Exhaust Gas Heat Exchangers

Size: px

Start display at page:

Download "Exhaust Gas Heat Exchangers"

Mildred Jackson
6 years ago
Views:

1 Exhaust Gas eat Exchangers eat Transfer Technology from owman eat Exchanger Technology by World Leader in eat Exchanger Technology

Turning waste heat owman Exhaust Gas eat Exchangers Recovering valuable heat energy from the exhaust stream of engine powered ombined eat &

only), to around % (with EGE only) and up to 80% + when heat is recovered from other areas of the engine!

applications up to 1MW, for engines using iogas, Diesel or Natural Gas.

thermal oil heating, generating electricity through OR or Stirling engine technology, or running a chiller for cooling.

combine high levels of heat recovery, with long life durability.

transfer performance with ease of installation and simple maintenance.

2 Turning waste heat owman Exhaust Gas eat Exchangers Recovering valuable heat energy from the exhaust stream of engine powered ombined eat & Power (P) systems n exhaust gas heat exchanger (EGE) is an extremely effective way of recovering valuable waste heat energy from an engine powered generating set. y recovering waste heat from the engine s exhaust stream, the overall efficiency of a gen-set can be increased from approximately 30% (power only), to around % (with EGE only) and up to 80% + when heat is recovered from other areas of the engine! s the U s leading manufacturer of exhaust gas heat exchangers, owman offer a comprehensive range of highly efficient units, suitable for applications up to 1MW, for engines using iogas, Diesel or Natural Gas. owman EGE s are designed for a wide range of commercial or industrial applications, including district heating and hot water, space heating, thermal oil heating, generating electricity through OR or Stirling engine technology, or running a chiller for cooling. Extensively proven in some of the most challenging installations on earth, owman exhaust gas heat exchangers are high quality units that combine high levels of heat recovery, with long life durability. Shell and tube design ll owman units are based on the company s renowned shell and tube heat exchanger design, which combines excellent heat transfer performance with ease of installation and simple maintenance. ll stainless steel construction The fully welded, all stainless steel construction of owman s EGEs, ensures maximum reliability and durability of the unit when handling extreme exhaust gas temperatures. utomated tube welding utomated tube end welding and % inspection, ensures the highest quality and structural integrity of the tube core for maximum reliability. nstallation options owman offer three ranges of exhaust gas heat exchangers: (i) without end covers, for direct connection into customer s pipework, (ii) straight end covers and (iii) 0 o (right angle) end covers. 2

into vital energy owman exhaust gas units are

Survey s alley V research station Right angle end

these end covers enable more compact packaging and

They also enable the tubes to be cleaned without

n anada, owman exhaust gas units within a ogen

PN6 flanges ll end cover flanges and shell side

Pressure relief valve owman EGEs are fitted with a

Should pressure exceed 4 bar on the shell or water

and bosses for vents and temperature sensors, all

3 into vital energy owman exhaust gas units are installed in the P system within the ritish rctic Survey s alley V research station Right angle end covers vailable across the range in all size options, these end covers enable more compact packaging and often reduce pipework requirements. They also enable the tubes to be cleaned without disturbing the pipework. n anada, owman exhaust gas units within a ogen system, provide heat for a remote off-grid community PN6 flanges ll end cover flanges and shell side flanges are PN6 to S EN102 for ease of installation. Pressure relief valve owman EGEs are fitted with a pressure relief valve as a safety feature. Should pressure exceed 4 bar on the shell or water side, it automatically activates to prevent excess pressure build up. omprehensive specification n addition to drain plugs and bosses for vents and temperature sensors, all owman EGEs are supplied with mounting brackets as standard, for ease of installation. n eco village in inland relies on owman units to recover waste heat energy for heating and hot water 3

Exhaust Gas eat Exchangers Product Range The figures given in the table below are typical examples of the performance of owman exhaust gas heat exchangers (EGE) and are intended only as a general

013 bar and 15⁰) and an exhaust gas inlet temperature of 0⁰ with a water inlet of 80⁰.

4 18 1 3-40-3738-6 32 2.4 163 21 1.3 3--3738-8 32 2.4 6 23 1.6 4-32-373-5 4.5 1 36 1.0 4-40-373-6 4.5 164 3 4--373-8 4.5 6 43 1.4 5-32-3740-5 0 6.7 15 1.0 5-40-3740-6 0 6.7 161 5 1.1 5--3740-8 0 6.

