tube and fins heat exchanger

 

A tube and fins heat exchanger is an equipment designed to transfer energy from one stream to another through different systems, mostly air, exhaust gases, water, overheated water, refrigerants and steam.

Some of these elements may have demanding characteristics such as viscosities and sediments, in addition to working in corrosive environments.

Some of the main uses are:

Evaporators
Condensers
Cold water
Heat water

In this sense, Boixac Tech offers tailor-made solutions, analyzed in detail, and offering a huge range of finned heat exchangers for different industries and applications such as wastewater treatment plants, paper mills, power plants, offshores, chemical industries or food processing plants.

 

HRSG

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HEAT RECOVERY STEAM GENERATOR HRSG and the importance of Economizers In a world increasingly aware of sustainability and energy efficiency, the need to recover and optimize available resources in industrial processes is crucial. One of the key elements in this process is the HRSG (Heat Recovery Steam Generators), designed to capture residual energy and convert it into steam. While the manufacture of HRSG is not part of your company’s offering, the economizers and heat exchangers you provide are essential components for improving the efficiency of these systems. What is an HRSG and how does it relate to economizers? HRSGs are equipment designed to recover thermal energy from exhaust gases in industrial processes or power plants. This residual energy is converted into steam, which can be used for power generation or industrial heat processes. While HRSGs are critical for this type of recovery, economizers play a crucial role in improving the overall efficiency of this process. An economizer is a heat exchanger designed to capture residual heat from exhaust gases before they are released into the atmosphere. Its main function is to heat the feedwater before it enters the boiler or steam generation system, thereby reducing energy consumption and improving the overall system efficiency. Benefits of economizers in energy recovery  The economizers and other heat exchangers we offer have a direct impact on reducing energy consumption and emissions, two key factors in the sustainability of any industrial operation. Here are some of the most notable benefits: Improved energy efficiency: A well-designed economizer recovers heat from exhaust gases, increasing system efficiency without the need to invest in additional fuels or resources. This energy savings is essential for any industrial plant. Reduction in operational costs: By better utilizing residual energy, economizers help reduce costs associated with fuel use and other energy sources. This is especially relevant for companies operating in energy-intensive industries. Reduced pollutant emissions: By recovering more energy from exhaust gases, the need to burn additional fuels is minimized, helping reduce CO₂ emissions and other harmful gases. Durability and robustness: Our heat exchangers are designed to withstand extreme conditions, ensuring a long lifespan and minimal maintenance. This is crucial for industries that require continuous and reliable operation. How heat exchangers optimize HRSG efficiency Heat exchangers are essential for maximizing the efficiency of an HRSG system. These units can be integrated into the overall design of the plant to optimize heat transfer between exhaust gases and feedwater. These exchangers not only improve efficiency but also enable better management of exhaust gas temperature, ensuring valuable thermal resources are not wasted. Optimizing heat transfer in the process can be achieved through better material selection, design, and configuration of exchangers, which improves heat recovery and increases the overall performance of the HRSG. Our products: Tailored solutions for more efficiency energy Our company specializes in the manufacturing and supply of economizers and heat exchangers designed to maximize energy recovery in industrial systems and help companies achieve greater energy efficiency. Our products not only allow for better recovery of residual heat but also provide an economic and efficient solution for reducing operational costs and minimizing environmental impact. Energy efficiency is a priority for many industries, and the solutions we provide are designed to ensure more sustainable operations, reducing expenses and improving plant performance. With custom designs for each need, our solutions can be integrated into various types of industrial processes, from power plants to chemical and textile processes, improving both productivity and sustainability. Why choose our economizers and heat exchangers? Customization: Our designs can be adapted to the specific needs of each client, ensuring energy performance is optimized to the maximum. Improved efficiency: With our range of economizers and heat exchangers, we can help companies reduce costs and increase overall operational efficiency. Commitment to sustainability: We advocate for solutions that contribute to reducing environmental impact, helping companies comply with regulations and reduce emissions of harmful gases. Reliability and durability: Our products are built to last, even in the most demanding conditions. The integration of HRSG, economizers, and heat exchangers in industrial systems is essential for achieving greater energy efficiency, reducing costs, and contributing to sustainability. While HRSGs are vital in many processes, their effectiveness depends largely on auxiliary components like economizers and heat exchangers. Our company offers solutions designed to optimize these processes, improving efficiency and reducing operational costs. If you want to learn more about how we can help you improve your plant’s energy efficiency, feel free to contact us. We would be happy to help you find a tailored solution that meets your needs.

