info.spiraxsarco.com/hphe Heat Pipe Heat Exchangers Recovering the unrecoverable
heat pipe heat exchangers A new energy recovery opportunity Energy recovery from industrial exhaust gases has the potential to unlock large amounts of valuable energy savings and reduce CO 2 emissions. However, in the past this opportunity has largely gone unexploited due to the hostile nature of exhaust environments, and the damage they could cause to the heat exchanger. 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. This will enable you to: Reduce fuel demands,co 2 and carbon emissions Capture waste energy Increase process efficiency Reduce costs by lowering fuel consumption These are just a few of the applications where valuable waste energy can be recovered: Biomass boilers Heavy fuel oil boilers Coal boilers Kilns Furnaces Ovens Incinerator Dryer 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 Harnessing your previously unrecoverable waste heat In hostile environments, such as those found in high temperature, aggressive applications, traditional heat exchangers struggle to operate effectively. Often suffering from a build-up of contaminants, causing corrosion and a reduction in heat recovery efficiency and inevitable equipment failure. Therefore, until now this valuable energy has gone unrecovered, often vented to atmosphere. 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. The HPHE solution offers: Long-term reliability and performance Inherent design of HPHE results in multi-redundancy improving reliability Free thermal expansion and contraction of individual components Isothermal pipe temperature avoids cold spots to help reduce corrosion Manufactured using a range of robust materials Flexibility of design Simple, sturdy HPHE construction can be applied in hostile environments Easily add, remove or replace individual heat pipes within the heat exchanger for precise optimisation and maintenance Ease of maintenance Optional removable heat pipe cassettes and a side inspection panel make in situ maintenance quick and easy Inline cleaning solutions are available to ensure heat exchange efficiency continues Manual maintenance is simple - easy access to both primary and secondary heat transfer areas Low risk operation No potential for cross-contamination No moving parts Proven technology with hundreds of installed units worldwide 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
heat pipe heat exchangers Why choose Heat Pipes? Vacuum tube Heating outgoing air, water, oil etc Heat out Cold incoming air, water, oil etc Condensation Separation plate Steam High particulate exhaust gas Heat in Cooled exhaust gas Multiple redundancy Each pipe operates independently so unit is not vulnerable to a single pipe failure. This prevents cross contamination each heat pipe acts as an additional buffer between the two fluids. Low fouling Use of smooth pipes allows exchangers to be used 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 cold corners and condensation. Allows greater energy recovery. Better longevity for thermal oil. Intermediate pipe working temperature Allows higher exhaust temperature limits on some applications. Low pressure drop Low pressure drop allows units to be installed with little or no impact on your process. 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. 4
info.spiraxsarco.com/hphe Unique and versatile design The unique design of the HPHE system provides an extremely efficient transfer of energy, up to 1000 times more efficient than copper. The patented superconductor heat pipe contains a vacuum filled with heat transfer fluid to exchange heat from the source to the process. SECONDARY SIDE HEATED MEDIA OUT HEAT PIPES HEATED MEDIA IN SEPARATOR PLATE EXHAUST IN EXHAUST OUT PRIMARY SIDE Robust materials & long life Design allows pipes to freely expand and contract, thus no thermal stress on structure. Thick pipe walls resist erosion/corrosion. Cross contamination The hot and the cold streams are separated by a plate, into which the heat pipe is fitted, with a seal between the hot and the cold sides eliminating any potential for secondary side contamination. Quick start-up As a result of the high quality construction of the heat pipe and in particular its high integrity vacuum, heat transfer between the hot stream and the cold stream is virtually instantaneous. Average payback under 24 months Payback is typically achieved in under 24 months, with the added benefit of significantly reducing CO 2 emissions. Minimal footprint Compared to other heat exchanger technologies, the HPHE has a small footprint per kw of energy recovered, whilst still providing a low pressure drop. Resistant to acidic corrosion Heat pipes do not rely upon thin metal surfaces for effective heat transfer and therefore can be constructed from robust materials that offer increased resistance to erosion. Highly reliable Heat Pipe Heat Exchangers are manufactured using a range of robust materials. This combined with a design that enables the free thermal expansion and contraction of individual components, gives the HPHE outstanding reliability. Safe operation Spirax Sarco will design and provide a complete HPHE System, including by-passes, control dampers, complete control system and safety equipment. 5
