A waste heat recovery unit (WHRU) is an energy recovery heat exchanger that recovers heat from hot streams with potential high energy content, such as hot flue gases from a diesel generator or steam from cooling towers or even waste water from different cooling processes such as in steel cooling. Waste heat is heat, which is generated in a process by way of fuel combustion or chemical reaction, and then “dumped” into the environment even though it could still be reused for some useful and economic purpose.
Waste heat can be classified into three categories according to the temperature such as
1. High Temperature range- refers to temperature above 650°C
2. Medium temperature range- 230°C – 650°C
3. Low temperature range: below 230°C
High and medium temperature range waste heat is released by furnaces while low temperature range waste heat is released by devices like condenser, solar flat plate collector, etc. Waste heat found in the exhaust gas of various processes or even from the exhaust stream of a conditioning unit can be used to preheat the incoming gas. This is one of the basic methods for recovery of waste heat. Many steel making plants use this process as an economic method to increase the production of the plant with lower fuel demand. There are many different commercial recovery units for the transferring of energy from hot medium space to lower one.
Recuperators: This name is given to different types of heat exchanger that the exhaust gases are passed through, consisting of metal tubes that carry the inlet gas and thus preheating the gas before entering the process. • Regenerators: This is an industrial unit that reuses the same stream after processing. In this type of heat recovery, the heat is regenerated and reused in the process. • Economizer: In case of process boilers, waste heat in the exhaust gas is passed along a recuperator that carries the inlet fluid for the boiler and thus decreases thermal energy intake of the inlet fluid. In case of boiler system, economizer can be provided to utilize the flue gas heat for pre-heating the boiler feed water. On the other hand, in an air pre-heater,the waste heat is used to heat combustion air. In both the cases, there is a corresponding reduction in the fuel requirements of the boiler.
Shell and Tube Heat Exchanger: When the medium containing waste heat is a liquid or a vapor which heats another liquid, then the shell and tube heat exchanger must be used since both paths must be sealed to contain the pressures of their respective fluids. The shell contains the tube bundle, and usually internal baffles, to direct the fluid in the shell over the tubes in multiple passes. The shell is inherently weaker than the tubes so that the higher-pressure fluid is circulated in the tubes while the lower pressure fluid flows through the shell. When a vapor contains the waste heat, it usually condenses, giving up its latent heat to the liquid being heated. In this application, the vapor is almost invariably contained within the shell.
With the experience and expertise in manufacturing various types of Heat Exchangers for Furnace Industry, Thermo Engineers Pvt Ltd Provides wide range of efficient and quality Heat Exchanger Solutions. With highly skilled and techno-savvy team of professionals to take care of all design related aspects like optimization, analysis and testing to improve the product in terms of Efficiency, Performance and Quality Thermo Engineers Pvt Ltd provides design, manufacture and supply Tailor made products as per need of our valued customers.
An Economiser is an equipment which is used as a heat exchanger by pre-heating a fluid to reduce the energy consumption. It is a type of Heat Exchanger specially designed and manufactured to heat up the fluids or recovers the heat from the combustion products. The Economiser / Pre- heater is used to economise the process of power generation.
The Economisers are used in Furnace Industry, Steam Power Plants and Thermal Power Plants. Economiser captures the waste heat from gases and transfers it to water. Economizers are commonly used as part of a heat recovery steam generator in a combined cycle power plants.
The Economizer and Pre-Heater consist of tube bundle, which is a vital part and consists of Finned Tubes, Headers/Water Boxes and Bundle framework. Selection of tube, Galvanization and application of special paints to the parts of the heat exchanger are the important points which need to be taken special care while designing the Economizer, Pre- Heater type Heat Exchangers.
As per design requirement and customer demand material of construction is selected.
| Tubes | Carbon Steel, Copper, Copper-Nickel (70:30), Copper-Nickel (90:10), Admiralty Brass, Stainless Steel 304/ 316/ 316L Titanium, etc. |
| Tube Plates | Carbon Steel, Naval brass, Stainless steel 304/316, Copper Nickel (70:30), Copper-Nickel (90:10), Titanium, etc. |
| Fin Material | Aluminium, Copper, MS etc. |
| Fin Type | Spiral Crimp Fin, Common Fin, L Fin |
We have in-house design facility so; we design the Water Coolers as per customer input data and requirement specifications. The major benefit of our in-house designing is to give most optimum solution for the customer requirements.
| Power Rating Range | Upto 2000kW/each element |
| Tube Execution | Single , Double |
| Cooler Mounting | Side Mounting , Top Mounting |
