Practically the heat exchange processes are not identical. Most often the processes vary in temperature, composition, consumption of exhausted gases, required temperature of air heating and air consumption depending on process technology, condition of furnaces and the whole process, operation conditions, quality of lining, breachings, gas ducts, availability and quantity of feed-up lines into the gas circuit, etc. In each particular case the corresponding heat exchanger can be designed to provide optimal process of heat recovery. Often adjustment to the specific customer is unprofitable for the manufacturer of the heat exchange equipment. This determines designing of a universal heat exchangers range for impersonal customer.

At that the final customer loses either in the mass-dimensional parameters and the costs (if he chooses the heat exchanger with excessive power) or in efficiency (if he chooses the heat exchanger with reduced power). Besides, generally it is necessary to modify the engineering design and to perform expensive readjustment of the existing gas duct system (according to the medium delivery points and item dimensions).

Our company doesn’t manufacture standard (not optimal) heat exchangers. Each device is manufactured for specific conditions and customer’s requirements including considering dimensions convenient for the customer. Thus, all our production can be build into the existing gas duct system with minimum adjustment.

We perform free design of heat exchangers based on both heat and power parameters and acceptable dimensions, and also taking into account existing and convenient for design gas duct delivery points.

Modular design of OPT heat exchanger

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 modules 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, partially or completely wear 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 that simplifies this operation. The modular assembly using welding is the most preferable method, as. At modules welding the sheet metal bars with 20-25 mm width and 1.5 mm thickness are used as the connections 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 against flange couplings.

This is possible because the required power of OPT type heat exchangers can be reached by diverse combination of design factors, height and channel ribbing interval.

We developed mathematical apparatus and software providing design optimization according to all customer’s requirements:
At the program input – initial data and customer’s requirements, at output – the heat exchanger sketch.

We accumulated large successful experience in replacement of the damaged heat exchangers of any design (including foreign heat exchangers) reserving all location dimensions as smaller mass and dimensional parameters always provide installation of our heat exchangers on the existing mounting support without adjustment of gas ducts and mounting load-carrying structures (generally replacement can be performed within a short time without additional costs for survey and designing).

Our equipment is used by: