Heat recovery
Ian Matthews
Sales & Marketing Director
Gasco
WASTE HEAT RECOVERY
AUSTRALIA’S LEADING PROCESS
AND THERMAL ENGINEERING
COMPANY
COMBUSTION, PROCESS & THERMAL ENGINEERING
BAYSWATER VICTORIA OFFICE AND WORKSHOP
KEY PRODUCTS
Flares
HRSG’s
Water Bath Heater
Regeneration Gas Heaters
Heat Exchanger
Pressure Vessel
Thermal Oxidiser
Terminals
API 560 Heaters Turkmenistan
RTO (Toyota)
Hot Oil Heater
GASCO KEY CUSTOMERS
TOYO
KOREA
An Inconvenient Truth!
• Over 60% of all industrial energy consumption ends up as waste heat
• A significant proportion of this waste heat is considered either difficult to recover or “irrecoverable”
Applications
• WHRU’s recover energy from exhaust of turbine/ engine/ other process
• Energy is recovered by heating a secondary fluid
• Secondary fluid provides process heat to plant or can be used to generate power
Applications
Typical waste heat sources:
Secondary fluid:
Furnaces
Boilers
Kilns
Turbines and engines
Steam
Thermal oil & Synthetics
Water
Water / glycol
Gases
Types of Heat Recovery Equipment
• Shell & Tube
• Coil Type  Serpentine coil
 Helical coil
• Heat Recovery Steam Generators (HRSG)
Single drum Bi drum
• Heat pipe Types of Heat Recovery Equipment
Shell and Tube Type
Types of Heat Recovery Equipment
Serpentine Coil Type
WHRU Water-Glycol Iona Gas plant Vic behind Solar
gas turbine
COIL TYPE EXCHANGER
GAS TURBINE WASTE HEAT RECOVERY UNIT
Serpentine Coil Type Heat Exchanger Construction
Manifold
Liquid in
Liquid out
U‐bends
Finned tube
Turbine Exhaust Gases
Types of Heat Recovery Equipment
Helical coil
BHP MINERVA GAS PLANT THERMAL OXIDISER
WITH HOT OIL HEAT RECOVERY
Types of Heat Recovery Equipment
HRSG
Heat Recovery
Boiler
Single drum natural circulation HRSG with supplementary firing
behind gas turbine – Eck Rohr Kessel design
The Heat Pipe – “A New Weapon in the War on Waste Heat”
• Thermal Superconductors
– 1000 times more thermally conductive than copper
• First developed by NASA in 60’s to deal with cooling of nuclear power generation in space
• Most efficient way of transferring heat from A to B
• Widely used in specialist exotic and micro applications • Now developed for use in industrial waste heat recovery by Econotherm
• Addresses all of the vulnerabilities of conventional heat recovery technology
• Potential to recover much of the “Irrecoverable”
Econotherm has broken the cost viability barrier for Heat Pipes
HEAT PIPES
Gasco is exclusive distributor for ECONOTHERM™ heat pipes from UK
Harnessing ECONOTHERM™ technology and experience for different heat recovery applications
Heat pipes imported from UK; rest local fabrication Installation and service support from Gasco Australia
ECONOTHERM® Principle of Operation
Heat Pipes
Preheated water return
to boiler
Cooled exhaust
Water from installation
Separation plate
Water tight system
Hot exhaust
Exposed area in water
Inspection plate
Exposed area in hot exhaust
ECONOTHERM® principle of operation
Heat Pipes
Inspection
plate
Heat Pipe / Heat Exchanger Operation
Recovering the Irrecoverable
Primary can be hot exhaust, air, liquid,
solid surface
Up to
350C
From
-30C
Secondary can be a gas, water, thermal
oil, glycol, R245fa and various others
Working fluid chosen according to
temperatures involved - water, ammonia,
acetone, Dowtherm, etc.
Up to
1000C
e.g.
120C
Pipe materials chosen according
performance requirement of fluid types and
temperatures: carbon steel, stainless steel,
aluminium, copper, etc.
