Cost-benefit analysis for OPT heat-exchanger unit in the tube rotating furnaces for nickel ore melting (the Ukraine), gas

Estimated data:

  • Nickel ore melting
  • Continuous furnace
  • Flue gas temperature is 326 С
  • Heated air temperature is 280 С
  • Flue gas volume is 95 000 Nm3/h
  • Heated air volume is 42 000 Nm3/h
  • Dust concentration is up to 150 g/m3
  • Unit purpose – gas saving
  • Number of the heat exchangers – 4 pcs.

Feasibility study for the heat exchanger application

Capital costs  
Heat exchanger price, $ VAT excl.596 550
Connections, construction and assembly operations, project design works, etc., $ VAT excl.278 270
Total capital costs, $ VAT excl.874 820
Day-to-day operation  
Heat flow returned back to the furnace, KW 6 844
Saving, Gcal per hour5,9
Gas volume in Nm3 required to produce 1 Gcal125
Price of 1 Nm3 of gas VAT excl., $0,5
Number of working hours per day24
Number of working hours per day 30
Saving for air heating per month, $248 525
Operating costs  
Energy, $ VAT excl.14 516
Repair of purchased equipment, $ VAT excl.7 742
Total operating costs, $ VAT excl.5 161
Total operating costs, $ VAT excl.27 419
Payback period for the heat exchanger, months 4,0

Operating effect

  • Technical parameters met requirements of the specifications
  • Fuel (natural gas) consumption saving is 736 м3/ч for each furnace

Ready solution

Рекуператор для подогрева воздуха с помощью дымовых газов с абразивной составляющей до 100г/Нм3
  1. Weight is 25 000 kg
  2. Heat power: 5 000 KW
  3. Used for gas furnace blast preheating
  4. Flue gas temperature: 350° С
  5. Heated air temperature: 280° С

Comment concerning equipment

Отзыв о рекуператоре для предприятия ПФК

Cost-benefit analysis of replacement of the existing low-performance heat exchanger by OPT heat exchanger in the metallurgic integrated plant, gas

Estimated data:

  • Metal rolling block
  • Continuous furnace
  • Connections shall be retained
  • Flue gas temperature is 900 С
  • Heated air temperature is 412 С
  • Heated air temperature after the current heat exchanger is 150С
  • Flue gas volume is 19 100 Nm3/hour
  • Heated air volume is 17 500 Nm3/hour
  • Unit purpose – gas saving
  • Number of the heat exchangers – 1pcs

Feasibility study for the heat exchanger replacement

Capital costs  
Heat exchanger price, rubles, VAT excl. 3 127 118,64
Connections, construction and assembly operations, project design works, etc., rubles, VAT excl. 0
Total capital costs, rubles, VAT excl. 3 127 118,64
Day-to-day operation  
Heat flow returned back to the furnace, KW 1 697
Saving, Nm3 of gas per hour 185
Price of 1 Nm3 of gas VAT excl., rubles 4,5
Saving for air heating per month, rubles 599 400
Operating costs  
Energy, rubles, VAT excl. 40 800
Repair of purchased equipment, rubles, VAT excl. 19 150
Other, rubles, VAT excl. -
Total operating costs, rubles, VAT excl. 59 950
Payback period for the heat exchanger, months6
Economic benefit from the heat exchanger operation during (10) years service life, rubles. 71 928 000

Operation effect

  • Technical parameters met requirements of the specifications
  • The existing system of air and flue gas ducts is retained
  • Fuel (natural gas) consumption saving is 185 Nm3/h

Ready solution

Рекуператор для металлургического производства
  1. Weight is 5 880 kg
  2. Heat power is: 2 669 KW
  3. Used for air heating at burners
  4. Flue gas temperature: 900° С
  5. Heated air temperature: 412° С

Comment concerning equipment

Отзыв о рекуператоре для предприятия Северсталь

Cost benefit analysis for installation of OPT air heater in the oil refinery, gas

Estimated data:

  • ELOU-AVT-5 installation
  • Connections should be retained
  • Flue gas temperature is 350 С
  • Heated air temperature is 218 С
  • Unit purpose – gas saving, replacement of the broken down foreign air heater
  • Number of the heat exchangers – 1pcs.

