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Energy
Efficiency
Super efficient custom tube heat exchangers
The Ekin Endustriyel team rolled up their sleeves for a heat recovery project in a textile plant in Bursa , Turkiye , applying their expert engineering knowledge in the field of energy efficiency .
By Enes Kuzey Er , Ekin Endustriyel
Due to the compactness of the design , this kind of heat recovery system is ideally suited to facilities which value the environment and are keen to preserve resources . An additional bonus is that in many countries , local governments support investments in this type of technology , which assists companies in fulfilling their aims of lowering carbon and other greenhouse gas emissions . The heat recovery systems , which in this case were specifically designed for the textile industry customer , can be manufactured in various configurations depending on the process details and facility layout . The heated oil and air resulting from the operation of the compressors contain a large amount of energy , which is recovered using a 3-stage heat exchanger system . This has resulted in significant savings in energy costs as the recovered waste heat provides hot water for the facility rather than using natural gas .
Three stage process In the first stage , air at approximately 80 ° C from each compressor flows through MIT shell and tube heat exchangers , heating the water . Two heat exchangers were designed for each of the two separate compressors . The exchangers measure DN150 * 1250 mm , are type BEM ( TEMA ) and are constructed from SF-Cu grooved tubes ( EN-12449 ) with an S235JR shell ( EN-10217 ). Approximately 35 kW of heat is recovered with each exchanger at this stage . In the second stage , the compressor recovers the hot oil in a closed cycle . At approximately 80 ° C , the oil passes through the primary circuit , and the water heated in the first stage passes through the secondary circuit . For this stage , two highly efficient MIT Plate Gasketed heat exchangers were deployed , and 150kW heat recovery per exchanger was achieved . In the third and final stage , the water heated by the first two stages passes through a single heat exchanger constructed entirely in stainless steel . A customdesigned MIT Tubular Series heat exchanger heats both hard water and soft water while keeping them separated . The exchanger measures DN200 * 2950 mm and is type BEM ( TEMA ). The construction material was AISI 316 ( EN-10216 ) for the tubes and AISI 304 ( EN-10217 ) for the shell . Clean water entering the system at 20 ° C was heated to 50 ° C , and a total heat transfer of approximately 350 kW was achieved .
Energy savings After passing through a stainless heat exchanger , the recovered clean hot water is used as domestic water by the facility . In this way , the business achieves significant reductions in fuel costs . The payback time of the system is calculated at approximately 14 months . Another advantage of the system may yet emerge , as the hot water obtained in the second stage may eventually be used for other applications in future .
About the author
Enes Kuzey Er is a Heat Transfer Product Sales - R & D Specialist at Ekin Endustriyel , responsible for the sale of heat transfer products such as plate heat exchangers ( gasketed or brazed ) and shell and tube heat exchangers . He also finds solutions for industry needs based on customer feedback and provides support for R & D processes .
The 3-stage heat exchanger system has resulted in significant savings in energy costs . www . heat-exchanger-world . com Heat Exchanger World February 2024
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