Efficient Combustion with Hot Air

Recuperator

Waste Heat Recovery Systems
Industrial Boilers

Recuperators provide preheating of combustion air or production of fresh air for the process by using the flue gas from the Steam Boiler, Hot Water, Hot Water, Hot Water, Hot Oil or Hot Air Boiler.

Air fluid circuits are evaluated with special software to obtain the desired mass flow, fluid velocity and pressure drop.

Recuperator Advantages;

Flue gas temperature can be reduced up to 160°C in fuel-oil fuelled devices and up to 120°C in natural gas fuelled devices with carbon steel materials. In gas-fired boilers, the flue gas temperature can be reduced below 50°C with condensing recuperators made of corrosion-resistant stainless steel.
An optimised combination of bare tubes is applied to control film temperatures.
Depending on the application, in-line or staggered pipe arrangements are designed.
Specially designed for high gas side pressure applications.
Clean energy supply
Custom design according to customer requirements.
Many years of experience in industrial/commercial recuperator technology
Ease of regulatory inspections
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 the Recuperator can be integrated into any industrial process.

One of the most common ways to recover energy is to preheat the fresh air for the current heat process, using the exhaust gas or discharge air from the stack. This can be in the form of an air-to-air exchanger downstream of the primary heat recovery device as described above, or it can be a way of recovering relatively low-grade heat from the exhaust gas.

In both cases, the exhaust gas from an industrial process is passed through a heat recovery device where the heat energy is extracted before passing into the atmosphere.

At the same time, the cooler fresh air is passed through the other side of the heat exchanger and receives the extracted heat. This preheated air can be fed back into the process - which means that less heat is needed for the process - or this preheated air can be used elsewhere.

The two air streams do not have to mix directly to allow heat transfer. There are various methods to do this, including some advanced heat exchangers that can capture up to 95% of the waste heat.

Energy saving and efficiency are key factors for modern industry.

One of the most important energy users in a typical production plant is the boiler. Recognising this, TSB ENERGY offers the Rekü+Eco solution, which provides improvements in boiler efficiency of up to 96%. In this system, the feed water temperature is first increased and then the combustion air is preheated with the remaining waste heat.

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

Beneficial both financially and environmentally, reusing waste heat results in less fuel being burnt. Every 600,000kcal - 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 Recuperators;

The exhaust flue gases are passed through a smoke-tube heat recovery device, whereby the waste heat energy is transferred to the fresh air and the air temperature is increased.

Design: Our vertical or horizontal type recuperators are designed and manufactured in accordance with 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 recuperators are protected against corrosion effect with by-pass valve as standard.

Our recuperators are delivered compactly on a single chassis, ready for operation. The only action required is to connect the recuperator to the electricity and hot air 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, and a control panel with summary maintenance instructions with warnings according to the duration of use make the use of the recuperator very reliable and understandable for the recuperator operator.

All security devices are monitored by PLC. Necessary safety measures are taken in case of alarm. Recuperator control is carried out by the recuperator 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 acquisition and recuperator status information is available via ModBus, Modbus TCP/IP and Profinet protocols.

Safety: Safety and standards are our top priority. Our recuperators are equipped with advanced safety features such as flue temperature monitoring, flap position monitoring and emergency recuperator shutdown mechanisms.

Material: Envelopes and mirrors of our recuperators are made of S235JR-G2, P355GH boiler sheet in accordance with EN 10028-2 or AISI304 - AISI316 stainless steel for corrosive gases such as biogas. Recuperator pipes are manufactured from P235GH or P265GH boiler pipes in accordance with EN 10216-2 or EN10217 or AISI304 - AISI316 - AISI316TI stainless pipes for corrosive gases.

Efficiency: All calculations of our recuperators 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 recuperators have been narrowed and the length of the recuperators has been extended. In this way, the velocity of the smoke gases in the recuperator has been increased at ideal back pressure and improved efficiency has been achieved.

Low heat loss is achieved thanks to 100mm thick high density recuperator 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 recuperators, aluminium profiles are optionally placed in the smoke pipes to ensure maximum heat transfer from smoke gases in smaller areas.

Environmentally Friendly Design: Our zero emission recuperators 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, and we customise our proven devices based on hundreds of examples and analyses of your process to make them the most suitable and ideal for you. It takes exceptional expertise to design and manufacture recuperators and, more importantly, to provide the engineering support and personnel required for a successful installation. You will not only buy a recuperator 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 Recuperator:

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

What is a Recuperator? When is the recuperator used?

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

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

Waste heat emission is present in all facilities where a fuel is burned. It is not correct to make a recuperator in every plant with waste heat release. A very good feasibility should be made in the enterprise where waste heat recovery will be made. In addition, the plant must 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 amortisation period of the device is also low.