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Economiser

Waste Heat Recovery Systems
Industrial Boilers

Economisers provide boiler feed water preheating, process hot water production, hot water or hot water production by using the smoke gases from Steam Boiler, Hot Water, Hot Water, Hot Oil Boilers.

Our economisers are specially designed for minimum liquid pressure drop, suitable outlet conditions and permissible liquid film temperatures.

Economiser Advantages;

5-17% fuel saving.
Due to sulphur, the flue gas temperature can be reduced to 160°C in fuel-oil fuelled devices and up to 120°C in natural gas fuelled devices with carbon steel material, and the flue gas temperature can be reduced below 50°C with condensing economisers made of corrosion-resistant stainless steel in gas-fired boilers).
Manufactured with an optimised combination of bare and finned tubes to control film temperatures.
In-line or staggered pipe arrangements according to the application.
The fluid circuits are properly evaluated to obtain the desired mass flow, fluid velocity and pressure drop.
Specially designed for high gas side pressure applications.
Clean energy supply
Custom design according to customer requirements.
Many years of experience in industrial/commercial economiser technology
Low maintenance and service costs
Easy user interface with Tsb Energy control system.
High process reliability, remote control is available.
Offers zero emissions at the user site, no COx, NOx and SOx,
Customer-specific software revision specific to your company with our expert staff.
The economiser can optionally be equipped with a PLC with different communication protocols such as Modbus, Profibus, etc., and thus economiser integration into any industrial process can be provided.

Economisers are used in boiler feed water preheating, process hot water production, hot water or hot water production up to 160 bar, 2320psig design pressure by using the waste heat energy of flue gas waste heat energy from Steam Boiler, Hot Water, Hot Water, Hot Oil Boilers.

These units are specially designed for minimum liquid pressure drop, favourable outlet conditions and permissible liquid film temperatures.

Beneficial both financially and environmentally, waste heat reuse eliminates the need for additional auxiliary fired boilers. Every 1000kg/h - 700kW of recovered heat energy eliminates 975 tonnes of CO2 and 302kg each, 666 lbs of NOx and CO per year to help meet emission reduction and decarbonisation targets.

It should not be forgotten that each 20 °C recovery from the hot smoke gas discharged from the chimney means 1% fuel recovery.

Working Principle of Economisers;

The waste flue gases are passed through a smoke-tube heat recovery device (specially designed heat exchanger), whereby the waste heat energy is transferred to the water and the water changes state under pressure.

Design: Our high pressure, water tube, vertical or horizontal type economisers are designed and manufactured according to TS EN 13445, AD-2000, Loyd's rules, TRD, DIN, EN, PED 2014/68/EC and ASME Section VIII Div 1. All electrical components are UL labelled and wired in accordance with the applicable National Electrical Code requirements.

All our economisers are protected against corrosion effect with by-pass valve as standard.

The economisers are delivered compactly on a single chassis ready for operation. The only action required is to connect the economiser to electricity, feedwater and steam users.

Ease of Operation and Maintenance: User-friendly controls and easy access to components simplify operation and maintenance, minimising downtime and operating costs. One-button start-up, self-checking of the device to stop the system against possible faults, a control panel with summary maintenance instructions with warnings according to the duration of use make the use of the economiser very reliable and understandable for the operator.

All security devices are monitored by PLC. Necessary safety measures are taken in case of alarm. Economiser control is carried out by the economiser operator via HMI. Active alarms and past alarms can be monitored on the same HMI. Alarm and running information is transmitted to other systems via digital contacts (dry contact). Remote data acquisition and economiser status information can be obtained via ModBus, Modbus TCP/IP and Profinet protocols.

Safety: Safety and standards are our top priority. Our economisers are equipped with advanced safety features such as overpressure protection, flue temperature, flap monitoring and emergency economiser shutdown mechanisms.

Material: Envelopes and mirrors of our economisers are made of P355GH economiser sheet in accordance with EN 10028-2 or AISI304 - AISI316 stainless steel for corrosive gases such as biogas. Economiser pipes are manufactured from P235GH or P265GH steel drawn boiler pipes in accordance with EN 10216-2 or AISI304 - AISI316 - AISI316TI stainless pipes for corrosive gases.

Efficiency: All calculations of our economisers have heat transfer surfaces calculated by adding the necessary error coefficients in line with our theoretical and practical knowledge, and maximum heat recovery and efficiency are obtained as they are designed to meet all the commitment limits we give.

As a result of the long-term studies of our university-supported R&D department with analysis programmes, the pipe diameters of our economisers have been narrowed and the length of the economisers has been extended, thus the speed of the smoke gases in the economiser has been increased at the ideal counter pressure and advanced efficiency has been achieved.

Low heat loss is achieved thanks to 100mm thick high density economiser insulation. The thermal insulation is covered with galvanised and painted DKP sheet with low lambda value. All insulation has low conductivity and high density materials.

In addition, in order to increase the efficiency of our economisers, aluminium turbulators are optionally placed in the smoke pipes to ensure maximum heat transfer from smoke gases in smaller areas.

Environmentally Friendly Design: Our zero emission economisers support your industrial system with alternative clean energy, helping you reduce your carbon footprint and achieve your carbon neutrality goals.

Customisation: We know that every manufacturing and process has its own unique differences, we customise our proven devices based on the analysis of your process to make them the most suitable and ideal for you. It takes exceptional expertise to design and manufacture economisers and more importantly to provide the engineering support and personnel required for a successful installation. You will not only buy an economiser from us, but also years of experience and know-how. If you have any further questions, please do not hesitate to request an individual expert consultation.

Our customers are offered the following extensions for each Economiser:

Automation and control technology
Pipework and chimney systems
Low emissions
Simple and easy maintenance
Robust design for very long life
Condensing economiser option
A fully integrated economiser solution.

What is Economiser? When to Use Economiser?

It is a heat exchanger device with sufficient heating surface, which is used for heating the boiler feed water or any liquid heat receiving fluid with the heat of hot smoke gases discharged into the chimney, which are formed by burning solid, liquid and gaseous fuels, providing energy recovery.

Economisers can be made in the form of coil-shaped pipe bundles, straight pipe bundles, spiral pipe bundles depending on their intended use.

In all facilities where a fuel is burned, there is smoke, i.e. waste heat release from the chimney. It is not correct to make economisers in every facility with waste heat release. A very good feasibility should be made in the enterprise where waste heat recovery will be made and the enterprise should have a process where waste heat can be used. Therefore, if we use the recovered heat energy efficiently somewhere, the business can get the return on investment. With an efficient project, the depreciation period of the device is also low.