heat pipe heat exchangers Opportunities for low grade heat recovery in the F&B industry The recovery and re-use of industrial waste heat is an attractive and achievable concept. Simultaneously reducing CO 2 emissions and energy costs. Untapped opportunities in the Food & Beverage industries Low grade industrial heat sources have often been overlooked due to the technological barriers preventing the reliable capture and transfer of high particulate heat sources without incurring any risk of product contamination. On average 64% of energy use in this sector is low temperature (<300 C) processes, such as baking, frying or pasteurisation. Many of these will have high concentrations of particulates making them unsuitable for traditional heat exchanger technologies. 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 HPHE s offer. Low pressure drop allows units to be installed with little or no impact on your process Ease of cleaning & maintenance Quick start-up No risk of cross contamination Low fouling Average payback under 24 months Example waste heat recovery opportunities Typical heat exhaust sources Applications Potential uses Food manufacturing Boiler economiser Oven, fryers, roaster Incinerator Biomass incinerator Dryers Anaerobic digester Slaughterhouse hair burners Heating air Heating water Preheat oven combustion air Preheat dryer air Preheat boiler combustion air Preheat boiler feed water Heat heating hot water supply Heat domestic hot water supply Preheat process water Brewing & Distilling Evaporators Distillation Malt fermenter Steam production Steam for sterilisation Steam for cooking 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 CASE STUDY CASE STUDY Heat Pipes have the answer where other technologies fail time and time again Location: Ireland Objective: Provide a solution that would overcome the difficult operating environment Solution: Heat Pipe Heat Exchanger gas to water unit Results: 488kW saved saving 87,000per annum A global commercial dairy was experiencing issues with a heat recovery application, using waste from an exhaust to preheat the boiler feed water. The Challenge The exhaust being fired from heavy fuel oil was high in sulphur, hence unsuitable for conventional equipment due to surface condensation and resulting corrosion. Many suppliers refused to quote for the application due to the high sulphur from HFO (Heavy Fuel Oil) combustion. The Opportunity Spirax Sarco and associate company Econotherm were asked to provide a solution which was able to overcome these challenges that caused traditional economisers to fail. If an appropriate solution could be found, some of the waste heat from the exhaust output of 285 C could be recovered to improve boiler efficiency by increasing the temperature of it feedwater supply. The Installation Spirax Sarco and its associate company, Econotherm, suggested that the customer install a Gas to Water Heat Pipe solution, which provided a robust and reliable solution for heat recovery in hostile applications such as this. The high metal temperature in the heat pipes and isothermal properties would ensure the heat pipe solution was appropriate and would succeed. The Performance Three heat pipe gas to water units were installed recovering 488kW saving 87,000 per annum, giving a payback of 19 months. Exhaust temp in/out 285 C/ 165 C Water temp in/out 110 C/ 142 C Exhaust/water mass flow Energy recovered 12,960 / 13,160 kg/h 488 kw 7
heat pipe heat exchangers Opportunities for low quality heat recovery in Healthcare As global healthcare spending per capita falls, the healthcare industry and its partners must find ways to improve process efficiency and make budgets do more with less. Most hospitals have a significant need to use energy for HVAC, hot water, lighting, ventilation and numerous clinical processes, all incurring significant associated greenhouse gas emissions. 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 1 C 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 CO 2 emissions. Minimal footprint Low fouling No risk of cross contamination Quick start-up Example waste heat recovery opportunities Typical heat exhaust sources Applications Potential uses Heating air Preheat HVAC Preheat boiler combustion air Boiler recuperator Healthcare Incinerator Biomass incinerator Sterilisers Generators Heating water Preheat boiler feed water Heat heating hot water supply Heat domestic hot water supply Steam production Steam for sterilisation Steam for cooking 8
info.spiraxsarco.com/hphe Waste heat recovery solution for the Chemicals industry Waste heat recovery is essential for increasing energy efficiency in the chemical process industries, brought into focus by increasing energy costs and environmental concerns. 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. HPHE s 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 equipment Heat recovery unit Robust materials & long life Diverted gas Highly reliable Hot exhaust gas Spent exhaust gas Resistant to acidic corrosion Multiple redundancy Diverter Water return Example waste heat recovery opportunities Typical heat exhaust sources Applications Potential uses Preheat oven combustion air Chemicals Boiler economiser Refinery process exhaust Process incinerator Chloride boiler exhaust Heavy fuel oil boilers Flue gas / Stack Gas Gas turbine Heating air Cooling or heating gas Heating water Preheat dryer air Preheat boiler combustion air HVAC Preheat liquid or gas stream Pre-cooling Re-heating Preheat boiler feed water Preheat process water Domestic hot water / heating water Steam production Heating for process Power generation 9
