Views: 0 Author: Site Editor Publish Time: 2026-02-25 Origin: Site
Industrial processes such as furnaces, kilns, thermal oxidizers, and metallurgical reactors discharge large volumes of high-temperature flue gas. A waste heat recovery air cooler heat exchanger is an effective solution to capture this otherwise lost energy, reduce exhaust temperatures, and improve overall plant efficiency—without the use of water.
This air-cooled waste heat recovery system is designed for harsh, high-temperature environments where flue gas temperatures can reach 850 °C. By transferring thermal energy from hot exhaust gas to ambient air, the system cools the flue gas down to 100–150 °C before it enters downstream equipment such as bag filters, ESPs, or stacks.
Typical applications include:
Industrial furnaces and reheating furnaces
Cement and lime kilns
Chemical and petrochemical process heaters
Steel, non-ferrous metal, and glass industries
Flue gas flow rate: up to 2000 m³/h
Inlet flue gas temperature: up to 850 °C
Outlet flue gas temperature: 100–150 °C
Cooling medium: Ambient air (dry cooling, no water consumption)
These parameters make the air cooler heat exchanger suitable for plants seeking energy recovery with minimal auxiliary systems.
To withstand extreme operating conditions, the waste heat recovery air cooler is engineered with:
High-temperature resistant tube materials (carbon steel, alloy steel, or stainless steel, selected based on gas composition)
Optimized tube bundle and fin design for efficient heat transfer on the air side
Thermal expansion compensation to prevent stress and deformation under large temperature gradients
Low pressure drop design to avoid negative impact on upstream process equipment
The modular structure allows customization for different layouts, footprints, and installation orientations.
Recovering waste heat from flue gas provides multiple advantages:
Significant reduction of exhaust gas temperature before environmental treatment
Lower thermal load on filters, ducts, and chimneys
Opportunity to reuse heated air for combustion air preheating, drying processes, or space heating
Reduced overall fuel consumption and CO₂ emissions
Because air is used as the cooling medium, the system is especially suitable for water-scarce regions.
The air cooler heat exchanger features:
Simple mechanical structure with high reliability
Easy access for inspection and cleaning
Stable performance under continuous high-temperature operation
Optional soot-blowing or dust-removal solutions can be integrated for flue gas with high particulate content.
A waste heat recovery air cooler heat exchanger designed for up to 2000 m³/h flue gas flow and 850 °C inlet temperature offers an efficient, water-free solution for high-temperature energy recovery. By cooling exhaust gas to 100–150 °C, it protects downstream equipment, recovers valuable thermal energy, and helps industrial plants achieve higher efficiency and lower emissions.
