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Advantages
  • Use of exhaust heat by heating oil or generating steam
  • Direct use of exhaust heat via mixing chambers for heating dryers
  • Robust design for solids-laden exhaust gas streams
  • Use of exhaust heat by heating oil or generating steam
  • Direct use of exhaust heat via mixing chambers for heating dryers
  • Robust design for solids-laden exhaust gas streams
  • Automatic cleaning systems are available

ADVANTAGES

  • High efficiency
  • Almost pressure-free process heat
  • Custom construction
  • Operation with synthetic oils possible up to almost 410 °C

ADVANTAGES

  • High performance can be achieved by connecting individual modules in series
  • Pullable design of the heating surfaces allows accessibility for repairs
  • Depending on the exhaust quality, aligned or offset pipe arrangements are possible
  • Cold heat exchanger housing thanks to internal insulation
  • Check of contamination condition possible via inspection openings during operation

ADVANTAGES

  • Small space requirement thanks to compact, vertical design
  • Cost-effective solution for exhaust gas flows with low solids content
  • Easy to clean by removing the boiler lid

ADVANTAGES

  • Robust construction with good cleaning options
  • Efficiency can be increased by adding additional convection heat exchangers, e.g., for preheating combustion air

Waste heat heater - type ETA

As different as the thermal industrial processes

Waste heat heaters use the heat from exhaust gases from combustion processes or from hot exhaust air streams from industrial processes.

The INTEC waste heat heaters are used behind solid fuel furnaces, afterburning systems, gas and diesel engines, melting furnaces and turbines in many industry sectors .

The type and design are determined by the composition of the exhaust gases, their temperature level and mass flow.

In particular, the solids content in the exhaust gas determines the design and arrangement of the heating surfaces. If the exhaust gas temperature is significantly above 600 °C, it makes sense to design part of the heating surface as a radiant heating surface. For medium to high levels of contamination caused by ash and other solids, the heating surfaces are arranged in alignment.

For clean exhaust gases, an offset pipe arrangement with higher heat transfer values ​​can be used.

Waste heat heater - type ETA

Radiant heater

Radiant heaters are used at exhaust gas temperatures above 800 °C, which occur in solid fuel furnaces, various melting, roasting and steel rolling heating furnaces as well as in high-temperature processes in the chemical industry.

INTEC radiation boilers are designed as a one-pass system with tightly wound tube baskets.

Radiant heaters are also used in high temperature quenching processes.

In order to prevent the polymerization of high-temperature cracked gas, it is necessary in the cracking process of the chemical industry to quickly cool the high-temperature cracked gas to a temperature level at which the cracking reactions are stopped.

    Waste heat heater - type ETA

    Convection heater

    INTEC convection heat exchangers, type ETA, are designed as smooth tube bundles in a meandering design for exhaust gases from solid fuel combustion systems.

    The heating surfaces consist of heat-resistant tubes, which are freely expandable and mounted in tube plates.

    The connection of the pipes to the external collectors is stress-free, so that stress cracks due to differential expansion between the pipes and collectors are excluded.

    The casings of the convection heat exchangers are lined with refractory materials on the inside at appropriate temperatures.

    Attached soot blowers enable the heating surfaces to be cleaned automatically during operation.

      Waste heat heater - type ETA

      Three-passage design

      Three-pass waste heat thermal oil boilers consist of two or more concentrically arranged tube baskets, which are primarily used in a vertical design for heat recovery from exhaust gas streams that are comparatively low in solids.

      With this design, the first pass is used as a radiant heating surface. At the end of the first train, the exhaust gases are diverted into the second train. The first draft is limited by a lid with an internal lining.

      This cover lies loosely with its weight on the outer pipe coil(s) and separates the first from the third draft on the exhaust side.

      In the event of a deflagration on the gas side, the lid is lifted by the increased internal pressure, thereby largely avoiding damage caused by increased internal pressure.

        Waste heat heater - type ETA

        Combined waste heat boiler systems

        A large number of exhaust gas streams from solid fuel combustion predominantly have temperatures between 750 °C and 1,200 °C.

        To use the energy of exhaust gas streams above 750 °C, it makes sense to use radiation heat exchangers (radiation heaters). These radiant heat exchangers have the advantage of cooling the solids in the exhaust gas to such an extent that they lose their sticky properties. Below 750 °C, the residual heat of the exhaust gases is recovered in meandering convection heat exchangers and transferred to the operating medium thermal oil.

        Waste heat boilers as a combination of radiation heaters and convection heat exchangers are a common, reliable and practically proven solution for efficiently absorbing the heat from exhaust gases from solid fuel combustion.

