For biomass boiler & process heat

From construction to production and assembly through to commissioning and after-sales service - in addition to the new and retrofitting of their systems, we also take over the renovation and servicing of existing systems for our customers. For unknown systems, we offer the installation of test systems in order to determine the exact design and operating parameters. We differentiate between heat recovery for biomass boilers and process heat.

 

Biomass boiler

The high heat content of the exhaust gases when moist biomass is burned is often unused and released into the environment. With an appropriately designed heat recovery system from HEGER, it is possible to cool the flue gas below the flue gas dew point, so that considerable increases in efficiency can be achieved.

The lower the residual oxygen content and the higher the fuel water content, the higher the achievable efficiency. Flue gas condensation with an integrated depluming system enables the plume of water vapor which emerges from the chimney to be invisible even at temperatures below 0°C.

Flue gas condensation HEGI-ED-2200 for biomass boiler 22.000 kW

By installing the HEGI-ED-2200 heat recovery system, the humid exhaust gases from the newly installed 22,000 kW biomass boiler are also used thermally.

The heat content of the exhaust gases is converted directly into useful heat for the heating network in a smooth tube heat exchanger made of stainless steel 1.4571.

Key data:

  • Two heat exchanger stages (ECONOMISER) in countercurrent design
    Heat output ECO 1.429 kW (w40, 80°C RT)
  • Housing parts, process tank and piping
    made of stainless steel  1.4571
  • Condensate cooler
  • Control technology
  • Engineering (procedural layout & design)
  • Delivery & Assembly
  • Startup
  • Training of operating personnel
  • Place of installation: SWITZERLAND

Flue gas condensation HEGC-C-120 for biomass boiler 1.200 kW

By installing the heat recovery system HEGC-C-0120, the moist flue gas from the biomass boiler (1.200 kW) is also used thermally by cooling in a CONDENSER.

The heat content of the exhaust gases is converted directly into useful heat for the two heating networks in a smooth-tube-heat exchanger made of high-quality stainless steel 1.4571. In addition to heat extraction, te HEGC-C-0120 also has a dedusting effect. A degree of dedusting of approx. 40-60% can be assumed.

Key data:

  • X-LARGE CONDENSER
    with pipes made of stainless steel 1.4571
    Heat output CONDENSER 226 kW (w50, 46°C RT)
  • Housing parts, process tank and piping made of stainless steel 1.4571
  • Connection to the existing flue gas system
  • Multi-chamber sedimentation tank
  • Automated sludge discharge using
    sludge pump in the BigBagStation
  • Control cabinet, automation
  • Engineering (procedural layout & design)
  • safety-related devices for evaluation via PLC
  • Integration of visualization
  • Delivery & Assembly
  • Cold-Startup in our factory
  • Warm-Startup & training of operating personnel
  • Place of installation: ITALY

Flue gas condensation HEGC-CD-0400 with depluming system for biomass boiler 4.000 kW

By installing the heat recovery system HEGC-CD-0400, the moist exhaust gas of the biomass boiler is also used thermally by cooling in a condenser.

The heat content of the exhaust gases is converted directly into useful heat for two heating networks in a smooth-tube heat exchanger made of high-quality stainless steel 1.4571. In addition to heat extraction, the HEGC-CD-0400 also has a dedusting effect. A degree of dedusting of approx. 50-60% can be assumed. 

Key data:

  • CONDENSER (district heating system) 
  • CONDENSER
    Heat output CONDENSER 889 kW (w50, 47°C RT)
  • Welded stainless steel AIR PREHEATER
    Heat output AIR PREHEATER 287 kW
  • All heat exchanger pipes made of stainless steel 1.4462
  • Housing parts, process tank as well as pipe & channel
    parts 
    made of stainless steel 1.4571
  • Depluming fan 45 kW
  • Connection to the existing flue gas system
  • Stainless steel control cabinet
  • Engineering (procedural layout & design)
  • Isolation
  • Assembly and Delivery
  • Control with remote maintenance
  • Startup
  • Place of installationi: AUSTRIA

Flue gas condensation HEGC-CS-0160 for biomass boiler 1.600 kW

By installing the heat recovery system HEGC-CS-0160, the moist exhaust gas of the biomass boiler 1.600kW (1100 kW+500kW) is used thermally by cooling in a CONDENSER.

The heat content of the exhaust gases is converted directly into useful heat for two heating networks in a smooth tube heat exchanger made of high-quality stainless steel 1.4571. 

