Heat Exchangers

ThermStack
TSE - 445

The ThermStack TSE-445 is a high-performance economiser designed to enhance boiler efficiency by recovering waste heat from flue gases. This advanced system not only improves energy utilization but also contributes to significant reductions in greenhouse gas emissions, supporting your sustainability goals.

Product Specifications

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  • Model: TSE - 445
  • Flow Shell: 1.4 kg/s
  • Flow Tube: 1.2 kg/s
  • Rating: 445 kW
  • dP (Tube Side): 3 mbar
  • dP (Shell Side): 19 mbar
  • Weight Empty: 2156 kg
  • Weight Filled: 3793 kg
  • Length: 1 m
  • Material: SS 304L
  • Talk to a Heat Exchanger Specialist
  • Submit an Enquiry

Product Information

Overview

Introducing the ThermStack TSE – 445, a state-of-the-art boiler economiser engineered to elevate your system’s efficiency while cutting down on energy costs. With advanced technology at its core, the TSE – 445 is designed to optimise boiler performance across a wide range of industrial applications. Crafted from premium materials, this economiser not only boosts process efficiency but also significantly reduces operational costs and energy consumption, making it a sustainable solution for your industrial needs.

We understand that every business is unique, and that’s why the TSE – 445 is tailored specifically to meet your company’s distinct requirements. Our economisers are designed with your specific situation in mind, ensuring a perfect fit for your operational demands.

  • Shell and Tube: The TSE - 445 features a shell and tube configuration, offering superior heat transfer efficiency through its extensive surface area. This design ensures highly effective heat exchange between fluids, enabling better recovery of waste heat from boiler flue gases compared to conventional box-type economisers.
  • Seamless Integration: Designed for easy retrofitting, the TSE - 445 can be smoothly integrated into existing boiler systems, providing a hassle-free upgrade to enhanced energy efficiency.
  • Versatile Design: The TSE - 445 accommodates various flow rates and configurations with customisable tube lengths, diameters, and materials to meet specific operational requirements.
  • Durability and Longevity: Built to endure high pressures and temperatures, this economiser is exceptionally durable, ensuring long-lasting performance even in the harshest industrial environments.
  • Enhanced Thermal Performance: The TSE - 445 utilises counterflow or crossflow configurations to maximise the temperature gradient between fluids, ensuring optimal thermal performance.
  • Superior Heat Transfer Efficiency: Designed to maximise energy recovery from flue gases, the TSE - 445 offers higher water heating efficiency and greater energy savings compared to traditional economisers.
  • Robust Construction: Constructed from high-quality SS 304L, the TSE - 445 is engineered for reliability and durability, making it suitable for demanding environments.
  • Cost Savings: By maximising heat recovery, the TSE - 445 reduces fuel consumption, leading to significant operational cost savings.
  • Environmental Benefits: Improved fuel efficiency and reduced emissions make the TSE - 445 an environmentally friendly choice, contributing to more sustainable operations.
  • Versatility in Design: The TSE - 445 can be customised with varying tube lengths, diameters, and materials, making it adaptable to different operating conditions and specific requirements.
  • Compact Design: Available in vertical or horizontal configurations, the TSE - 445 offers flexibility in installation, ensuring it fits into your available space without compromising performance.
  • Ease of Maintenance and Cleaning: Designed for easy disassembly, the TSE - 445 allows for straightforward inspection, cleaning, and maintenance. Individual tube cleaning ensures that the economiser maintains its high performance over time.
  • Enhanced Safety Features: Equipped with safety measures to handle high-temperature and high-pressure conditions, the TSE - 445 ensures safe and stable operation in demanding industrial processes.
  • Pressure Drop Management: Customisable tube arrangements and baffle placement allow for better control over pressure drop, ensuring efficient fluid flow and optimal heat exchange.

The ThermStack TSE – 445 is engineered to enhance the efficiency of a wide range of industrial applications by recovering waste heat from boiler flue gases. Ideal for use in:

  • Industrial Boilers in power plants, chemical processing facilities, food and beverage production, refineries, and petrochemical facilities.
  • Pulp and Paper Mills where reducing fuel consumption and lowering operational costs are crucial.
  • Textile Industry for improving energy utilisation in curing and drying processes.
  • Pharmaceutical Manufacturing to enhance energy efficiency and sustainability.

By incorporating the TSE – 445, facilities can achieve substantial reductions in fuel consumption, lower their operational costs, and significantly improve overall energy utilisation—all tailored to your unique business needs.

An economiser is designed to recover waste heat from flue gases or exhaust streams and use it to preheat incoming fluids, typically water or air, in a system. This process improves overall energy efficiency by reducing the need for additional heating.

The shell and tube design in an economiser enhances thermal performance by maximizing the heat exchange surface area. The design allows for efficient heat transfer between the hot gases flowing through the tubes and the fluid surrounding the tubes in the shell, resulting in improved heat recovery and higher thermal efficiency.

An economiser improves energy utilisation in industrial applications by capturing and reusing waste heat from processes such as combustion or steam production. This recovered heat can be used to preheat boiler feedwater, air for combustion, or other process fluids, thereby reducing the overall energy consumption and improving the efficiency of the system.

Economisers play a crucial role in reducing operational costs by decreasing the amount of fuel or energy needed to reach the desired heating levels in industrial processes. By utilising recovered waste heat to preheat fluids, economisers lighten the load on primary heating equipment, resulting in significant savings on fuel, energy consumption, and associated operational expenses.

Economisers deliver exceptional heat transfer efficiency when compared to traditional heat exchangers, thanks to their innovative design. This often includes features like extended surfaces (fins) on tubes and optimised flow arrangements such as counterflow. These enhancements significantly boost the heat transfer rate by increasing the contact surface area and optimising the temperature gradient between the hot gases and the fluids being heated.

Economisers play a vital role in promoting environmental sustainability by significantly reducing fuel consumption and the associated greenhouse gas emissions. By enhancing energy efficiency and capturing waste heat, economisers help to lower the overall carbon footprint of industrial operations, fostering more sustainable energy use.

The counterflow or crossflow configuration significantly improves the thermal performance of an economiser by optimising the temperature gradient between the hot gases and the fluid being heated. In a counterflow arrangement, the hottest gases meet the hottest fluid, sustaining a high temperature difference throughout the heat exchanger, thereby maximising heat transfer efficiency.

Safety features integrated into an economiser may include pressure relief valves, temperature sensors, and flow switches to monitor and regulate operation, thereby preventing issues such as overheating, overpressure, or fluid blockages. These safeguards are crucial in protecting the system from potential hazards like thermal stress, material fatigue, or mechanical failure.

The design of an economiser plays a pivotal role in its performance, directly influencing heat transfer efficiency, pressure drop, and its compatibility with the existing system. Key factors such as the size and arrangement of heat exchange surfaces, the choice of materials, and the flow configuration—whether counterflow, parallel flow, or otherwise—are critical in achieving optimal performance in terms of heat recovery and energy efficiency.

Retrofitting an existing system with a new economiser entails a thorough evaluation of the current system’s operational parameters, followed by the selection of a compatible economiser design. The integration process is carefully managed to minimise disruption, typically involving modifications to piping, controls, and support structures to seamlessly accommodate the new equipment. These adjustments are essential to ensure the system operates efficiently, leveraging the enhanced heat recovery capabilities provided by the economiser.

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

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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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