General information

The high heat content of exhaust gases, which is produced during combustion of damp biomass, often goes unused as a loss into the environment.

If it is possible, through a properly designed heat recovery system, to cool down the flue gas under the flue gas dew point it can be achieved a considerable increase in effectiveness. The lower the residual oxygen content and the higher the fuel water content, the higher the achievable effectiveness.

A flue gas condensation with an integrated depluming system enables, that the steam plume that exits the exhaust stack is not visible also below 0 degrees.

OUR REFERENCES

Flue gas condensation HEGC-0490

Scope of delivery:

  • X-LARGE Condenser with heat exchanger tubes made of 1.4462
  • Heat capacity CONDENSER 890 kW (w45, 30°C RL)
  • Casing parts, process tank and piping made of 1.4571
  • Connection to the existing flue gas system incl. bypass switch
  • Lifting device BIG BAG
  • Exhaust silencer
  • On-site control cabinet
  • Engineering (process engineering & design engineering)
  • Delivery
  • Assembly
  • Start-up in our factory
  • Start-up and professional training in May 2018

Flue gas condensation HEG-CD-0140

Scope of delivery:

  • X-LARGE Condenser with heat exchanger tubes made of 1.4462
    Heat capacitiy CONDENSER 267 kW (w50, 50°C RL)
  • Welded stainless steel air preheater made of 1.4571
  • Casing parts, process tank and piping made of 1.4571
  • Depluming fan
  • Connection to the existing flue gas system
  • Control cabinet
  • Engineering (process engineering & design engineering)
  • Delivery
  • Assembly in July 2017
  • Start-up in our factory
  • Start-up and professional training in November 2017

Flue gas condensation HEG-CD-0300 with
depluming for biomass boiler 2.500 kW

Scope of delivery:

- X-LARGE-CONDENSER with heat exchanger tubes made of 1.4462
- Welded stainless steel AIR PREHEATER with heat exchanger tubes made of 1.4571
- Casing parts, process tank and piping made of 1.4571
- Depluming fan 30 kW
- Connection to the existing flue gas system incl. bypass switchbypass pipe and insulation
- Heat capacity CONDENSER 354 kW (w50, 50°C RL)
- Heat capacity AIR PREHEATER 231 kW
- Stainless steel control cabinet
- Engineering (process engineering, design engineering)
- Assembly and delivery
- Control with remote maintenance
- Start-up in January 2015

Flue gas condensation before delivery
Flue gas condensation after assembly
Flue gas condensation after hot-start-up
Flue gas condensation system with depluming at -5°C outdoor temperature
WITH de-pluming
Flue gas condensation system without depluming
WITHOUT de-pluming
 

Flue gas condensation HEGC-0300
7.200 Nm³/h for biomass boiler 3.000 kW

Scope of delivery:

- X-Large Design
- Cross-counterflow-condenser with casing made of 1.4571
- Enlarged heat exchanger incl. casing made of 1.4571
- Exhaust chimney DN650 x 10000
- Engineering (process engineering)
- Insulation
- Assembly by customer
- Start-up in August 2013

Flue gas condensation system before cold start-up
Flue gas condensation system after cold start-up
Flue gas condensation system after hot start-up
 

Flue gas condensation HEG-EC-0600
for biomass boiler 6.000 kW

Scope of delivery:

- ECO with heat exchanger tubes made of 1.4462
- CONDENSER with heat exchanger tubes made of 1.4571
- Casing parts, process tank and piping made of 1.4571
- Connection to the existing fluegas system incl. bypass switching, fluegas fanfluegas pipe, silencer and exhaust air chimney
- Multi-chamber sedimentation
- Heat capacity ECO 460 kW (w60, 60°C RL)
- Heat capacity CONDENSER 1.684 kW (w60, 35°C RL)
- On-site control cabinet
- Engineering (process engineering & design engineering)
- Steel construction and insulation
- Assembly and delivery
- Control with remote maintenance
- Start-up in March 2015

Flue gas condensation during assembly
Flue gas condensation during assembly
Flue gas condensation after insulation and before start-up
Flue gas condensation after start-up
Flue gas condensation after start-up
Flue gas condensation system with demister unit

