Flue gas heat recovery systems
for Oil Refineries

Risk of corrosion limits you to recover more heat from flue gas. With polymer heat exchangers you can recover additional heat below the acid dew point without corrosion issues.

Improve fired heater efficiency >95%

Prevent Corrosion & Fouling

Reduce CO2 emissions

Your fired heater is losing 10% - 20% of its energy via the stack

What is keeping you from recovering this energy?

Identifying a robust solution

Finding a technically feasible solution to recover and reuse waste heat is a challenge.

Corrosive and fouling flue gases

Corrosion and fouling caused by acid condensation prevent further heat recovery to low flue gas temperatures.

Business case

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

Since 10 years we design and deliver heat recovery systems for Oil Refineries to reduce their carbon footprint

Save up to 10% energy on your thermal process

Recover heat - that is now lost - from flue gas.

Your thermal process has waste heat recovery potential

Select your thermal process to find out how

Recover more heat on fired heaters

Fired heaters are used throughout the refinery to heat product streams. Additional heat recovered from flue gas is used for combustion air preheating.

Recover more heat on steam boilers

Steam is made by firing fuels in a boiler. Additional heat recovered from flue gas is used to heat up water or preheat combustion air.

The way our heat recovery system works

Capture waste heat

When hot flue gas leaves the stack it still contains a significant amount of energy. Our heat recovery system captures this heat from fired heaters or boilers. 

Preheat combustion air or water

Cold combustion air, make-up water or boiler feed water is heated with the recovered waste heat. This directly reduces the consumption of fossil fuels. When your installation is duty limited, pre heating combustion air may increase the capacity.

Our heat recovery systems for Oil Refineries

Polymer Air Preheater

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

Stainless steel or Polymer Economiser

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

A 100,000 bbl/day refinery can save an additional 14 MW thermal energy and reduce 26,000 ton of CO2 every year

Refinery fired heater - CDU

4% increase of furnace efficiency

To reduce its carbon footprint, a refinery is focussing on waste heat recovery. A lot of heat is lost via the stack with the potentially corrosive flue gas. The customer wants to recover part of this heat.

So far no heat recovery was performed because of the corrosive nature of the flue gas. When the flue gas is cooled, sulphuric acid is formed and corrosion occurs inside the heat recovery system. The HeatMatrix polymer APH was selected because it can handle the formed sulphuric acid and makes additional heat recovery possible.

After the HeatMatrix polymer APH was installed, furnace efficiency increased with 4%. Corrosion rates downstream of the heat recovery system remained below 0.1 mm/year.

Your path to lower CO2 emissions, energy consumption and costs

1

Technical assessment

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

2

Heat exchanger design and Business Case

A proposal is made that 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 support your Engineering partner during the feasibility phase to create the budget estimate you need to get management approval for CAPEX.

FAQ's

The air preheater and economisers are constructed with polymers. The special Polymers are acid resistant, can handle high temperatures and can be used for heat exchange. Corrosion downstream of the polymer heat exchanger is comparable to normal corrosion rates. For an explanation, download our whitepaper.

The pressure drop will be increased with approximately 4-8 mbar on both the air side and the flue gas side of the exhanger.

Space is often a constraint in refineries. The footprint of the heat exchangers can be adjusted based on available space. Because of their low weight, polymer air preheaters of HeatMatrix can easily be put at elevation.

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.