The tubular heat exchanger is designed for the recovery of heat from flue gases containing a high proportion of dust particles. They are most commonly used to recover thermal energy from the flue gases of aluminium smelting furnaces, where a gas burner is used as the heat source. We design tubular heat exchangers to ensure that waste energy is utilised as efficiently as possible in our applications. The most common applications for tube-type heat exchangers are for preheating combustion air and utilising waste heat to heat the hall during the winter months.
Depending on the nature of the flue gases being cooled, an industrial heat recovery unit may be equipped with automatic regeneration of the heat exchange surface using mechanical scrapers or by back-flushing the unit’s tube bundles with pulses of compressed air. Regeneration ensures that deposits accumulating on the heat exchange surface are periodically cleaned, thereby maintaining constant operating conditions in the recuperator.
They are most commonly used for flue gas heat recovery in foundries, smelting plants, glassworks and other facilities where gas-fired melting units are used, with flue gas outlet temperatures of 300–700°C. They are also used in all applications where the material is heated by direct contact with a flame, resulting in the release of large quantities of dust particles carried away by the flue gases.
An industrial recuperator featuring automatic heat exchange surface regeneration technology is capable of continuously recovering heat from flue gases under varying conditions of inlet temperature and flue gas volume. The flue gas outlet temperature is maintained at a preset value, which is kept above the dew point. When using a tubular heat recovery unit and an integrated MaR system, we reduce the amount of waste heat to the operational minimum to prevent condensation in the flue gas cooler or in the downstream flue gas filtration system.
We design tube-type recuperators, in view of their use with aggressive flue gases from gas burners, exclusively in stainless steel construction. Based on our experience, we utilise heat recovery unit series with capacities ranging from 100 kW to 1 MW. Where higher heat recovery capacity is required, we employ a parallel configuration of tried-and-tested heat recovery units.
The technologies we implement operate as a compact unit, from the connection flange on the furnace through the flue gas coolers to the exhaust stack. The comprehensive flue gas treatment technology includes heat recovery equipment to utilise otherwise wasted heat, a sorbent dosing system to reduce HF and HCl, and filtration equipment to filter particulate matter (PM) before it is released into the atmosphere. The installed flue gas cooler technology incorporates a number of safety features to prevent damage to the filtration system caused by the high temperature of the filtered flue gas or any restriction on the production process.
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