Flue gas condensation HEGI-2000
for biomass boiler 20.000 kW

 

Scope of delivery:

- CONDENSER with heat exchanger tubes made of 1.4462
- Condensate cooler designed as a tube-bundle heat exchanger with heat exchanger tubes made of 1.4571
- Casing parts, process tank and piping made of 1.4571
- Connection to the existing fluegas system incl. bypass control valve, bypass pipes and flue gas pipes
- Heat capacity CONDENSER 7.639 kW (w65, 10,5°C RL)
- Engineering (process engineering & design engineering)
- Steel construction & insulation
- Assembly & delivery
- Start-up & professional training for operating staff

Process tank of the flue gas condensation
Flue gas condensation after start-up
Flue gas condensation after start-up
Flue gas condensation after start-up

Flue gas condensation HEGI-1650
for biomass boiler 16.500 kW

 

Scope of delivery:

- CONDENSER with heat exchanger tubes made of 1.4571
- Casing parts, process tank and piping made of 1.4571
- Bypass control valve
- Heat capacity CONDENSER 4.400 kW (w45, 25°C RL)
- Engineering (process engineering & design engineering)
- Control cabinet
- Steel construction
- Pre-assembly in our factory
- Assembly & delivery
- Start-up & professional training for operating staff
- Place of installation: Latvia

Flue gas condensation during assembly in Latvia
Flue gas condensation during assembly in Latvia
Flue gas condensation after assembly
Flue gas condensation after assembly

Flue gas condensation HEG-0150
for biomass boiler 10.500 kW

 

Scope of delivery:

- ECO with heat exchanger tubes made of 1.4529
- Casing parts, process tank, piping made of 1.4571
- Connection to the existing flue gas system inclusive steel construction and insulation
- Heat capacity ECO 715 kW (w50, 60°C RL)
- CONDENSER - total capacity 1.205 kW
- Engineering (process engineering, design engineering)
- Assembly
- Control with remote maintenance
- Start-up in September 2013

 

 

Flue gas condensation after start-up
Flue gas condensation after start-up

Flue gas condensation HEGC-ECD-0400
with de-pluming for biomass boiler
3.000 kW + BHKW 1.000 kW 

Scope of delivery:

- ECO with heat exchanger tubes made of 1.4462
- CONDENSER with heat exchanger tubes made of 1.4571
- Welded stainless steel air preheater with heat exchanger tubes made of 1.4571
- Casing parts, process tank, piping made of 1.4571
- Connection to the existing flue gas system inclusive steel construction and insulation
- Heat capacity ECO 309 kW (w45, 20 m³/h from 65->78,5°C RL)
- Heat capacity Condenser 881 kW (w45, 35 m³/h from 25->46,6°C RL )
- Engineering (process engineering, design engineering)
- Assembly
- Control with remote maintenance
- Start-up in November 2013

Flue gas condensation after hot-start-up inclusive de-pluming
sedimentation and bib-bag-station of the flue gas condensation
Flue gas condensation system with de-pluming
WITH de-pluming
Flue gas condensation system without de-pluming
WITHOUT de-pluming

HEGER ENERGY BOOSTER

HEGER ENERGY BOOSTER

With our latest development the innovative "HEGER ENERGY BOOSTER" we enable our customers to save energy and costs for fuel.

The Heger Energy Booster is a heat recovery system, which can be retrofitted by smaller biomass boilers to increase energy efficiency.

Exhaust gases normally escape the boiler unused, but the Energy Booster use these exhaust gases for heating the heating water.

Consequently, we obtain a significant heat recovery effect and save fuel, which can be translated into cash. The performance of the exhaust gas heat exchanger is approx 10% of the boiler output.

Heat recovery system for smaller biomass boiler up to 500 kW
Heat recovery system for smaller biomass boiler inclusive insulation

Heat recovery system for biomass boiler 4.800 kW

Scope of delivery

  • Smooth tube heat exchanger with heat exchanger tubes made of stainless steel 1.4571
  • Jacket pipe Ø 1600, head part as well as cleaning cover made of stainless steel 1.4571
  • Bypass switching 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
+43 7713 50260