Feasibility study for the air heater

Capital costs  
Heat exchanger price, rubles, VAT excl. 13 474 576
Connections, construction and assembly operations, project design works, etc., rubles, VAT excl. 3 836 186
Total capital costs, rubles, VAT excl. 17 310 763
Day-to-day operation  
Heat flow returned back to the furnace, KW 10 000
Saving, Nm3 of gas per hour 1 260
Price of 1 Nm3 of gas VAT excl., rubles 4
Saving for air heating per month, rubles 3 688 123
Operating costs  
Energy, rubles, VAT excl. 54 000
Repair of purchased equipment, rubles, VAT excl. 43 277
Other, rubles, VAT excl. 14 426
Total operating costs, rubles, VAT excl. 111 703
Payback period for the heat exchanger, months 4,8
Economic benefit from the heat exchanger operation during (10) years service life, rubles. 429 170 485

Operation effect

  • Technical parameters met requirements of the specifications
  • The existing system of air and flue gas ducts is retained

Ready solution

Рекуператор для подогрева воздуха на горение в трубчатой печи НПЗ
  1. Weight: 24 000 kg
  2. Heat power: 4 637 KW
  3. Used for air preheating for burning
  4. Flue gas temperature: 350° С
  5. Heated air temperature: 218° С

Comment concerning equipment

Отзыв о рекуператоре для предприятия Роснефть

Cost benefit analysis for installation of OPT heat exchanger at severe dust-laden gases, coke

Estimated data:

  • Nickel ore blast smelting
  • Intermittent furnace
  • Flue gad temperature is 900 С (designed), fuel gas temperature = 500 С (actual)
  • Heated air temperature is 300 С
  • Flue gas volume is 145 000 Nm3/h
  • Heated air volume is 65 000 Nm3/h
  • Dust content is up to 150 g/Nm3
  • Unit purpose – coke saving
  • Number of the heat exchangers – 2 pcs.

Feasibility study for the heat exchanger installation

Capital costs  
Heat exchanger price, rubles, VAT excl. 32 118 644
Connections, construction and assembly operations, project design works, etc., rubles, VAT excl. 27 565 000
Total capital costs, rubles, VAT excl. 59 683 644
Day-to-day operation  
Heat flow returned back to the furnace, KW 8 000
Saving, Gcal per hour 6,9
Coke quantity required for 1 Gcal, tons 0,154
Coke quantity required for 1 Gcal, tons 6 694,9
Saving for air heating per month, rubles 5 103 858
Operating costs  
Energy, rubles, VAT excl. 108 000
Repair of purchased equipment, rubles, VAT excl. 95 127
Other, rubles, VAT excl. 31 709
Total operating costs, rubles, VAT excl. 234 836
Payback period for the heat exchanger, months 12
Economic benefit from the heat exchanger operation during (10) years service life, rubles. 584 282 658

Operation effect

  • In 2013 the coke saving at flue gas temperature of 500 С was 17% per 1 ton of ore dried raw material concerning the coke specific consumption.
  • The data about efficiency at flue gas temperature of 900 С (design value) are currently unavailable because the furnace units don’t reach the designed temperature.

Ready solution

Три секции для сборки промышленного теплообменника
  1. Weight is 30 000 kg
  2. Heat power: 10 000 KW
  3. Used for coke furnace blast preheating
  4. Flue gas temperature: 590° С
  5. Heated air temperature: 360° С

Comment concerning equipment

Отзыв о рекуператоре для предприятия Режникель

Cost benefit analysis for installation of OPT heat exchanger for room heating

Estimated data:

  • Flue gases after the basalt fiber production units
  • Flue gas temperature is 200 С
  • Heated air temperature is 100 С
  • Flue gas volume is 17 000 Nm3/h
  • Heated air volume is 5 000 Nm3/h
  • Dust content is up to 150 g/Nm3
  • Unit purpose – shopfloor rooms heating

Feasibility study for the heat exchanger installation

Capital costs  
Heat exchanger price, rubles, VAT excl. 253 390
Connections, construction and assembly operations, project design works, etc., rubles, VAT excl. 215 200
Total capital costs, rubles, VAT excl. 468 590
Day-to-day operation  
Heat flow returned back to the furnace, KW 170
Saving, Nm3 of gas per hour 18,5
Price of 1 Nm3 of gas VAT excl., rubles 4
Saving for air heating per month, rubles 61 209
Operating costs  
Energy, rubles, VAT excl. 2 450
Repair of purchased equipment, rubles, VAT excl. 2 200
Other, rubles, VAT excl. 500
Total operating costs, rubles, VAT excl. 4 650
Payback period for the heat exchanger, months 8,3
Economic benefit from the heat exchanger operation during (10) years service life, rubles. 6 788 306

Operation effect

  • Improved working conditions

Ready solution

Рекуператор для подогрева воздуха в производственных помещениях
  1. Weight is 775 kg
  2. Heat power: 170 KW
  3. Used for room heating
  4. Flue gas temperature: 200° С
  5. Heated air temperature: 120° С




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