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Corrosion and fouling problems limit the recovery of more heat. With polymer heat exchangers you can recover additional heat and overcome these issues.
Finding a technically feasible solution to recover and re-use waste heat is a challenge.
Your flue gas or dryer exhaust air is potentially corrosive or fouling at low temperatures.
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, dryers, CHP systems, RTO’s or incinerators in chemical in plants.
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.
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.
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.
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 Air Preheater 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.
Our process engineers assess technical feasibility of additional heat recovery on your process. The potential reduction in CO2 emissions and energy costs is determined.
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.
In a chemical plant, a number of thermal processes are in operation, such as fired heaters, steam boilers, thermal oil heaters, dryers, ovens and others. On these thermal processes high grade heat is lost through the stack via hot flue gas. This can be as much as 15% of the used primary energy. By recovering the heat from flue gas to preheat combustion or drying air, a significant reduction in energy and CO2 emissions can be achieved. Alternatively, the waste heat can be used to warm up boiler feed or process water.
Making the thermal processes more efficient reduces fuel consumption and therefore lowers fuel costs. In addition, making the heat recovery resistant to corrosion enables a chemical plant operator to recover more heat when fuels that contain sulphur are being used like oil, coal and biogas. Clients have improved their efficiency by 5 to 10% and achieved payback times of 3 to 5 years. Request a free Technical Assessment to get insight in your saving opportunities.