Heatrecovery

IanMatthews
Sales&MarketingDirector
Gasco

WASTE HEAT RECOVERY

AUSTRALIAS LEADING PROCESS
AND THERMAL ENGINEERING
COMPANY

COMBUSTION,PROCESS&
THERMALENGINEERING

BAYSWATER VICTORIA OFFICE AND WORKSHOP

KEYPRODUCTS
Flares

HRSGs
Water Bath Heater
Regeneration Gas Heaters

Heat Exchanger
Pressure Vessel

Thermal Oxidiser
Terminals

API 560 Heaters Turkmenistan

RTO (Toyota)

Hot Oil Heater

GASCOKEYCUSTOMERS

TOYO
KOREA

AnInconvenientTruth!
Over60%ofallindustrialenergyconsumptionends
upaswasteheat
Asignificantproportionofthiswasteheatis
consideredeitherdifficulttorecoveror
irrecoverable

Applications
WHRUsrecoverenergyfromexhaustof
turbine/engine/otherprocess
Energyisrecoveredbyheatingasecondary
fluid
Secondaryfluidprovidesprocessheattoplant
orcanbeusedtogeneratepower

Applications
Typicalwasteheatsources:

Secondaryfluid:

Furnaces
Boilers
Kilns
Turbinesandengines

Steam
Thermaloil&Synthetics
Water
Water/glycol
Gases

TypesofHeatRecoveryEquipment
Shell&Tube
CoilType
Serpentinecoil
Helicalcoil

HeatRecoverySteamGenerators(HRSG)
Singledrum
Bidrum

Heatpipe

TypesofHeatRecoveryEquipment
ShellandTubeType

TypesofHeatRecoveryEquipment
Serpentine Coil Type

WHRU Water-Glycol Iona Gas plant Vic behind Solar

gas turbine

COIL TYPE EXCHANGER

GAS TURBINE WASTE HEAT RECOVERY UNIT

SerpentineCoilType
HeatExchangerConstruction
Manifold
Liquid
in

Liquid
out

Ubends
Finned
tube

TurbineExhaust
Gases

TypesofHeatRecoveryEquipment
Helical coil

BHP MINERVA GAS PLANT THERMAL OXIDISER

WITH HOT OIL HEAT RECOVERY

TypesofHeatRecoveryEquipment
HRSG
Heat Recovery
Boiler

Single drum natural circulation HRSG with supplementary firing

behind gas turbine Eck Rohr Kessel design

TheHeatPipe ANewWeaponin
theWaronWasteHeat
ThermalSuperconductors
1000timesmorethermallyconductivethancopper

FirstdevelopedbyNASAin60stodealwithcoolingofnuclear
powergenerationinspace
MostefficientwayoftransferringheatfromAtoB
Widelyusedinspecialistexoticandmicroapplications
Nowdevelopedforuseinindustrialwasteheatrecoveryby
Econotherm
Addressesallofthevulnerabilitiesofconventionalheat
recoverytechnology
PotentialtorecovermuchoftheIrrecoverable
Econotherm has broken the cost viability barrier for Heat Pipes

HEATPIPES
Gascoisexclusivedistributorfor
ECONOTHERM heatpipesfromUK
HarnessingECONOTHERMtechnologyand
experiencefordifferentheatrecovery
applications
HeatpipesimportedfromUK;restlocal
fabrication
InstallationandservicesupportfromGasco
Australia

ECONOTHERMPrincipleofOperation
HeatPipes
Preheatedwaterreturn
toboiler

Cooledexhaust
Waterfrom
installation

Separationplate
Watertightsystem
Hotexhaust
Exposedareainwater
Inspectionplate

Exposedareainhotexhaust

ECONOTHERM principleofoperation

HeatPipes

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

WideRangeOfApplications
GastoAir
Furnaces
Kilns
Backtoprocess

GastoWater
Boilers
Incinerators
ElectricityGeneration

GastoThermalOil
Incinerators
ElectricityGeneration

SteamGenerators
Anysource
Backtoprocess

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

IE

Food

Boiler feed water

440 kW

IT

Food

Process steam (genset)

520 kW

12

US

Incinerator

Thermal oil for ORC energy

760 kW

CA

Oil & Gas

Fracking water

2200 kW

UK

Waste > Energy

Thermal oil for ORC energy

940 kW

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

MultistageSteamGenerator
andWaterPreHeater

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

Waterorthermaloilfor
ORCenergygeneration

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

HEATRECOVERYAPPLICATIONS
Power generation

If no use for harnessed process heat, it is possible to generate power

using steam or Organic Rankine Cycle turbines
127

AUSTRALIASLEADINGPROCESS
ANDTHERMALENGINEERINGCOMPANY

BAYSWATER VICTORIA OFFICE AND WORKSHOP

Summary
WasteHeatRecoveryUnitsreduceglobalenergy
requirements,pollutionandenergycostsandcontributeto
cleaningtheenvironment.
GascoexpertiseinWasteHeatRecoveryUnitsprovideshigh
efficiencywasteheatrecoveryincompactmaintenance
friendlymodules.
Gascotrackrecordillustratesourcapabilityinwasteheat
recoveryunitsforawiderangeofapplications.

AUSTRALIAS LEADING PROCESS

AND THERMAL ENGINEERING COMPANY

THNKYOU
FORYOURTTENTION

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