1 10-40-3743-6 400 30.0 164 262 10--3743-8 400 30.0 6 28 1.4 12-32-3744-5 0 45.0 1 362 1.1 12-40-3744-6 0 45.0 164 32 12--3744-8 0 45.0 7 432 1.5 15-32-5745-5 50 70.0 200 563 1.0 15-40-5745-6 50 70.

4 Exhaust Gas eat Exchangers Product Range The figures given in the table below are typical examples of the performance of owman exhaust gas heat exchangers (EGE) and are intended only as a general guide. They are based on a natural gas engine with an air/fuel ratio of 10.23: 1 by volume, a fuel consumption of 0.34 m 3 /kwh (measured at bar and 15⁰) and an exhaust gas inlet temperature of 0⁰ with a water inlet of 80⁰. Type Typical Engine Power Exhaust Gas low Exhaust Gas Outlet Temp eat Recovery Exhaust Gas Pressure Drop kw kg / min º kw kpa or larger sizes contact our sales department. Maximum working gas side pressure 0.5 bar. Maximum working water side pressure 4 bar Maximum working gas side temperature 700º. Maximum working water side temperature 0º European Pressure Equipment Directive This range of products fall within rticle 3 Paragraph 3. (Sound Engineering Practice) and do not require E marking kpa =1 bar 24

Exhaust Gas eat Exchangers Selection Guidance 1: rom the exhaust gas heat exchanger range shown on page 4, first identify the engine size and then select the unit that will cool the exhaust gas to

2: s a general guide, the heat exchanger length determines the gas temperature reduction and the diameter determines the pressure drop.

necessitating cleaning to restore performance. 4: t temperatures below 0, condensation will occur, so the materials used downstream of the heat exchanger must be chosen accordingly.

Temperatures can be given in elsius, but if any calculations are to be made involving the universal gas laws, absolute temperatures in elvin must be used. To convert from elsius to elvin, add.

5 Exhaust Gas eat Exchangers Selection Guidance 1: rom the exhaust gas heat exchanger range shown on page 4, first identify the engine size and then select the unit that will cool the exhaust gas to the desired outlet temperature and recover the required amount of heat. 2: s a general guide, the heat exchanger length determines the gas temperature reduction and the diameter determines the pressure drop. 3: or diesel powered engines, the exhaust gas temperature should not fall below 0, as below this temperature, soot deposits can build up inside the heat exchanger, reducing efficiency and necessitating cleaning to restore performance. 4: t temperatures below 0, condensation will occur, so the materials used downstream of the heat exchanger must be chosen accordingly. 5: lways specify the gas mass flow, preferably in kg/min. Volume flows should be avoided because without also stating the pressure and temperature at which they are measured, they are meaningless. Temperatures can be given in elsius, but if any calculations are to be made involving the universal gas laws, absolute temperatures in elvin must be used. To convert from elsius to elvin, add. 6: t should be noted that adding an exhaust gas heat exchanger to an existing system will reduce the gas volume and velocity after the heat exchanger, thus reducing the back pressure through the silencer and the rest of the system. Typically, this reduction will be more than the back pressure through the heat exchanger, meaning that the addition of a heat exchanger to an existing system will often reduce the total system back pressure. 7: The target gas pressure drop through the heat exchanger should be about half the total back pressure permitted by the engine manufacturer. onsideration should also be given to the silencer. When specifying, ensure the supplier has the actual gas inlet temperature and the mass flow in kg/min, in addition to noise reduction requirements. Please note that for any gas flow through a particular silencer, back pressure will be proportional to the absolute gas temperature in elvin. Exhaust Gas eat Exchangers pplication hoice owman exhaust gas heat exchangers are available in a choice of three ranges to suit the requirements of the application: Without end covers This option enables the unit to be connected directly into the installation pipework. Straight end covers With PN6 flange connections on the end covers these units provide installation flexibility for using on a wide range of applications. Right angle end covers Designed to provide a more compact installation which can often reduce pipework, these end covers can be rotated to suit exhaust gas pipework. 25

G G G Without end covers WTER DRN PLUG Type D E G J L kg

3-32-4738-5 3-40-4738-6 3--4738-8 4-32-473-5 4-40-473-6

28 68 00 08 688 80 138 588 766 7 62 70 7 62 70 7 62 70.3.3 88.

