Heat Recovery Function

Hot exhaust gases from turbines, furnaces, or process equipment at 200-600°C contain valuable thermal energy. Cold process gases, combustion air, or feed streams require heating. Gas-to-gas exchangers transfer heat between streams, preheating cold gas while cooling hot gas, recovering energy that would otherwise waste to atmosphere. This recuperation reduces fuel consumption 20-40% improving operational economics.

Design Configuration

Shell-and-tube construction with hot gas on shell side and cold gas on tube side, or plate-type designs for compact installations. Multiple tube passes optimize heat transfer while managing pressure drop. ERGIL engineers exchangers based on both gas flow rates, temperatures, required effectiveness, and allowable pressure drops with typical duties 2-50 MMBTU/hr.

Applications

Turbine exhaust heat recovery preheating combustion air for boilers or process heaters, furnace flue gas recuperation warming feedstock, process gas heat integration between hot and cold streams, thermal oxidizer heat recovery, and waste heat utilization across refineries, chemical plants, power generation, and manufacturing facilities.

Material Selection

Stainless steel construction resists high-temperature oxidation and corrosion from flue gas components. Carbon steel suitable for lower temperature applications. Materials selected for gas compositions including sulfur compounds, moisture, and particulates. Design accommodates thermal expansion during temperature cycling and startup/shutdown operations.

Control Features

Bypass dampers enable temperature control preventing cold gas overheating or maintaining minimum hot gas outlet temperature. Temperature monitoring throughout exchanger protects materials and optimizes recovery. Integration with combustion or process controls balances heat recovery against operational requirements.

Performance Benefits

Substantial fuel savings reducing energy costs and greenhouse gas emissions. Improved process efficiency through effective heat integration. Rapid payback typically 18-36 months depending on energy prices and operating hours. Proven technology with extensive industrial application. Materials and design for reliable long-term high-temperature service.

Fouling Considerations

Gas-side fouling from particulates, soot, or sulfur compounds requires periodic cleaning. Design includes adequate fouling factors and cleaning provisions. Soot blowers or online cleaning systems maintain performance. Tube spacing and velocity prevent excessive fouling buildup.

Construction Standards

Design per ASME Section VIII or applicable standards with materials rated for temperatures to 650°C. Expansion joints accommodate differential thermal growth. Structural supports for high-temperature service. Complete documentation with thermal effectiveness calculations and maintenance procedures.

ERGIL gas-to-gas heat exchangers deliver dependable waste heat recovery maximizing energy efficiency and reducing operating costs through proven recuperation technology.