Professional Documents
Culture Documents
com/HPHE
For the first time, our innovative HPHE (Heat Pipe Heat Exchanger) design, combined with patented manufacturing techniques has
enabled our customers to reliably recover energy from hot corrosive and dirty exhaust. The HPHE solution is specifically designed
to operate in hostile exhaust streams, offering low risk, high value energy recovery where other heat exchangers repeatedly fail.
Contents
Why choose heat pipes.......................................................................................................................... p 5
Opportunities for low grade heat recovery in the Food & Beverage industry......................................... p 6
Healthcare Industry & Hospitals............................................................................................................. p 8
Oil & Gas Industry.................................................................................................................................. p 10
Pharmaceuticals.................................................................................................................................... p 12
Request a quote for your application..................................................................................................... p 14
2
info.spiraxsarco.com/HPHE
However, a breakthrough in manufacturing techniques and Heat Pipe Heat Exchanger design has allowed Spirax Sarco to make
the recovery of corrosive and contaminated exhaust waste heat a reality.
Our Heat Pipe Heat Exchanger solution resists fouling and efficiently recovers heat, creating a reliable energy recovery solution
which is completely at home within these previously unsuitable environments.
Energy efficiency in the process industry is becoming an increasingly important issue due to the rising
costs of both electricity and fossil fuel resources, as well as the tough targets for the reduction in
greenhouse gas emissions outlined in the 2015 Paris Agreement.
3
h e a t p i p e h e a t e x c h a n g e r s
Vacuum tube
Condensation
Separation plate
Steam
High particulate
Heat in Cooled exhaust gas
exhaust gas
4
info.spiraxsarco.com/HPHE
SECONDARY SIDE
HEATED HEATED
MEDIA OUT MEDIA IN
SEPARATOR PLATE
HEAT PIPES
PRIMARY SIDE
Cross contamination
The hot and the cold streams are separated by a Average payback under 24 months
plate, into which the heat pipe is fitted, with a seal Payback is typically achieved in under 24
between the hot and the cold sides eliminating months, with the added benefit of significantly
any potential for secondary side contamination. reducing CO2 emissions.
Minimal footprint
Resistant to acidic corrosion
Compared to other heat exchanger technologies,
Heat pipes do not rely upon thin metal surfaces
the HPHE has a small footprint per kW of energy
for effective heat transfer and therefore can
recovered, whilst still providing a low pressure drop.
be constructed from robust materials that offer
increased resistance to erosion.
5
h e a t p i p e h e a t e x c h a n g e r s
Heat Pipe Heat Exchanges offer a reliable, cost effective and low risk solution that enables energy
from contaminated or dirty heat streams to be captured and applied to other areas of the food
manufacturing process.
Food & Beverage companies around the world are benefiting from the cost savings the unique
design of HPHEs offer.
Evaporators
Steam Steam for sterilisation
Distillation production Steam for cooking
Malt fermenter
Brewing &
Distilling
Utilisation of waste heat sources is key to improving industrial energy efficiency, with an estimated 11.4 TWh of recoverable heat being
wasted each year, a quarter of which is from the food and drinks processing sector.
6
info.spiraxsarco.com/HPHE
Y
CASE STUD
CASE STUDY
Location: Ireland
A global commercial dairy was experiencing issues with a heat recovery application, using waste from an exhaust to preheat the
boiler feed water.
7
h e a t p i p e h e a t e x c h a n g e r s
Therefore, these utility costs represent a large proportion of most healthcare facilities
budgets. Whilst, around 15% of the overall carbon footprint of health services is due
to the energy consumed by buildings. All hospitals should look to implement measures
to improve energy efficiency while satisfying the energy requirements of these important
energy consuming end users.
Heating can account for as much as 60% of the total energy bill of a typical building.
Just 1C of overheating can result in an 8% increase in costs.
However, there is huge potential to make real and significant savings, removing thousands of tonnes of emissions per year through
the application of existing and innovative energy recovery technologies. The investments needed are relatively low and even
small scale projects can reap surprisingly high returns.
Heat Pipe Heat Exchangers offer clean, safe and efficient heat recovery from typical low grade waste heat sources within hospitals
and other healthcare facilities. Maximising process waste heat opportunities to reduce energy costs and CO2 emissions.
Minimal footprint
Low fouling
Preheat HVAC
Heating air
Preheat boiler combustion air
Boiler recuperator
Incinerator Preheat boiler feed water
Biomass incinerator Heating water Heat heating hot water supply
Sterilisers Heat domestic hot water supply
Healthcare
Generators
8
info.spiraxsarco.com/HPHE
High temperature stack gases represent the major area of energy loss in combustion
processes. However, until now, the flue gas acid dew-point temperatures have limited the
possible heat recovery technologies options due to excessive corrosion and eventual
failure of the installed heat recovery unit. HPHE are resistant to acidic corrosion, allowing
long-term performance and cost effective waste heat recovery.
