Turn waste Heat into Profit - industriewarmte.nl. HeatMatrix presentation... · “Turn waste Heat...
Transcript of Turn waste Heat into Profit - industriewarmte.nl. HeatMatrix presentation... · “Turn waste Heat...
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New generation heat exchanger improves industrial
energy efficiency
“Turn waste Heat into Profit”
By Robert Sakko
14 November 2013
www.heatmatrixgroup.com
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Content
2 Waste heat potential
3 HeatMatrix technology
1 HeatMatrix introduction
www.heatmatrixgroup.com
4 For corrosive and fouling service
5 Applications
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Introduction HeatMatrix Group
• Founded in 2008, employing 10 people with 10 – 30 yrs industrial
experience
• HeatMatrix develops and markets innovative plastic high efficiency heat
exchangers
• HeatMatrix’s mission is to increase industrial energy efficiency through
waste heat recovery
• ISO 9001:2008 certified
www.heatmatrixgroup.com
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www.heatmatrixgroup.com
Customers
Benelux
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Content
2 Waste heat potential
3 HeatMatrix technology
1 HeatMatrix introduction
www.heatmatrixgroup.com
4 For corrosive and fouling service
5 Applications
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Energy Management
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Efficient Technology
Optimize usage of assets
Stop leakage (a.o. insulation, steam
traps)
Direct integration of waste heat
Waste heat to heat grids, to electricity, heat pumps,
drying
HeatMatrix
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www.heatmatrixgroup.com
Stacks: Energy savings at centralized location
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HeatMatrix: Turns waste heat into profit
• ~ 90% of hot flue gas was previously cold (combustion) air.
Opportunity
Problem
• However, gaseous waste heat streams are difficult to recover
with existing technology due to corrosion, fouling, weight
• Simple direct heat integration improves energy efficiency by up to
4% and requires only 1 heat exchanger
Solution
• HeatMatrix offers a low weight corrosion resistant plastic heat
exchanger with an excellent pay-back for these applications
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Energy Efficiency Double Whammy
Energy Efficiency Reduce Fuel Expenditures and Realize CO2 Savings
Fuel Cost Saving CO2 Reduction
Higher Fuel and CO2 Prices Increase the Value of Waste Heat
$/barrel
Source: IEA 2009
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HeatMatrix Recovery Beyond the Conventional
Traditional
Heat-exchange
Technology
‘Problem’
Waste Heat
Fouling streams
Corrosive streams
Large gaseous flows
HeatMatrix
www.heatmatrixgroup.com
Compact
Low weight
Corrosion resistant
Counter current
Easy to install
✔
✔
✔
✔
✔
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Content
2 Waste heat potential
3 HeatMatrix technology
1 HeatMatrix introduction
www.heatmatrixgroup.com
4 For corrosive and fouling service
5 Applications
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HeatMatrix Technology Drinking Straw (Friedman)
Lasting Innovations are Simple
Invention (Patent 1936) Invention (Patent 2007)
Fig. 1 Fig. 2
1
2
3
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www.heatmatrixgroup.com
HeatMatrix® LUVO gas/gas exchanger
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Gas flow through heat exchanger
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HeatMatrix Heat exchanger Advantages
Compact (~ 215 m2/m3)
Thin Wall
Strong Honeycomb Structure
100% Counter Flow
Fouling resistant
Design
Excellent Heat Transfer Properties
=
Plastic
Corrosive resistant Durable +
Low Weight Cost Effective +
Outstanding Efficiency
www.heatmatrixgroup.com
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www.heatmatrixgroup.com
HeatMatrix® LUVO XL gas/gas exchanger
Typicals: • Modular design
• Scalable to any size
• Innox , coated, lined casing
• Nozzles in any direction
• Easy to clean
Operating Range • F: 5,000 – 500,000+ kg/hr
• Tdesign: 200 °C
• Pdesign: 150 mbar
• ΔP: ~6 mbar
Advantages: • Compact
• Low Weight
• Counter Current
• Corrosion resistant
• Easy maintenance
• Easy to install
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Content
2 Waste heat potential
3 HeatMatrix technology
1 HeatMatrix introduction
www.heatmatrixgroup.com
4 For corrosive and fouling service
5 Applications
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Plastic Pyramid
High Temperature
Highly corrosive
Low Temperature
Application
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Acid dew point
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Acid dew point corrosion of metal in biogas
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HeatMatrix in corrosive flue gas at Vion
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www.heatmatrixgroup.com
In-situ cleaning system: cleaning during operation
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Cleaning system
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Content
2 Waste heat potential
3 HeatMatrix technology
1 HeatMatrix introduction
www.heatmatrixgroup.com
4 For corrosive and fouling service
5 Applications
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Typical application I
www.heatmatrixgroup.com
Air preheating with flue gas from
combustion processes:
•Standard natural gas boilers
•(Petro) Chemical / Refinery boilers
•Furnaces / Fired heaters
•Biogas / biomass / coal fired boilers
•Incinerators / RTO’s
Boiler /
Furnace
(economizer)
Flue gas 130 – 200 C
Air 80 – 100 C
70 – 130 C
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Typical application II
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Air preheating in Dryers:
• Food / non-food industry
• Spray dryers
• ovens
Hot air
80 – 120 C
cold air
20 C
50 – 70 C
Dryer
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Typical refinery boiler case
Boiler
200,000 kg/hr
90C flue gas
200,000 kg/hr
108 C air
200,000 kg/hr
170 C flue gas
200,000 kg/hr
15C air
• Energy Saving
• Annual fuel costs saving**
• Price LUVO XL CR
• Installation costs (estimate)
• Return on Investment
• NPV (10yr, 6%)
• IRR (10 yr)
HeatMatrix LUVO
** Based on 8000 hr/yr and € 0.30 /Nm3
• 4.91 MW
• 1,278,000 €/yr
• 850,000 €
• 850,000 €
• 1.3 year
• 7,700,000 €
• 75 %
CO2 reduction = 8,600.000 kg/year
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www.heatmatrixgroup.com
Reducing stack temperatures:
• Recovers over 50% of the lost heat
• Has an average pay-back time of 1,5 year
• Is the most profitable investment in sustainability
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Robert Sakko
Director Technology
+31 6 15 48 40 31
www.heatmatrixgroup.com
www.heatmatrixgroup.com
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Typical design 1
Steam
Boiller
HeatMatrix
LUVO APH
air damper
M ECO
FD fan
ID fan < 200 C (400 F)
ID-fan allows for:
• Easy control and safe guarding
• Partial load APH design i.s.o. name plate
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Typical design 2
Steam
Boiller
HeatMatrix
LUVO APH
air damper
M ECO
FD fan
ID fan > 200 C (400 F)
Metal APH
Metal APH:
• Metal APH protects polymer APH against high temperature
• Polymer APH protects metal APH against acid dew point corrosion
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Typical design 3
Steam
Boiller
HeatMatrix
LUVO APH
air damper
M ECO
FD fan
ID fan > 200 C (400 F)
Metal APH
Flue gas recirculation:
• 3% flue gas recirculation reduces NOx by up to 40%
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Typical design 4
Steam
Boiller
HeatMatrix
LUVO APH
air damper
M ECO
FD fan
ID fan > 200 C (400 F)
Metal APH
Stack:
• German design standard for stacks recommends alloy 904 for
corrosive service