HigH HigH efficiency efficiency CondensingCondensingCondensingCondensingEconomizersEconomizers

COGENERATION RENEWABLE

HVAC

efficiency efficiency CondensingCondensingCondensingCondensingEconomizersEconomizers

COGENERATION ELECTRICAL RENEWABLE TECHNOLOGY

HVAC PLUMBING

CONDENSING ECONOMIZERS – KEY TO A SUCCESSFUL

Energy costs are the highest in recent history. Implementation of efficiencies in thermal processes is a vital element in streamlining rising energy costs.

Installation of condensing economizers could help companies improve overall heat recovery and steam system efficiency by even up to 15% (in standard applications).

SUCCESSFUL HEAT RECOVERY PROJECT

In the boiler room CESeconomizers transfer their waste heat to either the feed water or combustion air pre-heaters, essentially converting standard boilers into condensingboilers.

Covering a wide range of boiler sizes (from 250 kW to up to 6 000 kW), the CESdelivers real energy and cost savings for commercial and industrial installations.

CES economizers are an integral part of any efficiency improvement program. The total range includes 6 economizer models.

CES features and benefits:• increased systemefficiency• real energy and costsavings• converts standard boilers into condensing boilers• increases existing boiler efficiency by up to20%• feasible for boiler systems ranging from 250 kW to 6 000 kW• unique tube design for optimal thermal performance• easy installation, lowm

Typical economizer applicationsinclude:• Dying process• Absorption Chiller• food processingplants

FLUE GAS TEMPERATURE

BOILER INPUT

BOILER OPERATING TIME

ENERGYSAVING

PAYBACK SUMMARY

ANNUAL NATURAL GAS SAVINGS

ANNUALCO2REDUCTION

ANNUAL COST SAVINGS

*(natural gas avg price = 106 Rs/m3)

• food processingplants• pulp and paper mills• textile plants• Power plants• dairy processing facilities• hospitals• hotels

MONEY SAVINGS WITH CES ECONOMIZERS!!!Approximate energy savings achieved with CES4.5

economizer model:

INPUT DATAHOT WATER INLET TEMPERATURE 30°C

220°C

1 450kW

(145 m3/h – natural gas flow)

8 400 h/yr (full load operation)

15.7%

191 226 m3

382 452 kg

2,0270,000 Rs*

Latent11%

LatentHeatloss<

UP CHIMNE

Fluegasloss=3to5%UP CHIMNEY

Conventional boiler heat flow

35.0

34.0

33.0

32.0

31.0

30.0

29.0

28.0

27.0

26.0

25.0

24.0

23.0

22.0

21.0

20.0

19.0

18.0

17.0

16.0

15.0

14.0

13.0

12.0

11.0

10.0

9.0

8.0

7.0

6.0

5.0

4.0 10 15 20 25

Ene

rgy

savi

ng

s(%

)

30 35 40

Temperature of hot water entering

ENERGY RECOVERY FROM COOLING FLUE GAS

Fuel input =111%

Flue gas loss < 1 % UPCHIMNEY

Latentheat11%

Latentheat < 2%

CHIMNEY

Boilerstand-byandjacketloss< 1%

INTOMECHANICAL ROOM+6%9%

Condensing boiler heat flow

60 65 70

Flue gas

inlet

temperature

450°C

400°C

350°C

300°C

280°C

260°C

240°C

220°C

200°C

180°C

160°C

500°C

45 50 55

entering the economizer(0C)

ECON

Economizer’s simple technology and lack of moving parts gives it a very long and relative maintenance-free life cycle. Simple paybacks for condensing economizers are often less than 2 years.

The unique design of the heat exchanger tubes, the so-called “tear-drop” shape, guarantees maximum heat transfer sur- face contact with the flue gas, while decreasing the creation of flow wakes. The tubes are strategically positioned in a matrix to optimize the thermodynamic process, by inducing gas turbulence and increasing the heat transfer rate, and minimizing overall gas pressure drops through the system.

heat exchanger with unique

design

exhaustoutlet

stainlesssteelcondensate bottomdish

exhaust inlet

stainless steel inlet

The stainless steel durable construction is designed to with-stand the corrosive effects of condensing flue gases, and is insulated to minimize heat losses.

