Waste heat recovery systems utilize the residual heat contained in exhaust gas streams or process air and return it to the energy or production process in a targeted manner. Heat exchangers, economizers, and air preheaters can be used to tap existing energy potential and reduce fuel consumption. These systems contribute to higher overall plant efficiency and lower operating costs and emissions.
Details
| Designs | Meander-shaped heat exchangers, concentrically arranged tube basket version, single-pass radiation boilers |
| Heating type | Flue gases from various combustion processes |
| Heating surface cleaning systems | Ball shower system, compressed air cleaning with lances, steam cleaning with lances |
| Areas of application | In combustion plants with solid fossil fuels, in sewage sludge incineration plants, in waste incineration plants |
Details
| Design | Meander-shaped thermal oil waste heat systems |
| Application advantage | Longer service life between maintenance intervals thanks to efficient cleaning (e.g., ball rain systems, soot blowers) |
| Travel times | Up to two years between major maintenance intervals in some cases |
| Comparable systems | Thermal oil pipe basket waste heat recovery systems (several concentrically arranged pipe baskets) |
| Disadvantage of alternative designs | No effective cleaning systems exist for tube basket systems to date |
| Typical travel times for tube baskets | Often less than two to three months |
Details
| Designs | Finned tube heat exchanger (standard), smooth tube heat exchanger (special cases) |
| Heating media | Thermal oil, steam, hot water, etc. |
| Material selection | Black pipe, hot-dip galvanized steel fins, stainless steel |
| Areas of application | Hall heating, process drying, combustion air preheating, air conditioning units |
| Special features | Fin spacing according to air contamination level; individual design according to customer specifications |
Details
| Function | Utilization of exhaust gas energy from combustion and drying processes |
| Installation location | In exhaust gas ducts between the boiler system and the chimney |
| Design | Heat exchanger, exhaust gas ducts, internal/external bypasses |
| Media in the pipe | Feed water, warm water, hot water, thermal oil |
| Materials | Black steel, stainless steel, glass |
| Advantages | Higher process efficiency, reduced consumption, lower CO₂ emissions |
Details
| Function | Utilization of exhaust gas energy, similar to economizers – but exclusively for gaseous media |
| Media flow | Clean air through the pipes; exhaust gases flow around the pipes |
| Temperature range | Heated air up to approx. 520 °C |
| Areas of application | Drying processes, production processes |
| Design / material | Smooth pipes; material selection based on thermal, physical, and chemical exhaust gas parameters |
| Special feature | Suitable for dust-laden exhaust gases; can be used in exhaust gas towers with ball shower cleaning systems |
