The Edmeston Heat Recovery System

Carbon Black - Glass - Steel

EDMESTON

Edmeston provides you with the most efficient Heat Recovery Systems for optimum fuel savings
Edmeston is an engineering company established in 1984 and belonging to the Sandvik Group. Edmeston designs and sells advanced equipment and systems for the manufacture of sulphuric acid, sodium hydroxide etc, as well as heat recovery systems for the glass, carbon black and steel industries.

ENERGY SAVING MORE IMPORTANT THAN EVER

With increasing oil prices and higher environmental taxes many industrial processes can make substantial cost savings by installing a heat recovery system. During the last 15 years, oil prices have increased 60-70%. The incentive to recover energy is and will become more and more evident. Heat recovery also means lower exhaust gas volumes and lower emissions to the atmosphere. Heat recovery gives direct savings in terms of lower fuel consumption as well as indirect savings in lower environmental impact. Last, but not least, it facilitates smaller and more economic furnaces.
OIL PRICE 1988-2003 USD / barrel 35 30 25 20 15 10
88 89 90 91 92 93 94 95 96 97 98 99 00 01 02
900

EDMESTONs major business lines: Edmeston Heat Recovery Systems for

Carbon Black Glass, INKA Iron and Steel

Edmeston SX Systems for Sulphuric Acid Industry

Our business is based on: - A unique know-how in developing and manufacturing various steel grades, possessed by our parent company Sandvik - Our own strong process and material technology know-how - Our capabilities in design, manufacturing and marketing Our business is focused on: - Development and delivery of advanced, customized equipment and systems - Supporting our customers in construction and commissioning - Providing cost effective and technically optimized solutions For further information please visit the Edmeston homepage at www.edmeston.com
700 600
Annual Saving (kUSD / year)

19

19

19

19

19

19

19

19

19

19

19

19

20

20

20

Thus, heat recovery is a key factor to stay competitive in an even harsher economic environment. The example below illustrates the substantial annual savings achieved by preheating the combustion air in a carbon black plant.

Annual Saving at different oil prices Carbon Black 100 tubes Air Preheater (kUSD/year) 1 kUSD = 1000 USD

47 USD / barrel

500 400 300 200 20 USD / barrel 100 0 400 650 800 Preheating temperature (C)

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34 USD / barrel

Source: China Carbon Black Institute 2001 2

20

03

OUR SOLUTIONS
A heat recovery system from fluid gases often consists of a recuperator, i e a heat exchanger absorbing and transferring heat into another fluid. If the heat is directly returned into the primary process, typically by preheating the combustion air, energy saving is achieved. Preheating the combustion air in the carbon black process or in a glass furnace results in considerable savings. Depending on current oil prices, a typical pay back time of the investment is 1 - 2 years. Heat recovery systems from Edmeston cover a wide range of industrial applications and technical solutions for different temperature ranges. Our solutions are based on Sandviks high temperature materials with proven reliability and long lifetime. In some applications it is possible to achieve a lifetime of 10 years or more.
Application Carbon Black Glass Mineral Wool Iron and steel Type of recuperator Tube Bundle Tube bundle or Double Shell Tube Bundle Tube Bundle Heat transfer by Radiation + Convection Radiation Radiation Radiation + Convection Flue gas inlet temp oC 900 - 1030 1250 - 1400 1100 - 1400 700 - 1100 Preheat temp o C

CARBON BLACK AIR PREHEATERS

The technology gives a possibility to preheat cold air to 800-900 C by taking the heat from the exhaust gas from the carbon black reactor. The preheated air is then used as combustion air in the burner. Our scope of supply is shown below:
Our scope of supply

Filter

Air outlet Natural gas Quench water Air inlet

Carbon Black Additives Reactor Air Preheater

Edmeston provides two types of air preheaters: double and single shell design.

DOUBLE SHELL

SINGLE SHELL CB gas out

650 - 900 400 - 800 550 - 650 400 - 650

CB gas out

Air in

Air in

Air out

Air out

Cooling air in CB gas in.

Cooling air in

Cooling air out CB gas in

Cooling air in

The figure illustrates the basic principles of the two types of airpreheaters: The double shell type is of a non-fouling design. It consists of one inner and one outer shell. The air is preheated in the annular air gap, minimizing the thermal gradient in the upper part. This reduces the fouling tendency. This type is widely recognized for its low maintenance costs and few production stops. The number of cleanings due to fouling is minimized. Both the single and the double designs are equipped with an air cooled double bottom tube sheet. This design has proved itself to secure maximum lifetime for the bottom part. The air is flowing in counterflow to the carbon black gas inside the fire tubes and passing through baffles placed all the way downstream. 3

A carbon black 800C Air preheater for lower fuel consumption and energy saving

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Edmeston has supplied air preheaters to the carbon black industry since 1992. So far around 20 units have been installed worldwide. The sizes range from 76 to 144 tubes. The nominal air flow 10 000 28 000 Nm3/hr and the air preheat temperature 740 800C . Edmeston also has a design concept for a 900C air preheat temperature unit. Our material selection is based on Sandviks high temperature material technology. High temperature resistant materials such as 253 MA etc are used in tubes and shells. Ferrules in fire tubes are made of GRX a special and unique material with exellent hot corrosion resistance in reducing high carbon content atmospheres.

