Direct contact condensers

EcoRec
EFC - 5000

The EcoRec EFC-5000 is a high-performance direct contact flue gas condenser engineered to enhance energy efficiency and sustainability across various industrial applications. By recovering heat and water from flue gases, it reduces energy consumption and supports eco-friendly operations.

Product Specifications

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  • Model: EFC - 5000
  • Heat Transfer Capacity: 5000 kW
  • Tube Material: High-Grade Stainless Steel
  • Shell Material: Carbon Steel with optional Corrosion-Resistant Coating
  • Coolant Type: Water
  • Design Pressures: 1-5 bar
  • Operating Temperature Range: 70°C to 250°C
  • Extraction System: Axial / Centrifugal fan
  • Pump Type (if water-cooled): Centrifugal
  • Noise Level: <70 dB
  • Condensate Management: Advanced self-draining with weir system
  • Control System: Integrated Smart Control System with Real-time Monitoring
  • Weight: 2000 kg
  • Installation: Modular Design for Easy Installation and Expansion
  • Talk to a Direct Contact Condenser Specialist
  • Submit an Enquiry

Product Information

Overview

With over two decades of expertise, Enertherm Engineering has developed the EcoRec EFC – 5000, a high-performance industrial flue condenser that enhances efficiency in processes such as water recovery and energy optimization. This innovative system is designed to recover water by condensing flue gases from stacks in industries like wood drying, sugar refining, and textile drying. Its vertical design maximizes space efficiency, and the gravity-assisted condensate drainage boosts performance.

Constructed from high-grade stainless steel for superior resistance to corrosion and high temperatures, the EcoRec EFC – 5000 integrates seamlessly into fryer stacks, oven stacks, and dryer stacks. It is supported by robust features such as a pressure-controlled extraction fan, thermal insulation, and easy-to-maintain components. Whether you need to meet sustainability goals, reduce energy costs, or improve operational efficiency, this system provides a reliable and effective solution.

  • High-Efficiency Heat Transfer: Built with premium materials, the EcoRec EFC - 5000 ensures efficient heat exchange, delivering maximum performance in high-demand environments.
  • Optimized Tray and Water Spray Design: The tray/packing system maximizes heat transfer by providing increased surface area, lower pressure drop, and uniform distribution.
  • Robust Construction: Constructed from corrosion-resistant components, ensuring durability and minimal maintenance in harsh industrial conditions.
  • Advanced Condensate Management: Equipped with an efficient, self-draining condensate system to prevent blockages, reduce downtime, and streamline operations.
  • Energy Savings: Maximizes heat recovery, significantly reducing energy losses and operational costs.
  • Low-Noise Operation: Designed for quiet operation, minimizing noise pollution while maintaining top-tier performance.
  • Compact Footprint: Space-efficient design allows for easy installation, even in facilities with limited space.
  • Self-Adjusting Extraction Fan: Features Variable Speed Drive (VSD) control with pressure differential sensors to maintain optimal performance without disrupting downstream processes.
  • Advanced Technology Integration: Real-time monitoring and automated adjustments for optimized performance with minimal manual intervention.
  • Adaptive Cooling Technology: Incorporates chillers or heat pumps for precise temperature control and energy efficiency.
  • Corrosion-Resistant Coatings: Optional coatings are available for enhanced durability, especially in harsh industrial environments.
  • CIP Cleaning: Customizable CIP systems maintain peak performance and ensure efficient maintenance.
  • Modular Design: Allows for easy installation, expansion, and future upgrades, ensuring flexibility for a variety of industrial requirements.
  • Comprehensive Support and Service: Backed by expert customer support, maintenance, and rapid response to ensure uninterrupted performance.

The EcoRec EFC – 5000 is ideal for capturing and recycling water from flue gas, significantly enhancing sustainability across a wide range of industrial applications, including:

  • Food Frying Processes
  • Paper Drying
  • Sugar Refining
  • Chemical Manufacturing
  • Textile Drying
  • Pharmaceutical Drying
  • Fryer, Oven, and Dryer Stacks

By recovering energy from flue gases and reducing water consumption, the EcoRec EFC – 5000 supports eco-friendly operations, improves efficiency, and cuts energy costs across various sectors.

An industrial condenser cools gases into liquids by removing heat, typically through tubes or plates where cooling water or air absorbs thermal energy. It’s used in power generation, chemical processing, and refrigeration.

Ensure proper flow rates and temperatures of the cooling medium, regularly clean surfaces to prevent fouling, and use sensors to monitor key parameters like temperature and pressure for efficiency.

Costs include energy for fans and pumps, maintenance, and water treatment. Energy is the main cost driver, and systems like heat pumps can reduce costs with higher energy efficiency.

They capture and repurpose heat from gases, using it for other processes like preheating or generating steam, improving energy efficiency.

Thermal expansion is managed using expansion joints, flexible piping, and proper supports to prevent damage from temperature changes.

KPIs include heat transfer efficiency, pressure drop, cooling medium temperature differential, and energy consumption.

Consider the type of gas, condensation rate, cooling medium, temperature, pressure, and space constraints. Select materials and designs suited for the application.

Use baffles, flow devices, and CFD analysis to evenly distribute the cooling medium, ensuring uniform heat transfer.

Use stronger materials, thicker walls, and reinforced connections to handle high pressures, while managing flow rates and pressure drops.

The cooling medium’s temperature and flow rate, surface area, temperature difference, and cleanliness all influence the heat rejection rate. Regular maintenance is essential for efficiency.

  • Achieving Net Zero Together

Contact us today to explore solutions in an industrial environment—we’re here to assist you in reaching your net zero goals!

Whether you need more information about our products, services, or sustainable practices, we’re just a message away.

Contact Details

  • Enertherm Engineering,
    Allia Future Business Centre, London Rd,
    Peterborough PE2 8AN
  • +44 (0) 7949 863 273
  • +44 (0) 1733 666 701
  • info@enertherm-engineering.com

We provide innovative engineering solutions that enhance efficiency, reduce costs, and support sustainable growth across various industries.

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