Types of heat exchangers

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TYPES OF HEAT EXCHANGERS There are many types of heat exchangers and various ways to classify them. In this article, we will classify them based on: 1. Classification by Construction Direct contact Indirect contact Tube heat exchangers Plate heat exchangers 2. Classification by Operation Liquid-liquid heat exchangers Liquid-gas heat exchangers Gas-gas heat exchangers Bulk solid heat exchangers Classification by Construction Heat exchangers can transfer energy via direct contact, that is, by fully mixing the fluids, with cooling towers being one of their main examples. However, this system can lead to the transmission of contaminants between the two fluids, making it unsuitable for most cooling systems, energy recovery, and treatment of gases, liquids, and bulk solids. In these cases, where it is necessary to keep the two fluids separate, an indirect contact system is used. This construction involves an element, usually plates or tubes, which act as a wall and keep the two fluids separate. Within the category of indirect contact exchangers, there is a special case: rotary heat exchangers, where both fluids travel through the same space but alternately, which could cause a slight mixing, but this is considered almost negligible. Focusing on the two main families of indirect contact, those of plates and tubes, it can be said that for the same power, plates achieve a high heat transfer coefficient in a very compact space, but they reduce the fluid flow area, making them more prone to fouling. On the other hand, tubes provide a larger surface area for fluid flow, making them highly recommended in dirty, dusty environments, or with sticky, viscous fluids, or even with sediments. They are less likely to become clogged and thus also reduce maintenance and cleaning costs. Tube heat exchanger Tube heat exchangers consist of cylindrical, flat, or oval tubes, and their design is chosen based on the specific characteristics of each system. Within this family, we find: Smooth tube heat exchangers. Since they have a similar exchange surface both inside and outside the tubes, this is a very common design when working with fluids that have similar specific heat values. Thus, in applications between two air flows, we can refer to classic smooth tube exchangers, while in applications involving water, sludge, milk, or juices, we can refer to tubular, multitubular, pyrotubular, coaxial, or double-tube exchangers, as well as shell and tube exchangers. Tube and fin heat exchangers. These are specifically designed to compensate for the energy transfer between two fluids with different specific heat values. This is a common situation in systems where gas flows are in contact with other fluids such as superheated water, thermal oil, refrigerants (ammonia, R134, R410a, etc.), or steam. For example, the specific heat of gas is around 1,214 kJ/m³·K, while the specific heat of water is 4,186 kJ/m³·K. This means that water can release almost four times more heat than the air can absorb, and the way to correct this is by increasing the exchange surface on the air side using elements called fins, which can be continuous plates perpendicular to the tubes or helical plates wrapped around the tubes. Plate heat exchanger Plate heat exchangers consist of flat or corrugated plates. Among them, we find different designs suited to various applications: Pillow plate heat exchanger. Emerging technology, very versatile and efficient, with a surface in the shape of a pillow, giving it the name “pillow.” Its design allows it to handle not only viscous, sticky, and sediment-laden fluids, but also to transfer energy to granular solids. This makes it an excellent alternative to fluidized beds, reducing energy consumption, minimizing waste, lowering environmental pollution, and improving the final product quality by applying energy uniformly. Cross-flow plate heat exchanger. A plate system widely used in energy recovery for applications such as air conditioning, directly integrated into air handling units. It is an excellent system for achieving high efficiency, but it requires advanced air filters, as its compact form makes cleaning difficult. Welded plate heat exchanger. The plates are joined by welding, which prevents internal cleaning and limits their use to installations free from contamination. Plate and gasket heat exchanger. The gasket system allows plates to be disassembled, cleaned, and replaced. This makes it more versatile than the welded system, but the channels through which the fluids pass remain small and can easily become blocked, making them unsuitable for viscous, sticky, or sediment-laden fluids. Classification by Operation Heat exchangers are designed to transfer energy optimally. To maximize their efficiency, it is essential to consider the type of fluids and their properties. An example of this is the previous case, where heat exchange occurs between a gas with a specific heat of 1,214 kJ/m³·K and water with a specific heat of 4,186 kJ/m³·K. Similarly, we find: Liquid-liquid heat exchangers. These include pillow plates, welded plates, plate and gasket exchangers, concentric tubes, coaxial tubes, and pyrotubular exchangers. Liquid-gas heat exchangers. These include smooth tubes, tubes with continuous fins, and tubes with helical fins. Gas-gas heat exchangers. These include multitubular exchangers, smooth tubes, and cross-flow exchangers. Bulk solid heat exchangers. These use the Pillow Plate technology. Small design details can increase or decrease turbulence, enhancing the exchange coefficients and leading to substantial differences between one supplier and another. That is why investment in R&D is a key factor in the evolution of this sector, which is increasingly recognized for its contribution in terms of efficiency, savings, and sustainability.