Heat Pipe Advantages
Multiple Redundancy
Each pipe operates independently so
unit is not vulnerable to a single pipe
failure
Low Fouling
Smooth pipes permits use in high
particulate or oily applications
Ease of Cleaning & Maintenance
Can be maintained in situ (no uninstall)
Manual/automated cleaning systems
Isothermal Operation
No Hot or Cold spots - Eliminates condensation
Allows greater energy recovery
Better longevity for thermal oil
Robust Materials and Long Life
Pipes free to expand and contract, thus
no thermal stress on structure
Thick pipe walls resist erosion/corrosion
Recovering the Irrecoverable
Low Pressure Drop
Low parasitic load means less capital and
running cost on fans and greater energy
recovery possibilities
More Efficient
Usually smaller and/or lighter than
conventional exchangers
Highly Scalable, Customisable &
Configurable
Modular design allows on site assembly
Can be designed for future expansion, to
meet specific application or operational
needs
Reactivity
Fast reaction time, offers different control
options and suitable for sensitive
apparatus: does not require preheating
Wide Range Of Applications
• Gas to Air
– Furnaces
– Kilns
– Back to process
•
Gas to Water
– Boilers
– Incinerators
– Electricity Generation
•
Gas to Thermal Oil
– Incinerators
– Electricity Generation
•
Steam Generators
– Any source – Back to process
Case Study Summary
Recovering the Irrecoverable
SECTOR
APPLICATION
ENERGY
RECOVERED
PAYBACK (months)
US
Auto
Combustion air
500 kW
16
IN
Ceramics
Combustion air
600 kW
15
IT
Clothing
Process Steam
1000 kW
<3
UK
Energy
Process hot water (biofuel )
750 kW
1
IE
Food
Boiler feed water
440 kW
6
IT
Food
Process steam (genset)
520 kW
12
US
Incinerator
Thermal oil for ORC energy
760 kW
2
CA
Oil & Gas
Fracking water
2200 kW
1
UK
Waste > Energy
Thermal oil for ORC energy
940 kW
3
Gas to Air Unit, Automotive, Aluminium Furnace, USA 2008
Recovering the Irrecoverable
Gas to Air
Exhaust Temp In/Out
400 C/266 C
Air Temp In/Out
30 C/293 C
Exhaust/Air Mass Flow
12,000/ 6,374 Kg/h
Energy Recovered
528 KW
Recovered Energy
$155K p/a
Project Cost
$150K
Payback Period
16 Months
$/KW recovered
$123 (£76)
• Econotherm® GA 360 smooth pipe heat exchanger
• 500 kW combustion air pre-heater
• High particulate matter exhaust from furnace
• Low fouling, easy cleaning and maintenance, high reliability
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
• Unit positioned outside main factory premises
• Customer advised it was not possible by consultants (acid etc)
Gas to Air Unit, Antique Ceramics, Horizontal Roller Kiln, India 2010
Recovering the Irrecoverable
Gas to Air
Exhaust Temp In/Out
316 C/ 122 C
Air Temp In/Out
35 C/ 215 C
Exhaust/Air Mass Flow
9,800 Kg/h/ 12,000 Kg/h
Weight
8000 kg
Pressure drop
392 Pa
Energy Recovered
606 KW
Recovered Energy
RS 4.5m p/a
Project Cost
RS 6m
• Econotherm® GA 360 smooth pipe heat exchanger
• Prior attempts to deploy conventional equipment resulted in unit failures and
lost investment
• 600 kW combustion air pre-heater
• Highly acidic (SO2), sticky particulate matter exhaust from kiln dryer exhaust
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
• Innovative automatic pipe cleaning mechanism: moving plate system
Conoco Phillips Gas Compressor Station, Canada 2012
Recovering the Irrecoverable
Gas to Water
Exhaust Temp In/Out
454 C/ 180 C
Water Temp In/Out
