Heat recovery systems for flue gas or exhaust air in Chemical plants

Corrosion and fouling problems limit the recovery of more heat. With polymer heat exchangers you can recover additional heat and overcome these issues.

Improve thermal efficiency

Prevent Corrosion & Fouling

Reduce CO2 emissions

Your thermal processes are losing up to 15% of their energy through the stack

What is keeping you from recovering this energy?

Finding a robust heat exchange solution

Finding a technically feasible solution to recover and re-use waste heat is a challenge.

Corrosive and fouling flue gases

Your flue gas or dryer exhaust air is potentially corrosive or fouling at low temperatures.

Business case

The payback time of waste heat recovery projects must be less than 5 years.

We design and deliver heat recovery systems for Chemical plants to reduce their carbon footprint

Save up to 10% energy on your thermal process

Recover heat - that is now lost - from flue gas or exhaust air.

Your thermal process has waste heat recovery potential

Select your thermal process to find out how

The way our heat recovery system works

Capture waste heat

When hot flue gas and exhaust air leave the stack, they still contain a significant amount of energy. Our heat recovery system captures this heat from fired heaters, ovens, kilns, calciners, steam boilers, thermal oil heaters or dryers.

Preheat drying air, combustion air or water

Cold combustion air, drying air, process water, make-up water or boiler feed water are heated with the captured waste heat. This directly reduces the consumption of fossil fuels. 

Our heat recovery systems for Chemical plants

Polymer Air Preheater

Warm up combustion air or drying air by extracting heat from flue gas or exhaust air. The air preheater is corrosion resistant, easy to maintain and to clean.

Stainless steel or Polymer Economiser

Warm up boiler feed water, make-up water or process water with waste heat from flue gases or exhaust air. The economiser is corrosion resistant and easy to maintain and to clean.

CPVC producer Lubrizol

8% energy consumption reduction

Lubrizol is committed to environmentally responsible and sustainable solutions. To reduce their energy consumption on a drying process of CPVC, they wanted to recover heat from the exhaust air of the dryer.

Previously no heat was recovered from the hot drying air, because of the high hydrochloric acid content in it. When cooled down, through the water and acid dew point, hydrochloric acid is formed and corrosion occurs.

A HeatMatrix polymer APH was selected, because of its ability to handle corrosive exhaust air. Incoming cold air is heated from 10 to 56 °C, resulting in an energy saving of 170 kW. Corrosion free heat recovery is achieved.

Your path to lower CO2 emissions, energy consumption and costs

1

Technical assessment

Our process engineers assess technical feasibility of additional heat recovery on your process. The potential reduction in CO2 emissions and energy costs is determined.

2

Heat exchanger design and Business Case

A proposal shows all technical details and an economic assessment with payback time. You have everything you need for approval to start a feasibility study. 

3

Feasibility study

We or your preferred Engineering company can perform a feasibility study to create the budget estimate you need to get management approval for CAPEX.

FAQ's

Sulphur in fuels like natural gas, biogas, biomass, coal or fuel oil gets combusted and forms SOx. Most of this is in the form of SO2 and 2% to 4% is present as SO3. This SO3 condenses when flue gas is cooled and forms sulphuric acid (H2SO4). This leads to corrosion of metal surfaces, ducts and stacks. This condensation reaction takes place when the flue gas temperature drops below, or the flue gas comes in contact with a surface temperature below what is called the Acid Dew Point. The polymer heat exchange technology allows flue gas to be cooled without having the risk of corrosion.

HeatMatrix heat recovery systems are designed for low maintenance cost. The polymer heat exchangers have a low tendency of chemical bonding and therefore a lower degree of fouling. Furthermore an in-situ cleaning system can be installed which will facilitate cleaning during operation and limits the required downtime for maintenance purposes. Our non-polymer heat recovery solutions are designed in such a way that cleaning can be done off-line and no operational stop is required.

This depends on the size of a project and the geography. If you contact us, we can judge the situation. 

Technical Assessment of your situation

Our process engineers assess the technical feasibility of additional heat recovery on your process. The potential reduction in CO2 emissions, energy consumption and costs are determined.