A Waste Heat Recovery Unit (WHRU) captures thermal energy from exhaust streams that would otherwise be lost, repurposing it for valuable uses such as preheating air for combustion applications, generating steam for power or plant utilities, and heating thermal fluids to transport heat where needed.
Due to the immense amount of heat generated by thermal oxidizers, many Zeeco systems incorporate waste heat recovery equipment to further reduce operating costs by generating steam and/or heating oil that is used for other plant operations.
Carbon Monoxide (CO) Boilers are thermal oxidizers with integral waste heat recovery systems used to oxidize carbon monoxide-rich waste gases typically generated by Fluidized Catalytic Cracking Units (FCCUs) in petroleum refineries. They are traditionally referred to as “boilers” due to the large quantity of steam generated by integral waste heat recovery systems.
An alternative to the direct-fired approach is the indirect (also known as "extractive") system. Extractive systems offer exceptional flexibility, especially when other sources of thermal oil heating sources are limited. The additional control provided by the induced draft fan allows for very precise regulation of the oil outlet temperature, even when faced with fluctuating waste flow rates.
Extractive systems are commonly used in gas plants that utilize membrane technology. Due to the relatively high hydrocarbon content in the permeate gas from the membrane system, the available heat duty from the flue gas is often significantly greater than that required to be returned to the plant. A thermal oil heat exchanger placed directly in the flue gas path would generate more duty than could be effectively returned to the plant, since the oil circulation rate required to prevent degradation of the oil places constraints on the coil design.
Upgrading your plant to meet new regulations, improve efficiency, or retrofit equipment often means complex construction and installation challenges. Zeeco simplifies the process by taking single-point responsibility for your combustion system upgrade—reducing costs, saving time, and eliminating onsite hassles.
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