In addition to heat extraction, the HEGC-CS-0160 also has a dedusting effect. A degree of dedusting of approx. 40-60% can be assumed.

Key data:

  • X-Large CONDENSER with housing
    made of stainless steel 1.4571
    Heat output CONDENSER 300 kW (w45, 50°C RT)
  • Heat exchanger tubes made of stainless steel 1.4462
  • Connection to the existing flue gas system, flue gas fan
  • Multi-chamber sedimentation tank
  • Washer part for dust reduction
  • Control technology
  • Control cabinet, automation
  • Delivery & Assembly
  • Cold- and Warm Startup
  • Place of installation: AUSTRIA

Flue gas condensation HEGC-0300 for biomass boiler 3.000 kW

By installing the heat recovery system HEGC-0300, the moist exhaust gas from the biomass boiler (3.000kW) is also used thermally by cooling in a CONDENSER.

The heat content of the exhaust gas is converted directly into useful heat for two heating networks in a smooth tube heat exchanger made of high-quality stainless steel 1.4571. In addition to heat extraction, the HEGC-0300 also has a dedusting effect. A degree of dedusting of approx. 50-60% can be assumed.

Key data:

  • XX-Large CONDENSER
    with heat exchanger tubes made of stainless steel 1.4462
    Heat output CONDENSER 455 kW (w40, 40°C RT)
  • Housing, process tank as well as pipe- and channel
    parts made of stainless steel 1.4571
  • Bypass switch including connection to the existing
    flue gas system
  • Multi-chamber sedimentation tank
  • Automated sludge discharge, sludge thickening
  • BIG BAG lifting device
  • Saftey devices for condenser
  • Inspection and optimisation after test operation
  • Assembly & delivery
  • Place of installation: AUSTRIA

Heger Energy Booster HEG-EB50.0 for biomass boiler 4.800 kW

Key data:

  • Smooth tube heat exchanger with heat exchanger tubes made of stainless steel 1.4571
  • Casing Ø 1600, head part as well as cleaning cover made of stainless steel 1.4571
  • Bypass switch with connection to the existing fluegas system
  • Heat output of heat exchanger 644 kW (M50, 60°C RL)
  • Insulation of heat recovery system and flue gas piping
  • Continuous flue gas measurement
  • MSR-technology for monitoring plant control by SPS
  • Engineering (Process engineering & design)
  • Operational documentation
  • Assembly & delivery
  • Start up & training
Energy Booster during assembly
Energy Booster after assembly
Heat recovery system after start-up
Lower manhole: hardly any ash deposits

CONCLUSION - FINDINGS

  • EnergyBooster is reliable during the whole heating season (without cleaning)
  • No noticeable increase in pressure loss
  • Hardly any reduction in performance noticeable
  • Stainless steel design has proven itself considering the condensation occuring during start-up and shut-down
  • If the electrostatic precipitator is connected, cleaning at the end of the season is sufficient

Heger Energy Booster 2.0 ADV for biomass boiler 250 kW

HEGER ENERGY BOOSTERs are designed so that no flue gas is recirculated. Especially with dry fuel, this leads to high residual oxygen values ​​and a relatively constant amount of exhaust gas. If the boiler is equipped with recirculation, the amount of exhaust gas is reduced accordingly and it may make sense to switch to the next smaller size.

Basic information:

  • HEGER ENERGY BOOSTER 2.0
  • Dimensions: Ø406 x 220 mm
  • Incl. Engineering
  • Incl. Pressure test with workshop test
  • Incl. type label
  • Advanced design
  • Insulation EB2.0
  • Cleaning set
  • Automatic actuator including installation

 

 

Technical data:

Return temp.:

Heat output:

40°C (w25)

16 kW

Industrial process heat

Due to the massive increase in energy prices in recent years, the use of previously unused exhaust gas flows is becoming more and more important. As a consequence of this development, we offer innovative heat recovery systems with which enormous energy savings can be achieved. These systems reduce the dependency on energy imports from crisis regions and thus strengthen the regional business location. Heat recovery systems from Heger Edelstahl make a valuable contribution to reducing the greenhouse gas CO2 and thus contribute to climate protection.

Heat recovery system for gas burner

Plastic containers are manufactured in a prodcuction process. The process works in such a way that plastic granulate is filled into molds in a circular system. Then heated to approx. 280°C in a combustion chamber, which melts and results in the finished shape and finally cools down again in a cooling zone. The energy required for this process is brought into the combustion chamber via natural gas burners. Part of this energy is discharged to the outside as exhaust gas via a suction device to a chimney on the roof. 

