Integrated heat recovery systems for cogeneration plants

The complex block-modular heat recovery system

is a transportable module with boiler equipment mounted in it: a heat exchange module of the HL engine cooling circuit, a circulation pump of the heating circuit, a membrane expansion tank of the heat supply circuit, a heat meter with a flow-metering section, a condensate neutralizer with backfill and auxiliary equipment: fittings and materials, a condensate removal system, an air removal system, pipelines, which ensure the operability of the cogeneration unit, an automation system for the operation of the heat recovery complex in a cabinet design.

The complex block-modular heat recovery system is intended as permanent auxiliary equipment for the circulation of the coolant in the hot water supply network of the enterprise, when organizing a cogeneration cycle, it is installed on generator sets.

The FGR-BM heat recovery module

is an individually designed product that takes into account the features of the customer’s facility layout, the needs for the types and parameters of the coolant, operating conditions, characteristics of waste heat flows, the required level of automation and personnel competence. Taking these conditions into account, the selection and assembly of technical and technological equipment, and the hardware design of the block module are carried out. The heat module is supplied in full factory readiness, equipped with an automatic control cabinet and all systems, which allows for the most efficient use of waste heat energy from the turbine and internal combustion engine and requires minimal effort from the customer in designing and installing the system.

The FGR-BM module

is the main element of cogeneration plants based on gas turbine and gas piston engines. The heat recovery module (HRM) allows you to significantly increase the total efficiency of the heat and power unit, bringing its value to 98%.
The heat exchange blocks of the FGR-BM module are made of both austenitic steels (AISI 304, 304L, 316L, 316Ti, 321, 904L), and alloyed and duplex steels (SMO 254, SAF2205, 2307, LDX 2101, etc.). FGR-BM condensing blocks have high corrosion resistance, and are made of stainless steel, cast iron, copper, bimetallic pipes (steel-aluminum), polymeric materials and even ceramics. The use of corrosion-resistant materials has allowed us to create condensing heat exchangers also for the recovery of heat from liquid fuel exhaust gases.

SCOPE OF SUPPLY

The main equipment included in the delivery set of the heat recovery FGR-BM block module:

• 1. outlet after bypass;
• 2. heat exchanger blocks;
• 3. outlet after heat exchangers;
• 4. heat exchanger temperature sensor;
• 5. exhaust gas gate;
• 6. gate drive;
• 7. automation;

• 8. water temperature sensor at the inlet and outlet;
• 9. return water;
• 10. supply water;
• 11. safety valve.

Advantages of block-modular heat recovery systems:

The use of innovative FGR condensing type heat exchangers allows increasing the efficiency of fuel use of the cogeneration unit to 98%. This is the highest indicator in its class of equipment.
Heat exchange units of various types are used, shell-and-tube devices of fire-tube and water-tube design, plate-type, made of a finned bimetallic tube, based on “over heat-conducting elements” of heat pipes.
Minimal aerodynamic resistance in the exhaust gas process allows using FGR-BM for GTU with low exhaust gas pressure or using extended gas ducts from GPU.
Module layout with heat exchanger blocks for utilization of various heat flows, according to characteristics and environments with the production of one or more coolants.
The compact placement of equipment in the KSUT module allows them to be manufactured in relatively small containers, hoods or on a single frame for placement in the engine room. In the container and hood versions of the KSUT, due to their low weight, they can be installed on the roof of the generator container.
The ability to configure the module with different types of heat exchangers for heat/cold transfer between such media as gas/liquid, liquid/liquid, gas/steam, gas/gas allows the customer to work in a wide range of operating pressures, temperatures and with different types of media. Such a flexible and wide range allows you to choose the most optimal solution for heat and power supply of the customer’s facility regardless of the scope of application and industry.