Industry application

Heat Exchangers for Energy & Power

Industrial heat exchangers for waste heat recovery, power generation, ORC, renewable energy, hydrogen, grid cooling and energy storage.

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Heat Exchangers for Energy & Power heat exchanger engineering application

Application engineering

Process Role

Heat recovery connects an available source to a useful sink. Source duty alone is insufficient: the sink must need heat at a compatible temperature during the same operating hours. A heat pump may raise the delivery temperature, but its contribution needs a separate system assessment.

Power-generation cooling instead rejects heat to protect equipment or close a thermodynamic cycle. CHP recovery, thermal storage, ORC phase-change duties and hydrogen-related cooling therefore need distinct operating cases, rather than one generalized energy-saving claim.

Thermal interfaces

Typical Thermal Duties

Waste heat, CHP and flue gas

Assess liquid, steam or gas heat sources against feedwater, process-water or storage demand. For flue gas, composition and condensation conditions determine the corrosion, drainage and cleaning review.

ORC and power-generation cooling

Evaporation and condensation require working-fluid properties and a temperature profile. Turbine auxiliaries and generator oil circuits also need viscosity, pressure drop and cooling availability assessed.

Heat pumps, storage and hydrogen systems

Define the charge/discharge profile for thermal storage. Electrolyzer, fuel-cell or compression cooling must identify the actual process-side fluid, water-quality requirements and interface pressure; an application label is not a material specification.

Rating basis

Key Engineering Inputs

Source fluid/composition, flow and temperature range; sink fluid, flow and delivery/return temperatures.
Simultaneous operating hours and turndown, approach temperature, operating/design pressure and allowable ΔP.
Fouling, condensation, condensate chemistry, material compatibility, cleaning access and any phase-change conditions.

Design review

Application-Specific Design Challenges

Useful recovery versus available heat

Calculate the matched source/sink duty before assigning an energy benefit. Include storage losses or heat-pump input where relevant, and compare against a defined baseline; recovered exchanger duty is not automatically net energy savings.

System conditions behind refrigeration heat recovery

Condensing and corrosive streams

A gas cooler can encounter condensate as well as dry gas. Review contaminants, drainage, fouling and joining materials at local temperatures rather than relying on a general stainless-steel designation.

Material screening for complete process chemistry

Relevant HEXNOVAS Case Evidence

HEXNOVAS case evidence

Copper-free biogas cooling interface

The published case evaluates an all-stainless bonded plate exchanger for gas cooling with water. It supplies a defined gas/water temperature program, not a measured heat-recovery saving.

Published design-condition data

Biogas: 814 kg/h, 70.4°C → 25°C.
Water: 4500 kg/h, 8°C → 18°C.
Gas-side maximum allowable ΔP: 20 kPa.

No new duty is calculated from these figures. The application summary does not assert alloy purity, certification, measured performance or a transferable pressure rating.

View case study: Copper-free biogas cooling interface

Technology fit

Common Heat Exchanger Technologies

Plate & block / Compabloc

Consider welded blocks for compatible process recovery duties, with required cover access, fouling allowance and seal review.

Plate & shell / shell & tube

Compare the actual phase-change profile, pressure rating, passage geometry and service access for the duty.

Flue-gas BPHE

Evaluate only for the specified gas composition, condensation, fouling and pressure-drop conditions.

Flue-gas heat-recovery exchangers

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What HEXNOVAS Needs for Selection

Send source and sink operating schedules, fluid analyses, flow rates and temperature targets.
Identify phase change, expected condensation, foulants, allowable ΔP and mechanical design conditions.
For a recovery study, include the displaced heating method and simultaneous demand; for cooling, specify the available sink at the limiting condition.

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Engineering support

Send the operating conditions. We will evaluate the technology.

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