HPHEs placed in the exhaust stack or ductwork extract a large portion of thermal energy
in the flue gases and transfers it to processes for use throughout the refinery, such as the
incoming combustion air. In the case of fired heaters the amount of energy saved through
preheating the air can be as much as 20-30% .
Hot water or
steam to heating
or thermally
activated cooling Heat recovery unit Robust materials & long life
equipment
Diverted gas
Highly reliable
Multiple redundancy
Diverter
Water return
9
h e a t p i p e h e a t e x c h a n g e r s
HPHEs are currently savings millions of dollars in many Oil and Gas applications throughout the world, improving operational
performance by recycling waste heat energy back into the process. Reducing the extraction cost price per barrel, whilst adhering to
high standards of operational risk management.
10
info.spiraxsarco.com/HPHE
Y
CASE STUD
CASE STUDY
250 miles out in the South China Sea, a CNOOC (Chinese National Off-shore Oil Corporation) offshore oil rig is saving over 6.4
Mega Watts (MW) through the installation of a HPHE Steam Generator. The large oil rig required a heat recovery solution that
would cope with the challenging environmental conditions and the minimal footprint available for installation.
The Challenge
The offshore platform requires high volumes of steam for Spirax Sarco and Econotherm designed a bespoke heat
drilling injection process. Pumping steam into the steam bed recovery steam generator solution, complete with controls
to heat oil to a viscosity and pressure that allows displacement to accurately manage the steam flow, pressure and
temperature. The unit would meet the size and weight
and extraction. Therefore the operators required a steam
limitations of the installation site, whilst recovery 6.4 MW
generator that could meet the size and weight restriction of the
of waste heat energy from the gas powered turbines.
rig, whilst meeting the demand of 8.4 tonnes of steam per hour
at 12 bar g.
The Installation
The unit was delivered to the offshore site with Spirax Sarco
The Solution
and Econotherm engineers providing support as required at
Spirax Sarco and their associate company, Econotherm,
every stage. The unit matched the requirements exactly, and
worked with CNOOC to discuss potential solutions. Options
was installed on time and to budget.
included an alternative steam boiler or utilising the waste
heat from a gas powered turbine through a heat pipe heat
The Result
exchanger unit.
Since installation the unit has been working without fault,
recovery the predicted 6.4 MW, saving CNOOC approximately
Due to space limitations, cost saving benefits and the need for
2.4m per year and achieving payback with 17 months. This
high reliability it was decided that a HPHE steam generator was
saving does not include the cost that they would incurred had
the optimum solution. The HPHE unit would also enable instant
they been forced to invest in a new boiler.
start up from the gas turbine, as the unit does not suffer from
thermal shock and requires no pre-heating.
Exhaust temp in/out 400C/ 250C
The multiple redundancy and robust, long life material were
Water/steam temp in/out 50C/ 180C
also a factor, as reliability was vital in such a remote location.
The heat pipe unit benefits from independent operation of Exhaust flow/steam rate 130,000 / 8,000 kg/h
each pipe, so no pipe is dependent upon the other to operate Energy recovered 6,400 kW
effectively. The unique design also allows pipes to freely
Recovered energy 2,100K p/a
expand and contract, thus eradicating thermal stress on
the structure. Payback period 17 months
11
h e a t p i p e h e a t e x c h a n g e r s
Not only can energy efficiency reduce overall manufacturing costs and improve process
productivity, it usually reduces environmental emissions, establishing a strong foundation for
a corporate greenhouse-gas-management program. For most pharmaceutical manufacturing
plants, Heating, Ventilation and Air Conditioning (HVAC) is typically the largest consumer
of energy.
12
info.spiraxsarco.com/HPHE
Y
CASE STUD
CASE STUDY
Heat recovery systems reduce the energy required to heat or cool facility intake air by harnessing the thermal energy
of the facilitys exhaust air. For areas requiring 100% make-up air, studies have shown that heat recovery systems can
reduce a facilitys heating/cooling cost by about 3% for each degree (fahrenheit) that the intake air is raised/lowered.
Improving Energy Efficiency in Pharmaceutical Manufacturing Operations , www.pharmamanufacturing.com
13
h e a t p i p e h e a t e x c h a n g e r s
Speak to our expert engineers about your bespoke Heat Pipe heat
transfer solution or one of our many thermal energy solutions
14
info.spiraxsarco.com/HPHE
15
spiraxsarco.com
* Manufacturing sites
Spirax-Sarco ensures that it is fully compliant with all United Nations, European Union
and U.S. sanctions in relation to the supply of its products and services.
In relation to the manufacture of our products, we ensure we do not use conflict minerals.
Copyright 2017 Spirax Sarco is a registered trademark of Spirax-Sarco Limited.
SB-P211-02 CH Issue 2 Some products, services or solutions may not be availbale in certain markets.