In future, the hot exhaust gases will be used in a heat recovery system from HEGER. This should also improve the odor emission, or the reduced temperature makes it possible to incorporate a separte odor treatment stage.

Key data:

  • ECONOMISER with heat exchanger tubes
    made of stainless steel 1.4571
    Wärmeleistung ECO
  • Housing as well as pipe- and channel parts
    made of stainless steel 1.4571
  • Bypass switch including connection to the existing flue gas system
  • Isolation
  • Control technology
  • Engineering (procedural layout & design)
  • Fully automated control (EB-Control)
  • Assembly
  • Start up
  • Place of installation: AUSTRIA

Heat recovery system for heat treatment furnance for cast parts (2.174 Nm³/h at 497°C)

Exhaust gases from four different heat treatment furnances for cast parts are each cooled in a heat recovery system from HEGER. The energy released in the process is fed into the system´s internal hot water network or any excess is fed into the local district heating network.

A speed-controlled fan is installed after the heat exchanger to overcome the pressure loss on the exhaust gas side. The speed regulation takes place in such way that the optimum is extraceted from the exhaust gas, taking into account the internal requierements of the system. If the heat cannot be used, the flue gas flows directly into the chimney via the bypass.

Key data:

  • 4 heat recovery systems
  • ECONOMISER with tubes made of stainless steel 1.4571
    Heat output ECO 360 kW (exhaust gas temp. 500°C, 70°RT)
  • Housing parts made of heat-resistant stainless steel 1.4828
  • Connection to the existing flue gas system, flue gas fan
    Raw gas- and clean gas flaps, steel construction
  • Engineering (procedural layout & design)
  • Isolation 
  • Freestanding stainless steel fireplase
  • Assembly & delivery
  • Safety devices for evaluation via PLC
  • Control cabinet, remote maintenance
  • Startup
  • Place of installation: AUSTRIA

Heat recovery system for bread roll dryer

To utilize the waste heat from a roll dryer, the 4 installed heat recovery systems from HEGER use several exhaust gas flows. WRG1+2 were installed in the two burners (gas boiler), WRG3+4 were installed in the two steams.

Key data:

  • 2 x ECO (burner) including housing in countercurrent design
    Heat exchanger tubes made of stainlee steel 1.4571
    Heat output ECO 41,5 kW (65°C RT)
  • 2 x ECO (steam) 
    Heat exchanger tubes made of stainless steel 1.4571
    Heat output ECO 151 kW (40°C RT)
  • Isolation
  • Engineering (procedural layout, design)
  • Delivery & Assembly
  • 2 x connection to the existing flue gas system
    incl. bypass switch for heat recovery (burner)
  • 2 x connection to the exisiting flue gas system
    incl. bypass switch for heat recovery (steam)
  • Control technology
  • Safety devices
  • 4 x support steel construction
  • Startup
  • Place of installation: AUSTRIA

Heat recovery system for gas boiler

A heat recovery system from HEGER was installed to use the waste heat from a gas burner (10MW). This gives us additional energy.

Key data:

  • Heat recovery system HEG-C-1000-Sonder
  • 2-stage heat exchanger ECO and CONDENSER
    with tubes made of stainless steel 1.4571
    Heat output ECO & CONDENSER 1.150 kW
  • Housing parts made of stainless steel 1.4571
  • Connection to the exisiting flue gas system
    including bypass switch
  • Control technology
  • Control cabinet, automation
  • Assembly & delivery
  • Engineering (procedural layout, design, flow optimisation)
  • Startup
  • Place of installation: AUSTRIA

Heat recovery system for aluminium melt (14.040 Nm³/h at 640°C)

 

Key data:

  • Heat exchanger - material test
  • ECO Cat. IV  with heat exchanger tubes made of P235GH 
    for network return preheating of the
    high temperature water network

    Heat output ECO 2.590 kW (38 m³/h from 70 to 130°C)
  • Housing parts made of stainless steel 1.4828
  • Connection to the existing flue gas system,
    clean gas fan, flue gas damper, silencer, steel
    construction and isolation
  • Engineering (proceduarl layout, design, flow optimisation)
  • Assembly Section 1
  • Assembly Section 2
  • Control with control cabinet and remote maintenance
  • Startup
  • Place of installation: GERMANY

Advantages of a heat recovery system

  • Cost savings
  • Energy saving
  • Energy recovery
  • manageable investment
  • Payback within a few years
  • Additional income
  • Improved use of existing systems
  • "For the environment"
  • The subject of the future
  • Fundable
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