Heat Pipe Heat ExchangersRecovering the unrecoverable

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A new energy recovery opportunity

Energy recovery from industrial exhaust gases has the potential to unlock large amounts of valuable energy savings and reduce CO2 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,CO2 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

ContentsWhy choose heat pipes..........................................................................................................................Opportunities for low grade heat recovery in the Food & Beverage industry.........................................Healthcare Industry & Hospitals.............................................................................................................Oil & Gas Industry..................................................................................................................................Pharmaceuticals....................................................................................................................................Request a quote for your application.....................................................................................................

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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:

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.

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

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Why choose Heat Pipes?

Multiple redundancy Intermediate pipe working temperature

Efficient

Highly scalable, customisable & configurable

Low pressure drop

Low fouling

Ease of cleaning & maintenance

Isothermal operation - no hot or cold spots

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.

Allows higher exhaust temperature limits on some applications.

Usually smaller and/or lighter than conventional exchangers.

Modular design allows on site assembly.Can be designed for future expansion, to meet specific application or operational needs.

Low pressure drop allows units to be installed with little or no impact on your process. Use of smooth pipes allows

exchangers to be used in high particulate or oily applications.

Can be maintained in situ (no uninstall).Manual/automated cleaning systems.

Eliminates cold corners and condensation.Allows greater energy recovery.Better longevity for thermal oil. Reactivity

Fast reaction time, offers different control options and suitable for sensitive apparatus & does not require preheating.

Heat out

Vacuum tube

Condensation

Steam

Heat in

Separation plate

Heating outgoing air, water, oil etc

Cold incomingair, water, oil etc

High particulate exhaust gas Cooled exhaust gas

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Quick start-up

Average payback under 24 months

Resistant to acidic corrosion

Safe operation

Robust materials & long life

Cross contamination

Minimal footprint

Highly reliable

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.

Payback is typically achieved in under 24 months, with the added benefit of significantly reducing CO2 emissions.

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.

Spirax Sarco will design and provide a complete HPHE System, including by-passes, control dampers, complete control system and safety equipment.

Design allows pipes to freely expand and contract, thus no thermal stress on structure. Thick pipe walls resist erosion/corrosion.

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.

Compared to other heat exchanger technologies, the HPHE has a small footprint per kW of energy recovered, whilst still providing a low pressure drop.

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.

Unique and versatile designThe 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

EXHAUST IN

HEAT PIPESSEPARATOR PLATE

EXHAUST OUT

HEATED MEDIA IN

PRIMARY SIDE

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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 CO2 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 (

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Quick start-up

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CASE STUDY

Heat Pipes have the answer where other technologies fail time and time again

CASE STUDY

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 ChallengeThe 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 OpportunitySpirax 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 t