3 1.3 1.3 1.3 1.3 106 106 136 136 136 1 1 1 14 14 14 ¾ ¾ 1

PD 4 PD 4 PD 174 PD 174 PD 174 PD 4 x 4 x 8 x 8 x 8 x 8 x

PLUG WTER DRN PLUG Type D E G J L kg kg mm mm mm mm mm mm

8-40-4742-6 8--4742-8 10-32-4743-5 10-40-4743-6 10--4743-8

15-40-4745-6 15--4745-8 1038 668 870 1378 648 850 1358 8

46 710 12 20 21 21 21 324 324 324 284 284 284 340 340 340

2 PD 2 PD 3 PD 3 PD 3 PD 376 PD 376 PD 376 PD 4 PD 4 PD 4

6 G G G Without end covers WTER DRN PLUG Type D E G J L kg mm mm mm mm mm SP mm mm mm mm ¾ ¾ 1 ½ 1 ½ 1 ½ PD 0 PD PD PD PD 4 PD 4 PD 4 PD 174 PD 174 PD 174 PD 4 x 4 x 8 x 8 x 8 x 8 x 8 x 8 x 8 x 8 x 8 x WTER DRN PLUG WTER DRN PLUG Type D E G J L kg kg mm mm mm mm mm mm mm mm mm PD 200 PD 200 PD 2 PD 2 PD 2 PD 3 PD 3 PD 3 PD 376 PD 376 PD 376 PD 4 PD 4 PD 4 PD 8 x 8 x 8 x 8 x 8 x 8 x 12 x 12 x 12 x 12 x 12 x 12 X 16 X 16 x 16 x

M M M M Straight end covers G WTER DRN PLUG ONDENSTE DRN PLUG G WTER DRN PLUG ONDENSTE DRN PLUG Type D E G J L M kg mm mm mm mm mm SP mm mm mm mm 2-25-3737-4 0 0 588.

mm 0 mm mm mm mm DN50 54 16 3-40-3738-6 2-25-3737-4 3--3738-8 2-32-3737-5 0 62 28 1670 0 20 728 28 58862 766 70.388.

1.3 0 1 1 ½ 0 0 80 DN50 DN64 66 16 17 22 3--3738-8 1670 28 70 88. 0 DN50 54 16 23 4--373-8 1700 08 70 1.3 1 1 ½ 0 0 80 66 22 4-32-373-5 0 68 1.

3 1.3 10 10 2 2 82 82 26 28 26 5-40-3740-6 1232 80 62 1.3 10 2 82 26 32 5--3740-8 1740 138 70 1.

6-32-3741-5 6-40-3741-6 6--3741-8 8-32-3742-5 8-40-3742-6 8--3742-8 10-32-3743-5 10-40-3743-6 10--3743-8 12-32-3744-5 12-40-3744-6 12--3744-8 15-32-5745-5 15-40-5745-6

7 M M M M Straight end covers G WTER DRN PLUG ONDENSTE DRN PLUG G WTER DRN PLUG ONDENSTE DRN PLUG Type D E G J L M kg mm mm mm mm mm SP mm mm mm mm ¾ DN Type D.3 E ¾ G J DN25L 34 M g mm mm 7 mm 7 mm 88. mm 0 mm mm mm mm DN ¾ ¾ DN25 DN25 DN5034 DN ½ DN ½ DN50 DN DN ½ ½ ½ ½ WTER DRN PLUG ONDENSTE DRN PLUG G G WTER DRN PLUG ONDENSTE DRN PLUG Type D E G J L M kg mm mm mm mm mm mm mm mm mm mm mm DN200 DN200 DN200 DN DN DN

G G G G Right angle end covers 1 1 WTER DRN PLUG ONDENSTE DRN PLUG WTER DRN PLUG ONDENSTE DRN PLUG Type 1

4-32-583-5 4-40-583-6 4--583-8 5-32-5840-5 5-40-5840-6 5--5840-8 20 108 8 00 108 1237 3 148 6 4 2010 0 728

3 1.3 1.3 1.3 1.3 0 0 0 1 1 1 10 10 10 ¾ ¾ 1 ½ 1 ½ 1 ½ 2 2 2 0 0 0 70 70 85 85 85 80 80 80 DN25 DN25 DN50

DRN PLUG ONDENSTE DRN PLUG Type 1 D E G J L kg mm mm mm mm mm mm mm mm mm mm mm 6-32-5841-5 6-40-5841-6

12--5844-8 15-32-5845-5 15-40-5845-6 15--5845-8 00 14 20 46 1648 2156 1528 1730 2238 1720 2430 80 2082 668

203 7 62 70 0 52 0 52 736 38 46 710 12 20 21 21 21 323.