50 C/ 90 C
Exhaust/Water Mass Flow
28,567/14,470 Kg/h
Water Mass Flow
14,470 Kg/h
Weight of unit
5,100 Kg
Exhaust pressure drop
750 Pa
Energy Recovered
1,200 KW
Recovered Energy Value
£180K p/a
Heat Exchanger Cost
£45K
• Econotherm® GW 1200 finned to finned pipe heat exchanger
• 1.2MW process water heater (Genset)
• Remote location: chosen for high reliability, no single point of failure, low fouling,
easy cleaning and low maintenance, small footprint and weight
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
• Client indicates they will order many more once first is proven
G2W, Shale Gas Well Head Fracking,
Thermal Oxidiser, Canada 2012
Recovering the Irrecoverable
Gas to Water
• Econotherm® GW 2000 hybrid pipe heat exchanger
• 2.2MW fracking water heater: highly robust mobile unit for travelling around Canada
• High particulate matter exhaust from furnace; removable panels incorporated for cleaning
• Low fouling, easy cleaning and maintenance, high reliability
Exhaust Temp In/Out
816 C/ 150 C
Water Temp In/Out
5 C/ 16 C
Exhaust/Water Mass Flow
11,016/180,000 Kg/h
Weight of unit
3,600 Kg
Exhaust pressure drop
800 Pa
Energy Recovered
2,260 KW
Recovered Energy Value
£360K p/a
Heat Exchanger Cost
£65K
Payback Period
<3 Months
Price per KW recovered
£27
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
Biofuel plant gensets,, UK 2012
Recovering the Irrecoverable
Gas to Water two pressure
vessels
Exhaust Temp In/Out
440 C/ 371 C
Water Temp In/Out
75 C/ 98 C
Exhaust/Water Mass Flow
46,500/ 36, 210 Kg/h
Weight of unit
1,556 Kg
Exhaust pressure drop
850 Pa
Energy Recovered
750 KW
Recovered Energy Value
£175K p/a
Heat Exchanger Cost
£16,675K
Payback Period
1 Month
Price per KW recovered
£17
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
• Econotherm® GW 650 double water vessel heat exchanger
• 750 kW unit, low pressure drop
The reason for the shape was the large duct diameter, necessitating a large cross sectional area on
our unit. However they only needed to recover a small amount of energy to get the maximum grant hence a small temperature drop. This meant a lot of heat pipes across the unit, but only a small
number of rows. The shape necessitated two water
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
Gas to Water unit, Clothing Industry, Steam,
Recovering the Irrecoverable
Italy 2012
Gas to Water (pressurised)
Exhaust Temp In/Out
490 C/ 119 C
Water Temp In/Out
112 C/ 116 C (5 bar)
Exhaust/Water Mass Flow
7,300/ 220,000 Kg/h
Weight of unit
1,500 Kg
Exhaust pressure drop
800 Pa
Energy Recovered
1023 KW
Recovered Energy Value
€180K p/a
Heat Exchanger Cost
€20K
Payback Period
<3 Months
Price per KW recovered
€18 (£15)
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
• Higher than expected / better performance than heat exchanger previously installed: Primary Smoke Ti = 525 ° C T = 154 ° C Q = 7314 kg /
h; Secondary hot water Ti = 115 ° C T = 117.5 ° CQ = 300,000 kg / h., Energy Potential = 871 kW
• We have found in the field to the new heat exchanger the following data: Primary Smoke Ti = 490 ° C T = 119 ° C range not measured;
Secondary hot water Ti = 112 ° C T = 116 ° CQ = 220,000 kg / h; Energy Potential = 1023 kW
• From the above it can be seen that we have improved the performance of the system, increasing the recovered heat by 15% and for this we
about the construction company Spirax-Sarco.