          Firing fuels
          Firing fuels
          Biomass | Wood waste | Fossil dust | Oils | Gases | Production waste
          Energy source
           Energy source
          Flue gas
          Technical specifications
          Capacity
          0,5 – 80 MW
          Hot exhaust fumes
          150 °C - 1,200 °C
          Maintenance cycle
          Up to 4,000 h
          Industry sectors

          Wood | MDF manufacturing

          Combustion fuels
          Firing fuels
          Wood waste | Sanding dust
          Energy source
          Fuels
          Energy source
          Flue gas
          Technical specifications
          Capacity
          1.5 MW
          Hot exhaust fumes
          950 °C
          Efficiency
          93 %
          Industry sectors

          MDF production

          Firing fuels
          Firing fuels
          Wood waste
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Capacity
          5 MW
          Hot exhaust fumes
          750 °C - 950 °C
          Efficiency
          93 %
          Industry sectors

          Wood | Wood processing sawmill

          Firing fuels
          Firing fuels
          Wood waste
          Energy source
          Fuels
          Energy source
          Flue gas
          Technical specifications
          Capacity
          4.45 MW
          Hot exhaust fumes
          850 °C - 1,050 °C
          Industry sectors

          Wood | Chipboard production

          Firing fuels
          Firing fuels
          Wood | Wood scraps | Sanding dust
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Capacity
          9.5 MW
          Hot exhaust fumes
          850 °C

          Overall efficiency 93 %

          Industry sectors

          Energy | Wood | Utilities | Chemicals

          Firing fuels
          Firing fuels
          Wood | Wood scraps | Sanding dust
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Capacity
          0.5 - 80 MW
          Hot exhaust fumes
          400 °C - 900 °C
          Efficiency
          93 %
          Industry sectors

          Energy | Wood |  Utilities | Chemicals

          Firing fuels
          Firing fuels
          Wood | Wood scraps | Sanding dust | Coal dust
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Capacity
          0.5 - 80 MW
          Hot exhaust fumes
          400 °C - 900 °C
          Efficiency
          93 %
          Industry sectors

          MDF chipboard

          Firing fuels
          Firing fuels
          Bark | Wood chips | Production waste | Grinding dust
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Capacity
          19 MW
          Hot exhaust fumes
          1,200 °C
          Efficiency
          > 90 %
          Industry sectors

          Petrochemical

          Firing fuels
          Firing fuels
          Bark | Wood chips | Production waste | Grinding dust
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Capacity
          1 - 15 MW
          Hot exhaust fumes
          750 °C - 950 °C
          Industry sectors

          Wood processing | Sawmill

          Firing fuels
          Firing fuels
          Wood | Wood waste | Sawdust
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Capacity
          12 MW
          Hot exhaust fumes
          950 °C
          Industry sectors

          Wood processing industry

          Firing fuels
          Firing fuels
          Wood | Sawdust
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Vlow temperature
          300 °C
          Capacity
          15 MW
          Hot exhaust fumes
          900 °C

          Location: Australia

          Industry sectors

          Wood | MDF production

          Firing fuels
          Firing fuels
          Production waste | Wood chips | Bark | Grinding dust
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Vlow temperature
          320 °C
          Capacity
          16 MW
          Hot exhaust fumes
          950 °C
          Efficiency
          93 %
          Industry sectors

          Wood | MDP production

          Firing fuels
          Firing fuels
          Wood waste | Bark | Production waste | Grinding dust | Fiber residues | Palm fibers
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Vlow temperature
          330 °C
          Capacity
          9.5 MW
          Hot exhaust fumes
          450 °C - 1,100 °C
          Efficiency
          93 %

          The plant is located in Vietnam and uses domestic organic and production waste as fuel for firing.

          Industry sectors

          Wood | MDF production

          Firing fuels
          Firing fuels
          Wood waste | Bark | Sanding dust
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Capacity
          22.6 MW
          Hot exhaust fumes
          450 °C - 1,100 °C
          Efficiency
          93 %

          The plant is located in Spain.

          Industry sectors

          Wood | MDF production

          Firing fuels
          Firing fuels
          Wood waste | Production residues
          Energy source
          Fuels
          Flue gas
          Technical specifications
          Vlow temperature
          280 °C
          Capacity
          11.3 MW
          Hot exhaust fumes
          450 °C - 950 °C
          Efficiency
          93 %

          For providing process heat to an MDF board production facility in Australia, wood and production waste are used as fuel. The energy from the hot flue gases is transferred to the heat transfer medium thermal oil via a combined waste heat boiler with a capacity of 11.3 MW.