heat pipe heat exchangers Safe, reliable and highly effective waste energy recovery in the Oil & Gas Industry When you re two hundred miles out to sea and days away from help, you need an ultra reliable, safe and efficient heat recovery solution that won t let you or your process down. Heat Pipe Heat Exchangers are fast becoming the Oil & Gas industries heat exchanger of choice for low grade, dirty heat sources due to their excellent reliability and safety record. Specialists in recovering heat from heavy particulate heat streams, heat pipe heat exchangers offer a long-life, low maintenance solution with inbuilt redundancies providing a highly attractive payback periods. Improving extraction process efficiency is a sound investment in any market conditions. The sustained reduction in oil and gas prices, coupled with a forecast of modest recovery, requires the industry to apply increased focus and rigor to operations performance. While new exploration and growth will always be a cornerstone of upstream operations, failure to improve operational performance and economics could have lasting effects on a company s long-term growth and viability. Driving operational performance in oil and gas, www.ey.com HPHE s 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. Minimal footprint Robust materials & long life Multiple redundancy Suitable for off & onshore applications Highly reliable Safe operation Example waste heat recovery opportunities Typical heat exhaust sources Applications Potential uses Heating air Preheat boiler combustion air Preheat Liquid or Gas Stream Oil & Gas Refinery Exhaust Turbine Generator Gas Compressor Stations Thermal oxidisers Oil preheaters Cooling or heating gas Heating water Pre-cooling Re-heating Compressor Gases Trace Heating Preheat boiler feed water Preheat process water Steam production Oil heating for process Trace heating 10
info.spiraxsarco.com/hphe CASE STUDY CASE STUDY Offshore oil rig installs Heat Pipe Steam Generator saving 2.1m per annum Location: South China Sea Objective: Generate steam for oil extraction process meeting restrictive size and weight limitations. Solution: Heat Pipe Heat Exchanger Steam Generator Results: 6,400kW recovered, ROI 17 months. 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 drilling injection process. Pumping steam into the steam bed to heat oil to a viscosity and pressure that allows displacement and extraction. Therefore the operators required a steam generator that could meet the size and weight restriction of the rig, whilst meeting the demand of 8.4 tonnes of steam per hour at 12 bar g. The Solution Spirax Sarco and their associate company, Econotherm, worked with CNOOC to discuss potential solutions. Options included an alternative steam boiler or utilising the waste heat from a gas powered turbine through a heat pipe heat exchanger unit. Due to space limitations, cost saving benefits and the need for high reliability it was decided that a HPHE steam generator was the optimum solution. The HPHE unit would also enable instant start up from the gas turbine, as the unit does not suffer from thermal shock and requires no pre-heating. The multiple redundancy and robust, long life material were also a factor, as reliability was vital in such a remote location. The heat pipe unit benefits from independent operation of each pipe, so no pipe is dependent upon the other to operate effectively. The unique design also allows pipes to freely expand and contract, thus eradicating thermal stress on the structure. Spirax Sarco and Econotherm designed a bespoke heat recovery steam generator solution, complete with controls to accurately manage the steam flow, pressure and temperature. The unit would meet the size and weight limitations of the installation site, whilst recovery 6.4 MW of waste heat energy from the gas powered turbines. The Installation The unit was delivered to the offshore site with Spirax Sarco and Econotherm engineers providing support as required at every stage. The unit matched the requirements exactly, and was installed on time and to budget. The Result Since installation the unit has been working without fault, recovery the predicted 6.4 MW, saving CNOOC approximately 2.4m per year and achieving payback with 17 months. This saving does not include the cost that they would incurred had they been forced to invest in a new boiler. Exhaust temp in/out 400 C/ 250 C Water/steam temp in/out 50 C/ 180 C Exhaust flow/steam rate 130,000 / 8,000 kg/h Energy recovered 6,400 kw Recovered energy 2,100K p/a Payback period 17 months 11