Coil for temperature control in wine tank

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COIL FOR TEMPERATURE CONTROL IN WINE TANK OPTIMIZATION OF TEMPERATURE CONTROL IN CULTIVATION TANKS One of the largest sparkling wine producers has implemented a temperature control system for 23 cultivation tanks with a total capacity of 142,000 liters, aiming to ensure optimal fermentation and maintain the quality of the final product. This project has focused on processes taking place in the so-called yeast farms, two rooms where fermentation occurs over five days at a strict temperature range of 18 to 20 ºC. Composition and process conditions The fluid present in the tanks consists of wine solution, tirage liqueur (a sugar-rich syrup), and yeast. This combination is essential for fermentation, as the yeast converts the sugars in the liqueur into alcohol and carbon dioxide, producing the characteristic foam of sparkling wine. Maintaining the fluid temperature within the specified range is crucial for ensuring controlled, high-quality fermentation. Heat exchanger system with internal coils To achieve this thermal control, heat exchanger coils have been introduced inside the tanks. These coils, made of AISI 316 stainless steel with electropolishing, provide excellent corrosion resistance and ensure maximum hygiene, two essential factors in sparkling wine production. The coils are certified under the MOCA (Materials in Contact with Food) standard, ensuring the materials used meet food safety requirements. CLAMP no need All system components have been custom-designed to perfectly fit the tanks’ characteristics and the client’s needs. A design eliminating the need for CLAMP connections was chosen, reducing the risk of leaks and simplifying system cleaning and maintenance. This tailored approach has also maximized heat exchange efficiency and optimized temperature control throughout the fermentation process. Wine tank heat exchanger coil benefits Implementing this system has provided numerous operational advantages: Thermal Stability: Maintaining a constant temperature within the specified range has been key to ensuring homogeneous, high-quality fermentation. Energy Efficiency: Electropolished stainless steel coils offer optimal thermal conductivity, reducing the energy consumption needed to maintain the proper temperature. Food Safety: Compliance with MOCA standards ensures the quality and safety of the final product. Reduced Maintenance: The absence of CLAMP connections simplifies maintenance and minimizes potential technical issues. BOIXAC, HEAT EXCHANGE SOLUTIONS This project is an excellent example of innovation applied to the wine industry, where precise control of fermentation conditions makes a significant difference in the quality of the sparkling wine produced. Implementing custom systems and high-quality materials ensures not only process improvement but also greater efficiency and sustainability throughout the production chain. Contact us Heat exchange solutions for the food and beverage industry Water coil Water coil that is often used to condition the environment of greenhouses and breeding farms, improving animal welfare. Energy economizer Energy economizer or heat recovery system that allows the reuse of excess energy, for example, from biomass boilers. Finned heat exchanger Finned tube heat exchanger, a temperature control system that optimizes durability even in environments with certain contamination factors.

Economizer for greenhouses

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ECONOMIZER FOR GREENHOUSES GREENHOUSES AND FARMS An economizer for greenhouses or farms refers to the heat recovery system designed to improve efficiency in an environment where, among other things, crop performance is optimized by controlling temperature, ambient humidity, and CO₂. Within the wide range of implementations, we highlight three main areas: 1. The first block refers to water treatment for the hydroponic growth of tomatoes, lettuces, peppers, strawberries, etc. Hydroponic cultivation allows plants to grow faster and more vigorously thanks to direct access to nutrients. These nutrients are dissolved in a water flow that is distributed to the plants through channels. For proper nutrient absorption, it is important to maintain the water within certain temperature ranges, which is achieved thanks to our finned tubes. This heat exchange system can use spiral fins or continuous fins following the same direction as the tubes, maintaining a homogeneous temperature and optimizing both plant growth and quality. 2. The second block is air treatment through overhead ducts, where BOIXAC provides the finned heat exchangers that condition the air in the greenhouse or breeding farm. These exchangers can include various accessories such as fans, humidity controls, and temperature controls. 3. The third block refers to the technology that enriches the environment, thus increasing photosynthetic activity. We achieve this by reusing the excess energy from exhaust gases through the ECO, AIRY, or GASY heat recovery systems. These thermal exchange units are selected based on primary and secondary fluids; in addition, the materials are also chosen according to the specific needs of each installation. Custom solutions for energy optimization in greenhouses and farms. Heat recovery systems for greenhouses and farms Water coil Water coil that is often used to condition the environment of greenhouses and breeding farms, improving animal welfare. Energy economizer Energy economizer or heat recovery system that allows the reuse of excess energy, for example, from biomass boilers. Finned heat exchanger Finned tube heat exchanger, a temperature control system that optimizes durability even in environments with certain contamination factors.