• Replaced much larger shell and tube system
Multi-stage, in series, steam/water, natural gas, Spirax Sarco
Italy 2012
Recovering the Irrecoverable
Multi‐stage Steam Generator
and Water Pre‐Heater
• Anaerobic digester genset in food industry
Exhaust Temp In/Out
420 C/ 160 C
Water Temp In/Out
160 C/ 198 C (12 bar)
Exhaust/Water Mass Flow
11,484/ 900 Kg/h
Weight of unit
1852 Kg
Exhaust pressure drop
700 Pa
Energy Recovered
520 KW
Recovered Energy Value
£19K p/a
Heat Exchanger Cost
€19K
Payback Period
12 Months
Price per KW recovered
£36
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
• 1 stage of 198C/12 Bar steam generation, left hand side
• 2 stages of water heating delivered by 2 standard modules, visible on right of unit
• Pipes screwed in from underneath on standard modules; modules can be removed individually
• Hinged access doors for easy cleaning, sealing nuts will be replaced by latches on future units
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
Biomass Incinerator, exhaust G2O or G2W, Air Burners,
Recovering the Irrecoverable
USA
Water or thermal oil for
ORC energy generation
• Mobile thermal oxidiser for use in forestry and other mobile applications
• Process - or for ORC energy generation - hot water or thermal oil
• Range of capacities
• High temperature
Exhaust Temp In/Out
950 C/ 600 C
Water /Glycol Temp In/ Out
203 C/ 254 C (12 bar)
Exhaust/Water Mass Flow
28,800/ 57,000 Kg/h
Weight of unit
4320 Kg
Exhaust pressure drop
450 Pa
Energy Recovered
760 KW
Recovered Energy Value
£140K p/a
Heat Exchanger Cost
£25K
Payback Period
<3 Months
Price per KW recovered
£32
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
Gas to Oil unit, Waste Processing Plant, Pyrolysis,
Recovering the Irrecoverable
UK 2011
Gas to Oil (for ORC)
Exhaust Temp In/Out
1000 C/ 250 C
Oil Temp In/Out
135 C/ 280 C
Exhaust/Water Mass Flow
4,150/ 9,200 Kg/h
Weight of unit
1,800 Kg
Exhaust pressure drop
650 Pa
Energy Recovered
940 KW
Recovered Energy Value
£150K p/a
Heat Exchanger Cost
£25K
Payback Period
3 Months
Price per KW recovered
£23
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
• Econotherm GW940, smooth/finned hybrid pipe ‘through-flow’ heat exchanger
• 940 kW thermal oil heater; very high inlet exhaust temperature catered for by ‘through-flow’ model
• To feed and ORC engine to generate electricity
• Very high particulate matter exhaust from furnace; removable panels incorporated for cleaning
• Low fouling, easy cleaning and maintenance, high reliability
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
Oil Cooler
Recovering the Irrecoverable
Indirect Cooling
Exhaust Temp In/Out
1000 C/ 250 C
Oil Temp In/Out
135 C/ 280 C
Exhaust/Water Mass Flow
4,150/ 9,200 Kg/h
Weight of unit
1,800 Kg
Exhaust pressure drop
650 Pa
Energy Recovered
940 KW
Recovered Energy Value
£150K p/a
Heat Exchanger Cost
£25K
Payback Period
3 Months
Price per KW recovered
£23
Multi
Redundancy
Robust Material
Low Fouling
Working
Temperatures
Efficient
Cleaning &
Maintenance
Low Pressure
Drop
Scalable &
Customisable
Reactivity
Isothermal
Operation
1. Lower cost on a like for like £ per delta T basis
2. Superior thermal transfer ensures smaller cooler volume and footprint
3. Simple structure and passive operation deliver low maintenance and reduced ongoing operation costs
4. High reliability through intrinsic redundancy from Multi-pipe design. A single pipe failure will not significantly affect cooler operation
HEAT RECOVERY APPLICATIONS
Power generation
If no use for harnessed process heat, it is possible to generate power
using steam or Organic Rankine Cycle turbines
127
AUSTRALIA’S LEADING PROCESS AND THERMAL ENGINEERING COMPANY
BAYSWATER VICTORIA OFFICE AND WORKSHOP
Summary
• Waste Heat Recovery Units reduce global energy requirements, pollution and energy costs and contribute to cleaning the environment.
• Gasco expertise in Waste Heat Recovery Units provides high efficiency waste heat recovery in compact maintenance friendly modules.
• Gasco track record illustrates our capability in waste heat recovery units for a wide range of applications.
AUSTRALIA’S LEADING PROCESS
AND THERMAL ENGINEERING COMPANY
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