Save costs with heat recovery systems
Waste heat in the form of vapor, hot water, oil or hot air is a result of almost any production cycle, but it does not have to go to waste. With BPHE's heat can be recovered and reused for other purposes, contributing to the reduction of carbon emissions and to significant cost savings for both producers and end users.
Applications where BPHE solutions are used in heat recovery
Heat recovery from air compressors
Reclaim more energy from compressed air systems and utilize most of the energy produced.
Approximately 10% of all electricity used in industry is accounted for by compressed air systems. Most of this energy is converted to heat without a purpose, which means that with inefficient systems, energy is first used to generate heat and then more energy is used to remove it with cooling fans. With energy recovery, you can significantly lower both cost and carbon footprint.
- Approximately 96% of the total electrical input can be recovered
- Quick payback
- In oil-lubricated compressors, oil cooling is the main energy source, providing up to 81% recovery. Compressed air provides an additional 15% recovery.
- In oil-free compressors, compressed air is the main energy source, providing up to 91% recovery. Transmission oil cooling provides an additional 5% recovery.
Airflux- significant cost savings and lowered CO2 emissions through efficient heat-recovery solutions
Airflux, based in Lille, France, is one of the leading providers of air compressors for the French market.
To maximize heat-recovery efficiency, Airflux engineers have designed the Ecosph’Air Energy-Recovery System. Its purpose is to recover heat energy produced by air compressors
Heat recovery using Combined heat and power (CHP)
Simultaneous production of electricity with the recovery and utilization of heat
Traditional Combined heat and power systems (also called CHP) produce electric power with an efficiency of around 40%. To make the system more effective you can install cogeneration systems that collect thermal energy from the engine jacket water, lubrication oil, and exhaust gas. Hot water can subsequently be produced via heat exchangers, substantially raising the total energy utilization efficiency.
Combined heat and power engines are ideal for reliable energy production at remote settlements or for emergency power for hospitals and mobile power packs. They can also be used as additional engines during peak hours.
- Gain over 90% total energy efficiency with combined heat and power production.
- Exact match with high performance and quick response for longer maintenance intervals
- Water-cooled generator adds to heating capacity and minimizes unwanted heat radiation
- Lower emission levels and higher engine output with an efficient charge air cooler
Shining a light on tomatoes
Our customer GE Jenbacher is one of the most recognized producers of gas engine CHP systems.
A single J624 from GE Energy with an output of 4 MW can cover the power needs of about 9,000 European households. Moreover, this flagship is helping to shine a light on Dutch tomatoes consumed all over Europe.
Heat recovery from Organic Rankine Cycle
Generate electricity from low-temperature waste recovery
The Organic Rankine Cycle is a sustainable technology that makes it economically feasible to recover waste heat from low-temperature sources such as geothermal, solar and industrial waste heat and turn it into electricity.
Clean power when ORC system recovers waste heat
When the Japanese-based company Daiichi Jitsugy got a request to install an ORC system, their engineers knew that they would need an out of the ordinary heat exchanger.
Current technology has limited the process to heat sources of medium- to high temperatures (above 500°F/260°C), when most of the waste has temperatures below 300°F/150°C. However, new technologies are emerging which allow for lower temperatures.
Rank® ORC technology with applications in heat recovery solution
ORC RANK® equipment capacities range from 2 to 100 kWe. The activation range for the low-temperature equipment starts at just 85 °C. SWEP's heat exchangers are installed as economizers, evaporators and condensers.
Heat recovery with Chillers
Utilize the energy of high-temperature superheated refrigerant gas
Industrial refrigeration systems with air-cooled condensers waste energy by emitting condensation energy to the ambient air. By installing a desuperheater, a large proportion of this waste heat can be turned into hot water that may be used for many purposes.
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Brazed Plate Heat Exchangers (BPHE's) are an integral tool that allows extra heat to be extracted from the refrigeration system. A BPHE, installed as a desuperheater, is inserted between the compressor and the condenser. This enables the BPHE to extract the heat from the gases before it enters the condenser and becomes condensate (the liquid collected by condensation).
Installing a BPHE not only helps to increase efficiency levels to achieve the demanding recent EU Ecodesign Directive that covers high temperature process chillers. It can also can be used extract heat from the gas providing up to 91% recovery, as well as additional 5% from the transmission oil.
Heat recovery within process industry
High heat transfer and low flow resistance
Industries generally end up with a lot of excess heat from their processes, such as steam or hot water that can be reused for other purposes. The challenge is to keep maintenance and operation costs to a minimum without compromising performance.
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Göteborg Energi sees the bigger picture
Western Sweden's leading energy company, Göteborgs Energi has been supplying the city with district heating since 1952.
The heat recovery block station replaced an outdated technical setup. The space required for the BPHE's was less than half the size of the previous heat exchanger.