8 G G G G Right angle end covers 1 1 WTER DRN PLUG ONDENSTE DRN PLUG WTER DRN PLUG ONDENSTE DRN PLUG Type 1 D E G J L kg mm mm mm mm mm mm SP mm mm mm mm mm ¾ ¾ 1 ½ 1 ½ 1 ½ DN25 DN25 DN50 DN50 DN WTER DRN PLUG ONDENSTE DRN PLUG WTER DRN PLUG ONDENSTE DRN PLUG Type 1 D E G J L kg mm mm mm mm mm mm mm mm mm mm mm DN200 DN200 DN200 DN DN DN

nstallation Guidelines MPORTNT: Please follow these guidelines when designing an exhaust gas heat recovery installation. 1.

The heat exchanger should be connected for counter flow so that the cooling medium flows in the opposite direction to the exhaust gas stream. Please see below for reference. 3.

MPORTNT: the water circuit must be fully vented via the vent plug to prevent the possibility of air pockets being present or aeration taking place. 5.

9 nstallation Guidelines MPORTNT: Please follow these guidelines when designing an exhaust gas heat recovery installation. 1. owman exhaust gas heat exchangers should be installed horizontally and levelled accurately with the water connections on top, so that they are always full of water. 2. The heat exchanger should be connected for counter flow so that the cooling medium flows in the opposite direction to the exhaust gas stream. Please see below for reference. 3. The heat exchanger should be installed below the level of the cylinder head, so that in the unlikely event of a tube leak occurring, water will not leak back into the engine. 4. MPORTNT: the water circuit must be fully vented via the vent plug to prevent the possibility of air pockets being present or aeration taking place. 5. f ethylene glycol, or any other cooling medium is used in the water circuit, use the correct concentration advised by the engine manufacturer. 6. utomatic engine shutdown equipment must be provided with temperature probes in the exhaust gas heat exchanger and the engine. 7. Under no circumstances should the pressure relief valve be removed or tampered with. 8. The inlet and exit exhaust pipe bore must not be smaller than the heat exchanger connections. Water Outlet Pressure Relief Valve Operation Guidelines 1. Should the gas circuit be shut down, it is important to ensure that the water circuit continues to operate for a period of time to enable residual heat to disperse from within the heat exchanger, to prevent the possibility of damage. 2. t is important to ensure that the water circuit pumps operate continually whenever the gas circuit is in operation, to prevent the possibility of damage to the unit through overheating. 3. t is also important to ensure that any valves or ancillary equipment fitted to the heat exchanger cannot be accidentally turned off, preventing water flow through the heat exchanger. Water nlet Exhaust Gas Outlet Vent Plug Exhaust Gas nlet 2

Servicing the unit Simply unbolting the end covers or access plates (depending on the version) allows access to the tube plates, which can then be

ejbowman.co.uk, or should you need further advice, contact our technical sales team on +44 (0) 121 35 5401.

Replacement Parts comprehensive range of replacement parts is available including end covers, gaskets, pressure relief valves, end cover fixings, feet

Total Engine ooling Solutions or nearly years, owman has provided efficient, reliable cooling solutions for normally aspirated and forced induction

During that time the company has amassed a wealth of expertise and can provide a complete cooling solution for both marine and land based stationary

Suitable for engines up to 0kW. Engine & Gearbox Oil oolers range of compact units suitable for engine or transmission oil cooling.

uel oolers owman in line plate fuel coolers are compact, easy to install and suitable for use with all fuel types including Ethanol rich fuels ombined

10 Servicing the unit Simply unbolting the end covers or access plates (depending on the version) allows access to the tube plates, which can then be easily cleaned in accordance with guide lines given in the nstallation, Operation and Maintenance Manual. You can download a copy by visiting or should you need further advice, contact our technical sales team on +44 (0) NOTE: on reassembly, new gaskets should always be used when refitting end covers or access plates. Replacement Parts comprehensive range of replacement parts is available including end covers, gaskets, pressure relief valves, end cover fixings, feet and drain plugs. Total Engine ooling Solutions or nearly years, owman has provided efficient, reliable cooling solutions for normally aspirated and forced induction engines. During that time the company has amassed a wealth of expertise and can provide a complete cooling solution for both marine and land based stationary engines, including: eader Tank eat Exchangers owman s unique design combines high efficiency engine cooling, with long life durability. Suitable for engines up to 0kW. Engine & Gearbox Oil oolers range of compact units suitable for engine or transmission oil cooling. harge ir oolers mproved combustion efficiency and reduced fuel consumption are just some of the benefits provided by owman charge air coolers. uel oolers owman in line plate fuel coolers are compact, easy to install and suitable for use with all fuel types including Ethanol rich fuels ombined heat recovery performance table Type Engine Power Jacket Water Engine Oil harge ir ooler Exhaust Gas Total Reclaimed Energy kw kw kw kw kw kw The figures should be used as a guide only, and an optimised design is available on request. ll material contained in this brochure is the intellectual property of EJ owman (irmingham) Ltd. t is protected under copyright and may not be reproduced without prior written consent of the company.