heat pipe heat exchangers Opportunities for low grade heat recovery in Pharmaceuticals Energy efficiency may not be the number one priority for a pharmaceutical manufacturer trying to maintain quality and output to maximise sales. However, the energy is still a significant expenditure on any pharmaceutical companies profit and loss. Pharmaceutical manufacturing plants in the U.S. alone spend more than $1 billion each year on fuel and electricity they need to keep their facilities running. This cost can increase in volatile energy markets where energy prices fluctuate. Improving energy efficiency should therefore be a strategic imperative for any plant manager or manufacturing professional working in the drug industry today. 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. Utilise your waste heat to make a step change in operational efficiency Heat Pipe Heat Exchangers offer clean, safe and efficient heat recovery from low grade waste heat sources found in typical pharmaceutical manufacturing processes. Maximising process efficiencies to reduce energy costs and CO 2 emissions through the recycling of waste heat back into the process to preheat application such as boiler combustion air, process water, autoclave steam or your HVAC system. Low pressure drop allows units to be installed with little or no impact on your process Highly reliable Low fouling Proven solution in this industry No cross contamination Safe operation Example waste heat recovery opportunities Typical heat exhaust sources Applications Potential uses Oil & Gas Boiler economiser Oven Incinerator Dryers Anaerobic digester Sterilisers / Autoclaves Heating air Cooling or heating gas Heating water Preheat oven combustion air Preheat dryer air Preheat boiler combustion air HVAC Pre-cooling Re-heating Preheat boiler feed water Heating hot water supply Heating domestic hot water supply Preheat process water Steam production Steam for sterilisation Steam for cooking 12
info.spiraxsarco.com/hphe CASE STUDY CASE STUDY Highly reliable, low risk Heat Pipes meet stringent pharmaceutical risk management criteria to unlock contaminated energy Location: Pharmaceutical manufacturer based in the Republic of Ireland The Challenge Contaminated process exhaust gas currently being vented to atmosphere and not recovered as potential risk of failure was too high with traditional heat exchanger technologies. Risk management criteria meant that no solution available could meet the high standards required for the application. The Opportunity The Spirax Sarco HPHE offered the potential for a low risk, highly reliable solution to efficiently capture large amount of waste exhaust heat energy. Multiple redundancies allows heat pipe to continue operating with no single point of failure The Installation We suggested the installed a Gas to Water Heat Pipe solution, which provided a robust and reliable solution for heat recovery in hostile applications such as this. The high metal temperature in the heat pipes and isothermal properties would ensure the heat pipe solution was appropriate and would succeed. The Performance Since installation, in 2009, the unit has been functioning without fault. Exhaust temp in/out 350 C/ 140 C Water temp in/out 38 C/ 248 C Exhaust/water mass flow 112,960 / 13212 kg/h Smooth pipes reduced fouling considerably allowing HPHE unit effectively operate for lengthy periods in contaminated exhaust streams Unique design allows pipes to freely expand and contract, reducing thermal stress Energy recovered ROI / Payback HPHE Type e.g. Gas to 821 kw Circa 16 months Gas to air Zero potential for cross contamination from energy source to transfer media Heat recovery systems reduce the energy required to heat or cool facility intake air by harnessing the thermal energy of the facility s exhaust air. For areas requiring 100% make-up air, studies have shown that heat recovery systems can reduce a facility s 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
heat pipe heat exchangers Speak to our expert engineers about your bespoke Heat Pipe heat transfer solution or one of our many thermal energy solutions We can provide a quote for your proposed application: All installations include controls for monitoring and auto-adjustment of pressure, temperature and flow. HPHE system can integrate with BMS or SCADA system. Installations support supplied as required. All quotes will include estimate energy savings and payback periods. Energy validation systems can be provided. 14
info.spiraxsarco.com/hphe Designed by experts to meet your individual application requirements We have long realised that our customers want assistance with complex heat recovery applications, which do not form part of their core business but can make a big difference to their environmental impact and energy usage. We can assess your system requirements, provide pre-engineering services, project management, installation, commissioning, start-up assistance and training. You will deal solely with Spirax Sarco throughout the process and we will take on responsibility for everything, taking the stress out of designing, specifying, building and installing complicated steam, condensate and water systems. Visit info.spiraxsarco.com/hphe for more information or to request a quotation 15
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