Our offer is to respond to ever-increasing requirements concerning environmental protection which make the companies responsible for prevention or reduction of any harmful emissions, in accordance with IPPC (Integrated Pollution Prevention and Control) Directive with application of BAT (Best Available Techniques). One of the Directive requirements is the minimization of energy consumption rate per product unit. Besides the combustion optimization, we achieve reduction of energy intensity by heat recovery, and by utilisation of the heat of flue or process gases.
We use the heat contained in flue/process gases to warm the air for combustion, by installing recuperators on exhaust/gas ducts.
When we have to deal with low temperature waste energy, as in liquids with temperature below 150°C and gases with temperature below 250÷300°C, an efficient utilisation of such energy is direct heating of other carriers, such as air for combustion, water supply, water in a heat distribution network or domestic hot water, by heat exchanger installation. These are the simplest investments, and have the shortest payback periods.
For industrial high temperature installations, such as electric arc furnace exhaust extraction systems, heat recovery steam generators have been applied. Specific construction design of a heat recovery steam generator depends on the temperature of the intake gases. Traditionally applied furnace cooling and using utility water to cool down the extraction ducts are the simplest, but inefficient methods, as they require vast amounts of cooling water, and the heat carried away with that water is irrecoverable. Moreover, this option implies significant investment expenditures to build tanks, cooling towers, pump stations etc. The most effective way to recover this energy is evaporative cooling, based on the utilisation of water evaporation heat to take away the heat from the elements being cooled; as a product steam is generated that could be used either for technological or heating purposes, or to produce electricity with additionally installed turbine/generator unit. Steam could be also used to drive steam turbines propelling large pumps, fans etc. Furthermore, in a special afterburner/sediment chamber being a part of the heat recovery boiler system, carbon monoxide (CO) combustion takes place. The replacement of traditional raw water cooling with evaporative cooling process brings benefits in useful energy recovery (ca. 60% of the effect), reduction of water consumption (ca. 20% of the effect) and the elements’ durability increase (ca. 20% of the effect). The water consumption reduction and durability improvement makes the evaporative cooling cost effective even in the case when the produced steam is simple released to air.
Implementation of heat recovery steam generators facilitates environmental protection both in direct and indirect way, as it leads to savings in base fuel (coal, natural gas, heating oil, etc.) consumption by the utilisation of waste energy. It also allows lowering the expenditures related to fuel processing and transportation, and reduces emission of harmful substances. Evaporation cooling systems directly reduce water consumption, following the BAT requirements of promoting activities to close water circulation and minimize irrecoverable losses; it also reduces CO content using special afterburning chambers, effectively increasing the heat recovery.