The following changes in the standard design are made if the heat exchanger operates in gases with severe dust condition:

  1. Wear-resistant steels are used. The steels increase wearing capacity 3-5 times against standard corrosion-resistant steels and 5-10 times against low-carbon steel used in gas ducts;
  2. The heat exchanger channel section is selected in the way that the flue gas velocity exceeds the channel scouring velocity;
  3. The screens are mounted at the gas circuit inlets significantly reducing wear of the heat exchanger butt ends;
  4. The modular design of the heat exchanger improves its maintainability. If one of the sections is worn out, it is fully replaced; or the most and the least worn sections are interchanged. At that it is permissible to leave other heat exchanger sections unchanged if they are operational;
  5. Assembly manholes are mounted in the heat exchanger circuits to provide access to the most loaded sections;
  6. The heat exchanger is mounted on the gas circuit section after partial (or full) gas cleaning.



If the modules located on the most loaded chimney flue segments are partially or completely worn out (for example, due to strong abrasive ability of dusty mediums)you may interchange the most and the least worn modules.

Modular design of OPT type heat exchangers

Note that if case-tubular heat exchangers are used, you cannot replace worn-out damaged pipe. If the pipe is worn-out, it should be welded at the gaseous medium inlet resulting in reduced effective cross-section and heat-transfer surface of the heat exchanger. So, the heat exchanger efficiency is also reduced.

After 3-5 years at the time of the case-tubular exchanger replacement subjected to some these repairs (even if the mediums are not dusty) its effectiveness will be decreased by 20-50% as compared with the initial one. Yet without considering costs for the heat exchanger repair and downtime for the equipment repairs decreased effectiveness causes relevant rise of energy source consumption. In general, this gradual increase cannot be detected and appears only at the end of the heat exchanger service life. Thus, the heat exchanger usage doesn’t provide actual decrease in energy consumption and saving values are incorrect.

The heat exchanger head (the element where heat exchange is performed) is assembled out of a set of standard modules with the base of 840х840 mm using bolted or welded joints. The module height varies depending on the required power, air resistance restrictions and dimensions of the mounted equipment.

If the modules located on the most loaded chimney flue segments are partially or completely worn out (for example, due to strong abrasive ability of dusty mediums) you may interchange the most and the least worn modules. For this purpose the modules are disconnected and then they are assembled in any other combination (without dismantling of the whole heat exchanger unit and its transportation to the place of repair). The weight of each module varies within 500-1500 kg depending on its height which simplifies this operation. The modular assembly using welding is the most preferable method. The modules are welding using the sheet metal bars with 20-25 mm width and 1.5 mm thickness as the joints between the modules. At replacement of modules connected in like manner it is enough to cut and reweld the bars. Experience has proven that this method simplifies and speeds up the process of modules disconnection and further assembly as compared with flange couplings.

Application of the above mentioned technologies makes ОПТ type heat exchangers unchallenged in economic and technologic parameters.




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