ECONOMIZER CONSTRUCTION MATERIAL:• stainless steel 316L or 304L

-for economizers working with gas-fired boilers• stainless steel 904L

-for economizers working with heavy-oil fired boilers (optional)

WORKING PRESSURE 11 BAR

flue gas inlet

ECONOMIZER ONSTRUCTION

nozzleforoutlet waterconnection

heat exchanger – tubetype unique “tear-drop shape”

design constructed from a highgrade stainlesssteel

flue gas outlet

durable solid standconstruction

made ofcarbonsteel

waterconnection

CES casing– easily removable metalpanelsinsulated with mineral wool allow for inside surface inspection andcleaning

eLINEmodel E35.1

in its casing

wool

E

GH

BJ

A

F

D

Exhaust Outlet

Exhaust Inlet

Technical Product Specifications

ModelNominal Boiler Input Exhaust Inlet E

kW MBTUH ømm øin

CES 3.2 1

A

mm in

B

mm in

Larger sizes (multiple-units) or custom-designed

CES 3.2 1

CES 3.3 3

CES 3.4 5

CES 3.6 6

CES 3.8 7

CES 3.9 8

CES 4.2 11

CES 4.4 13

CES 4.5 15

C

Water Inlet

Water Outlet

Exhaust Outlet Water Inlet Water Outlet Drain Nozzle

ømm øin mm in mm in mm in

J

mmin

designed economizers available upon individual request.

Condensing Economizer Increases Condensing Economizer Increases Efficiency OverEfficiency Over

CH4 + 2O2 + 7.52N2

16 lb1 lb

One lb of CH4 produces 2.25 lb

One lb of Natural Gas (1005 Btu/ft3) produces

• Water in products of combustion is vaporized due to heat of

• Water vapors absorb about 10% of fuel input

• Energy lost to atmosphere with exhaust gases through

• Heat of vaporization can be recovered if flue gases are cooled below water dew

• When water vapour condenses, it releases heat of vaporization

• Condensing economizer recovers both heat of condensation (latent heat) and sensible

Basic Concepts Basic Concepts of of Condensing Heat RecoveryCondensing Heat Recovery

Condensing Economizer Increases Condensing Economizer Increases Boiler Boiler Efficiency OverEfficiency Over 90%90%

CO2 + + 7.52 N22H2O

36 lb2.25 lb

produces 2.25 lb of H2O(1005 Btu/ft3) produces 2.14 lb of water

Water in products of combustion is vaporized due to heat of combustion

through stack

Heat of vaporization can be recovered if flue gases are cooled below water dew point

When water vapour condenses, it releases heat of vaporization

Condensing economizer recovers both heat of condensation (latent heat) and sensible heat

Condensing Heat RecoveryCondensing Heat Recovery

Condensation Starts Below Water Dew Point

Dew point varies with O2, CO2 and H2Oin products of combustion

Example: For 4% O2, CO2 is 9.5%

Dew Point = 57 C

93C/200F

• X-axis: Exit Flue Gas Temp

• Y-axis: Efficiency – percent of high

heating value

• Latent heat transfer starts at 59 C

• Excess air 15%

• Entering flue gas temp 232 C

• Exit Flue gas temp 42 C

• Efficiency w/o economizer 80%

• Efficiency with condensing

economizer 95%

Email: applicationandproject@coenergiesystem.com

Website: www.coenergiesystem.com , Mobile

Address 1: A 421, Block-1, Gulshan-e-Iqbal

Site: Industrial Plot No. 3/10, 3/11 SurbeyNo. 3, Karachi, Pakistan.

Condensation Starts Below Water Dew Point

applicationandproject@coenergiesystem.com,

Mobile No: 03208304070

Iqbal, Karachi-75300, Pakistan.

Surbey Street No. 1, Shah Faisal Colony

ConEconomizer

Boiler4%

Boiler FW 127 C

Flue Gas 149 C

Natural Gas

3275 m3/hr

Feedwater Economizer

BoilerExcess O2: 4%Efficiency: 83% With Econo

Steam

149 C

Energy SavingCondensing Economizer

42 C

Condensate ReturnDeaerator/

Condensate Tank

Steam

Steam production

Make-up water flow rate

Make-up water temperature entering condensing economizer

Make-up water temperature leaving condensing economizer

Flue gas temperature leaving condensing economizerEnergy recovered

Boiler operating hoursGas costEnergy cost savings

Gas Saving Potential

ondensing Economizer

Steam Production 45 Ton/hr @ 100 psig

Boiler Blowdown

Boiler Make-up Water 50%, (23 ton/hr)

Flue Gas

30 C

93 C

149 C

Potential with Condensing Economizer

42 C

Return

45 Ton/hn

50%

entering condensing economizer30 C

up water temperature leaving 93 C

42 C

7.55 MMBtu/hr

8000 hrsRs1283/MMBtu77,493,200 Rs