chieving 80% Gen-set efficiency EVNG 80% GEN-SET EENY Simply by recovering

recovered and used as valuable heat energy.

cost, in terms of fuel used or O2 generated.

uses, including district heating and hot water, space heating, process

y recovering waste heat energy, overall gen-set efficiency can be

uel % Losses 20% Waste heat can be recovered from most areas of an engine

11 chieving 80% Gen-set efficiency EVNG 80% GEN-SET EENY Simply by recovering waste heat from your engine, overall gen-set efficiency can be increased to 80%* and beyond! Power 31% eat 4% Up to 50% ** of all fuel input into the gen-set can be recovered and used as valuable heat energy. This valuable energy source can be harvested and used at no additional cost, in terms of fuel used or O2 generated. nd it can be used for a wide range of domestic, commercial or industrial uses, including district heating and hot water, space heating, process heating, generating electricity, or running a chiller for cooling. y recovering waste heat energy, overall gen-set efficiency can be increased from around 30% (power only) to 80% (combined heat and power), or even more. Waste heat recovery potential ombined eat and Power Generation ow it works uel % Losses 20% Waste heat can be recovered from most areas of an engine powered gen-set, taking it from power only, to a highly efficient P facility. 24% % from Engine Lubrication 12% from Turbo harged ir from Engine ooling % from Exhaust Gas heat recovery *ssociation of Decentralised Energy **Digest of United ingdom Energy Statistics (DUES)

world of applications owman exhaust gas heat exchangers can be found recovering valuable waste heat energy in some of the most diverse and technically challenging applications around the world.

V, where winter temperatures plummet to - 50º, snow falls for half the year and the station is literally cut off throughout the winter period.

n the first year since installation, the system has reduced fuel consumption at a innish farm by half saving around,000 litres of diesel per year!

n the US, owman heat exchangers are at the heart of ground breaking technology, designed to increase gen-set efficiency and reduce fuel consumption.

winter temperatures regularly fall to - 40º. ll owman exhaust gas heat exchangers are produced to the highest quality in our dedicated U manufacturing centre, to SO 001:2008 standards.

12 world of applications owman exhaust gas heat exchangers can be found recovering valuable waste heat energy in some of the most diverse and technically challenging applications around the world. ere are just a few examples: n the ntarctic, owman exhaust gas heat exchangers are a vital part of a P system that supplies lifesaving energy to the ritish ntarctic Survey s research station, alley V, where winter temperatures plummet to - 50º, snow falls for half the year and the station is literally cut off throughout the winter period. n inland, a new closed loop grain drying system, using owman waste heat recovery technology, has significantly reduced energy costs for this traditionally energy intensive operation. n the first year since installation, the system has reduced fuel consumption at a innish farm by half saving around,000 litres of diesel per year! s demand for electrical power increases, owman exhaust gas units are being used on leading edge technologies that capture waste heat and convert it into more electricity. n the US, owman heat exchangers are at the heart of ground breaking technology, designed to increase gen-set efficiency and reduce fuel consumption. n the Northwest Territories of anada, owman heat exchangers have been installed as part of a new cogeneration system that has halved energy costs for the remote community of ort Providence, where winter temperatures regularly fall to - 40º. ll owman exhaust gas heat exchangers are produced to the highest quality in our dedicated U manufacturing centre, to SO 001:2008 standards. With over 50 years experience producing highly efficient waste heat recovery solutions, you can have complete confidence when you specify owman exhaust gas heat exchangers. EJ owman (irmingham) Ltd hester Street, irmingham 6 4P, U Tel: +44 (0) ax: +44 (0) info@ejbowman.co.uk World Leader in eat Exchanger Technology EJ owman (irmingham) Ltd, reserve the right to change specifications without prior notice. M38224 L

Header Tank Heat Exchangers

Header Tank Heat Exchangers Heat Transfer Technology from owman Heat Exchanger Technology by World Leader in Heat Exchanger Technology Staying cool under owman Header Tank Heat Exchangers For marine propulsion