Recuperator payback
Estimation of operating efficiency of the heat exchangers manufactured by Termo Nord Stream through the examples of the implemented projects
Pobuzhie Ferronickel Plant
Cost-benefit analysis for ribbed plate heat-exchanger unit in the tube rotary furnace for nickel ore melting (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 content 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 hour
5,9
Gas volume in Nm3 required to produce 1 Gcal
125
Price of 1 Nm3 of gas VAT excl., $
0,5
Number of working hours per day
24
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
Прочие, $ без НДС
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
Solution
Weight is 25 000 kg
Heat power: 5 000 KW
Used for gas furnace blast preheating
Flue gas temperature: 350° С
5. Heated air temperature: 280° С
Heat power: 5 000 KW
Used for gas furnace blast preheating
Flue gas temperature: 350° С
5. Heated air temperature: 280° С
Reference
Severstal
Cost-benefit analysis of replacement of the existing low-performance heat exchanger by ribbed plate 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 150 ℃
- 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, months
6
Economic benefit from the heat exchanger operation during (10) year service life, rubles.
71 928 000
Operational effect
- Technical parameters met requirements of the specifications
- The existing system of air and flue gas ducts is retained
- Fuel (natural gas) consumption savings is 185 Nm3/h
Solution
Weight is 5 880 kg
Heat power is: 2 669 KW
Used for air heating at burners
Flue gas temperature: 900° С
Heated air temperature: 412° С
Heat power is: 2 669 KW
Used for air heating at burners
Flue gas temperature: 900° С
Heated air temperature: 412° С
Reference
JSC Rosneft
Cost benefit analysis for installation of ribbed plate air heater in the oil and gas refinery
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
Operational effect
- Technical parameters met requirements of the specifications
- The existing system of air and flue gas ducts is retained
Solution
Weight: 24 000 kg
Heat power: 4 637 KW
Used for air preheating for burning
Flue gas temperature: 350° С
Heated air temperature: 218° С
Heat power: 4 637 KW
Used for air preheating for burning
Flue gas temperature: 350° С
Heated air temperature: 218° С
Reference
