case study for industrial boilers

WASTE TREATMENT

During chemical processing or processing of waste, corrosive off-gas can be generated. This corrosive off-gas is often treated in a dedicated incinerator (RTO) or co-fired in an existing steam boiler or CHP-unit. Waste heat from corrosive flue gas can be used to preheat off-gas, combustion air or any other available outlet like a city heating grid when a polymer HeatMatrix exchanger is applied.

The HeatMatrix plastic heat exchanger is a new generation exchanger that enables heat recovery from corrosive and/or fouling flue gas streams. This exchanger contains polymer tube bundles that are corrosion resistant to concentrated sulphuric acid at elevated temperature.

CERAMIC

Processing of ceramics requires energy intensive processing steps, such as occur in kilns, ovens and dryers. Flue gas or off gas from these steps is corrosive and requires special care when waste heat is recovered from these streams. Standard metal exchangers suffer from rapid corrosion as result of acid dew point corrosion.

The HeatMatrix polymer heat exchanger is a new generation exchanger that enables heat recovery from corrosive and/or fouling flue gas streams. This exchanger contains polymer tube bundles that are corrosion resistant to concentrated sulphuric acid at elevated temperature. Typical application for this exchanger is preheating of combustion air, cold process air of cold water. This exchanger can be equipped with an in-situ cleaning system for cleaning during operation.

See also the following links to:
HeatMatrix air preheater
In-situ cleaning system
Business Case Calculator

“Most profitable investment in sustainability”