High Pressure Gas Heater

Advantages of Pressurised Hot Air Boiler;

• High pressure heating is provided within 10-15 seconds after switching on.
• Since the vehicle is not liquid, there is no danger of purification, waste liquid, freezing and leakage,
• Designed in a horizontal or vertical position, it is suitable for almost any position.
• Very low maintenance, minimum inspection, service and long life and corrosion free,
• It has a front boiler cover at hand touch temperature.
• Custom design according to customer requirements.
• Many years of experience in industrial/commercial boiler technology
• H2 ready
• Low maintenance and service costs
• Easy user interface with Tsb Energy control system.
• Flow monitoring systems integrated into the heater design and included in all our devices ensure smooth and reliable operation.
• High process reliability, remote control is available.
• Low NOx emissions are available.
• CO2 emissions are reduced by burning up to 100 per cent hydrogen.
• Customer-specific software revision specific to your company with our expert staff.
• The boiler can be optionally equipped with a PLC with different communication protocols such as Modbus, Profibus, etc. and thus boiler integration into any industrial process can be provided.

Working Principle of Pressurised Hot Air Boiler;

As the clean air fed at pressurised and high speeds passes through the pipes designed in a horizontal or vertical construction so that there is no stagnant point in the turbulent flow in the spiral pipes, the temperature of the air is raised to the desired temperature range indirectly and pressurised with the heat energy received from the flame-smoke gases formed by combustion in the spiral pipe bundle.

Different gases can be utilised to meet specific process heating requirements, making our hot air boilers a very flexible system.

The compressed air compressor is specifically dimensioned to the flow rate and back pressure requirements of each application, maintaining a safe film temperature on the surfaces. The burner modulation and compressor drive are controlled by PID control according to the process requirements, so that the required heat input is provided proportionally.

Design: Indirect pressurised hot air boilers are designed and manufactured to EN 12952, AD-2000, Loyd's Rules, TRD, DIN, EN and ASME Section VIII Div 1 in a horizontal or vertical construction. All electrical components are UL labelled and wired in accordance with the applicable National Electrical Code requirements.

The boiler is delivered compactly on a single chassis ready for operation. All that is required is to connect it to electricity and appliances that use hot air.

With our university-supported R&D, we offer unrivalled efficiency and safety, minimal carbon footprint, easy maintenance and long life. High thermal performance and low film temperatures are achieved with compact design, high gas and fluid velocities.

TSB ENERGY Hot air boiler is designed for you to earn while using, not buying.

Ease of Use and Maintenance: It is easily maintained due to its simple structure and lack of control equipment.

Since clean air or gases are used as the heat transfer medium, users do not face known problems such as scale formation, corrosion and risk of freezing.

Unlike a steam system, there are no condensate and thus no flash steam losses, no blow-off losses or feedwater demand, no wastewater discharge and the systems are completely corrosion-free without the need for expensive chemical treatment. All these are significant savings for businesses.

User-friendly controls and easy access to components simplify operation and maintenance, minimising downtime and operating costs. Thanks to a control panel with one-button start-up, self-checking of the device to stop the system against possible errors, and summary maintenance instructions with warnings according to the duration of use, boiler operation has become very reliable and understandable for the boiler operator.

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

Safety: Safety and standards are our top priority. Our boilers are equipped with advanced safety features such as air flow prosthesis, outlet temperature protection, pressure switches, flue temperature, surface safety temperature monitoring and emergency boiler shutdown mechanisms.

Material: Envelopes and covers of our pressurised hot air boilers are manufactured from P355GH boiler sheet in accordance with EN 10028-2 or hygienically from AISI304 quality stainless sheet in accordance with EN 10028-8, boiler pipes are manufactured from AISI304 or AISI321 stainless high temperature pipes in accordance with EN 10216-7.

Efficiency: It produces pressurised hot air within 10-15 seconds as soon as it is switched on, and when the system stops, it stops heating, so there are no storage and preheating losses as in boilers, there are no waiting losses, no unnecessary heat losses.

With the studies of our R&D department, the pipe diameters and flame-smoke gas flows of our hot air boilers have been redesigned with the support of analysis programmes and the boiler back pressure and air back pressures have been minimised. In this way, both electrical energy is saved by using electric motors with lower power (KW) compared to standard boilers, and fuel is saved by discharging less NOx gas into the environment and high boiler efficiency is achieved.

Our hot air boilers have three rows of insulation system on the front door and inferno cover. The first row is Hycast SS alumina reinforced fired concrete which traps the high heat in the inner wall, then ceramic fibre blanket prevents the heat load from the concrete from passing to the boiler door, and finally "ceramic paper" is adhered to the cover to keep the cover at touch temperature.

100mm thick high density outer wall insulation provides low heat loss from radiation. The thermal insulation is covered with galvanised and painted DKP sheet with low lambda value. All insulation has low conductivity and high density materials.

During chlorine production and similar chemical processes, most of the hydrogen gas is released into the atmosphere without being used. This waste and difficult to store hydrogen can be used in our boilers by using suitable burners.

Environmentally Friendly Design: Our aim is a cleaner environment and for this we try to minimise emissions, In a clean combustion, NOx emissions in our gas-fired boilers: 70 mg/Nm3 in our gas fired boilers and 150 mg/Nm3 in our liquid fuelled boilers.

All of our TSB ENERGY industrial liquid-gas fuelled products can operate with 100% hydrogen by equipping them with a suitable burner that can operate with 100% hydrogen. Since the boiler structure and working principle are designed according to high-speed flame-smoke gases, NOx level remains far below the standards even in hydrogen fuel. At the same time, CO2 emissions are significantly reduced.

Customisation: We know that every manufacturing and process is unique to each business, and we customise our proven equipment based on hundreds of examples and analysis of your process to make it the most suitable and ideal for you. Designing and manufacturing our Svı-Gas fired boilers and more importantly providing the necessary engineering support and personnel for a successful installation requires exceptional expertise. You will not only buy a boiler 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 our pressurised indirect hot air boiler:

• Automation and control technology
• Air compressor
• Safety temperature sensors and flow sensors,
• Chimney systems
• Very high efficiency and low emissions
• Micromodulation as standard
• Simple and easy maintenance
• Dual and mixed fuel ignition options
• O2 and CO trim options

What is Pressurised Indirect Hot Air Boiler?

A pressurised hot air boiler is a closed pressurised vessel with air as a heat-receiving fluid on one side of its surface and the flame-smoke gases generated as a result of the combustion of a heat-giving fuel on the other side, the combustion cell is specially designed according to the flame length and heat load, the pipes are designed in diameter and length to absorb high temperature by calculating the film temperatures on the surface.

When to Use Pressurised Hot Air Boiler?

Pressurised hot air boilers provide economical and high quality production in industrial drying processes since they are designed based on the principle of economical and fast movement of air and the hot air outlet temperature can be kept clear within the desired range with the automated control of the compressor and burner.

• In chemical plants and refineries,
• Boron processing plants
• Drying of mine ore, fire soil and similar granular materials
• In artificial fertiliser production
• Drying of powder detergent and similar powder or granular chemical products