GLASS RECUPERATORS - INKA

Edmeston INKA glass recuperators have been developed during more than 50 years of service experience of the glass industry. More than 400 recuperator systems have been installed over the years and the applications cover most glass types, such as container glass, C glass, E glass, technical glass, TV glass and crystal glass. Out of the 400 systems supplied, 40 % are of the combined tube bundle and double shell types, 30 % are tube bundles and 30 % are double shell systems. The heat recovery is recuperative (not regenerative ). It is used for air preheating up to 800C, and for furnace sizes of 10-400 ton/day. The recovery process is based on preheating air by transferring heat from the exhaust gases to the cold air. The preheated air is then transported back to the burners in the glass furnace. The exhaust gas flows inside the tube bundle and the air flows inside the tubes. Normally, parallel flow is used between exhaust gas and air. Edmeston glass recuperators can be designed as a tube bundle, as a double shell or as a combination of these two types, as shown in the table below:

A unit ready for delivery

Tube Bundle and Double Shell

Tube Bundle 750 < 1450 50 - 400 90 - 800

Double Shell 550 < 1200 10 - 70 30 - 70

One unit ready for delivery

Air preheat temp oC Flue gas temp oC Furnace size (ton/day) Investment level, KUSD

800 < 1450 50 - 400 125 - 1200

The energy saving potential is illustrated in the diagram below. For a typical flue gas temperature of 1350C and air preheat temperature of 800C, the energy saving is about 45%.

SAVINGS IN FUEL CONCUMPTION AT DIFFERENT FLUE GAS INLET AND AIR PREHEAT TEMPERATURES Calculation according to "The Handbook of Glass Manufacture" 60 55 50 45 40 35 30 25 20 1000 600 700 800 900

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Fuel saving (%)

C C C C

1050

1100

1150

1200

1250

1300

1350

1400

1450

1500

Flue gas temperature (C) before air preheat

Top and bottom view of a carbon black airpreheater during assembling

The picture shows a tube bundle and double shell air preheating system for a container glass furnace with the production capacity of 230 ton/day and a preheating temperature of 800C.

Cold Air 275oC Air

Hot air 800oC to theburners

Fluegas

Soda Lime Glass Furnace Recuperator 230 ton/day

GLASS CASE HISTORY:

The following example is taken from a big container glass furnace showing the short pay back time for the investment:

Furnace production Energy consumption Oil consumption Exhaust temperature Air preheat temp Fuel saving Oil price Saving: Investment Lifetime Pay back time Waste gas outlet temperature Air flow

230 ton glass/day or 84 000 ton glass/year 2600 kcal/kg glass (no airpreheating) 0,27 kg oil/kg glass 22 750 ton oil/year 1350C 800C 45% or 10 235 ton oil /year

2,05 MUSD/year 1,3 MUSD 10 years (one campaign) 8 months! 800C 17 400 Nm3/hr 5

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200 USD/ton

Double shell recuperator assembly

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A tube bundle system under construction

OTHER APPLICATIONS - IRON AND STEEL

Edmestons long experience of radiant heat recovery systems in the glass and carbon black industries is also used in applications for the iron and steel industries. The figure illustrates the basic principle of the recuperators:

DRI (direct reduction of iron)

Air inlet temperature Air outlet temperature Waste gas inlet temperature Waste gas outlet temperature Air flow Watse gas flow 190C 650C 1070C 800C 74 000 Nm3/hr 94 000 Nm3/hr

Hot air out

Cold air in

The recuperator saving gives a pay-off time less than one year of the investment.

Flue gas in

Flue gas out

The furnaces often work at combustion air temperatures as low as 400C. Raising the air temperature with 100C results in about 6% fuel savings. This substantially reduces the operating costs of the furnace. Several references are available.

A steel air preheater prior to installation

Recuperators for billet reheating furnaces

25 MW input power and a furnace temperature of 1000C. The furnace is heated by natural gas and open gas burners. The flow is cross-parallel. Air preheat temperature Waste gas inlet temperature Waste gas outlet temperature Air flow Waste gas flow 400-450C 810-975C 522-655C 26000-38 000 Nm3/hr 27000-40000 Nm3/hr

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The recuperator was installed 1992 and is still in operation.

EDMESTON

www.edmeston.com

2003-04

EDMESTON AB (Head Office) Olof Asklunds gata 8 S-421 30 VSTRA FRLUNDA, Sweden Tel: +46-31 335 63 50 Fax: +46-31 335 63 65 E-mail: info@edmeston.com

EDMESTON US c/o Sandvik Process Systems LLC Totowa, NJ 07512 USA E-mail: info@edmeston.com