Industrial economizer

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ECONOMIZER HEAT RECOVERY SYSTEM IN AN INDUSTRIAL BOILER In the context of industrial production, energy efficiency is a key factor in reducing operating costs and minimizing environmental impact. Industrial boilers are essential for many processes, such as steam generation, water heating, or thermal oil heating. One of the key components that improve the efficiency of these boilers is the heat economizer or heat recovery system. This device allows for the recovery of thermal energy from exhaust gases that, without this technology, would be lost. In this article, we will explore how an economizer works in a two-pass industrial boiler, using a heat exchanger to efficiently transfer thermal energy to fluids such as steam, superheated water, or thermal oil. What is an economizer? An economizer is a device that recovers the residual heat from the exhaust gases of a boiler to heat the feedwater before it enters the boiler. This way, the system increases the thermal efficiency of the boiler and reduces fuel consumption. The principle of operation of an economizer is based on the use of a heat exchanger that transfers thermal energy from the combustion gases to an incoming fluid, usually water or another thermal substance. This way, the feedwater reaches the boiler at a higher temperature, reducing the amount of energy required to heat it to its final use. How an economizer works in a Two-Pass Industrial Boiler Two-pass industrial boilers, also known as double-pass or double-circuit boilers, have a structure designed to optimize the heat transfer of combustion gases. This type of boiler is designed to maximize the utilization of exhaust gas energy by using two circuits of gas flow. In this context, the economizer is installed in the first pass of the exhaust gases before passing through the boiler heat exchanger. Exhaust gases and heat exchanger: When fuel is burned inside the boiler, the generated gases have a very high temperature. The gases exit the boiler and circulate through the first circuit, passing through the economizer. This is where the heat recovery system takes advantage of this residual heat to transfer it to the feedwater through a steam or water heat exchanger. Heat transfer: The heat exchanger used in the economizer can be a steam heat exchanger, a superheated water heat exchanger, or even a system designed to heat thermal oil. Each of these systems uses a similar principle: the exhaust gases transfer their heat to the circulating fluid, raising the temperature of the feedwater before entering the boiler. This allows the boiler to use less fuel to reach the required temperature to generate steam or heat other thermal fluids. Energy efficiency improvement: The feedwater, once heated thanks to the economizer, enters the boiler at a higher temperature. This means that the boiler will need less energy to heat it to the desired operating temperature. This fuel saving directly translates into a reduction in operating costs and a greater environmental sustainability for the plant. Economizer design and materials: To ensure efficient heat transfer, industrial economizers are often made from materials resistant to high temperatures and corrosion, such as stainless steel or special materials for extreme operating conditions. These materials ensure that the devices have a longer lifespan and are efficient under demanding working conditions. Types of economizers used The design of the economizer depends on the type of fluid to be heated and the specific conditions of each industrial plant. Below are the most common types of heat exchangers used: Steam heat exchanger: In some cases, the boiler needs to generate steam for industrial processes. A steam heat exchanger allows the use of exhaust gas energy to raise the temperature of the water before it reaches the boiler, thus facilitating steam production with less energy. Superheated water heat exchanger: When it is necessary to heat water beyond its saturation temperature, a superheated water heat exchanger is used. This system keeps the water in a superheated state for specific industrial applications, such as heat production or energy generation. Thermal oil heat exchanger: For industrial processes that require heating at high temperatures, thermal oil is a popular option. Thermal oil heat exchangers are specifically designed to transfer heat from exhaust gases to the oil, allowing the system to maintain a constant and efficient temperature throughout the process. Advantages of using an economizer Among the many advantages offered by the use of Economizers and Heat Recovery Units, we can highlight: Reduction in fuel consumption: One of the main advantages of installing an economizer is the significant reduction in fuel consumption. By recovering residual heat, less energy is needed to reach the desired operating temperature. Increase in overall efficiency: Thanks to the recovery of residual heat, the overall efficiency of the heating system significantly improves, which contributes to a smaller carbon footprint. Economic savings: Operating costs decrease since the boiler requires less fuel to generate the same amount of steam or heat water. Sustainability: Reducing fuel consumption not only provides economic benefits but also contributes to sustainability by minimizing the environmental impact of industrial operations. In this sense, economizers or heat recovery systems in two-pass industrial boilers are essential components for improving energy efficiency and reducing operating costs in industrial processes. By using steam, superheated water, or thermal oil heat exchangers, the thermal energy from exhaust gases can be used to heat fluids such as feedwater. This way, a more efficient and sustainable system is achieved, contributing to resource optimization and reducing environmental impact. BOIXAC, A WORLD OF INDUSTRIAL ENERGY RECOVERY We have a wide range of different technologies, including smooth tube heat exchangers, finned tube heat exchangers, and pillow plate exchangers. This constructive variety allows us to customize the solutions we propose, adapting to the reality of each production process and thus optimizing the thermal resources available at each plant. Our advanced technical knowledge enables us to offer a range of economizers and heat recovery systems capable of working with combustion gases below their dew point, thus allowing condensation and recovery of acidic condensates from the gases themselves. … Read more

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