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1.3 Heat exchangers A key component in waste heat recovery is the heat exchanger. The profitability of an investment in waste heat recovery depends heavily on the efficiency of heat exchangers and their associated life cycle costs (purchase, maintenance, etc). Different designs All these factors vary considerably between different heat exchanger technologies. Although compact heat exchangers are very common in the process industry today, shell-and-tube heat exchangers are still dominating. Compact heat exchangers have many benefits over shell-and-tubes: • Up to five times higher heat transfer efficiency • Lower costs for both initial investment and maintenance • Much smaller in size These arguments are especially true for heat recovery services where the differences are maximal. An important choice x5 Compact heat exchangers are up to five times more efficient than shell-and-tubes, making heat recovery profitable even where the energy sources traditionally have been deemed worthless. Figure 1.4 The diagram shows the heat recovery level as a function of initial cost. The yield from compact heat exchangers is up to 25% higher than for shell-and-tubes at a comparable cost. To reach the same levels of heat recovery, shell-and-tube solutions often become several times more expensive. The basis of compar- ison is a BEM shell-and-tube system with stainless steel tubes and fusion bonded AlfaNova compact heat exchangers. For more details, please visit www.alfalaval.com/waste-heat-recovery. Heat recovery 100% 95% 90% 85% 80% 75% 70% Compact heat exchanger +25% Shell-and-tube heat exchanger 0123456 Cost units The choice of heat exchanger is very important and has a direct impact on the bottom-line result. In fact, replacing old shell-and-tubes with new compact heat exchangers in existing heat recovery systems is often a very good investment, thanks to the strong benefits. 9PDF Image | Waste heat recovery Optimizing
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