The installation method for waste heat recovery heat exchangers needs to be adjusted according to the equipment type (e.g., gas-to-gas, gas-to-liquid, thermal oil, etc.), application scenario (boiler, air compressor, industrial kiln, etc.), and the manufacturer's specific requirements. Based on currently available authoritative and timely public information, the following are general installation points:
General Installation Steps
- 1. Location Selection
- Install in a well-ventilated location that is easy to maintain and close to the heat source.
- For flue gas waste heat recovery exchangers, they should be connected in series with the exhaust duct; for thermal oil or air compressor waste heat recovery exchangers, they need to be close to the high-temperature oil or gas lines.
- 2. Brackets and Foundation
- Install brackets or a concrete base to ensure the equipment is level and stable, avoiding vibration during operation.
- The equipment base should be approximately 100 mm above the ground and damped with rubber pads.
- 3. Piping Connections
- Flue Gas Side: Flange connections are used. The outlet flue should preferably be made of stainless steel. Ensure a downward slope of ≥1% for the 1–2 m flue, and install a sludge collection hopper and a condensate pipe with a water seal at the lowest point.
- Water/Oil Side: Standard flange connections are used. Water flow direction is "low in, high out," and oil lines are laid in the direction of heat flow. Valves must be installed on both inlet and outlet pipes.
- 4. Sealing and Corrosion Protection
- All interfaces must be well-sealed to prevent leakage.
- In corrosive flue gas environments (such as those containing SO₂), the equipment casing or interior should be coated with high-temperature resistant polymer composite materials or made of stainless steel.
- 5. Electrical and Control Systems
- Most waste heat recovery heat exchangers do not require modification of the original system's electrical control, but it is recommended to install temperature and pressure monitoring instruments.
- Complex systems can be connected to a PLC or DCS for automatic adjustment and safety interlocking.
- 6. Testing and Acceptance
- After installation, conduct a hydrostatic test or airtightness test to confirm no leaks before trial operation.
- Preheat before initial operation, gradually increasing to the operating temperature.
Special Requirements for Different Types of Equipment
- Heat Pipe Waste Heat Recovery Unit
- Can be flexibly installed in boiler flues or outlets, supporting online replacement of single-stage heat pipes.
- Compact structure, only 1/3 the size of a conventional heat exchanger, suitable for space-constrained applications.
- Thermal Oil Radiator
- Insulation of the oil circuit and radiator is required to reduce heat loss.
- The oil pipe length should not be too long to avoid affecting heat transfer efficiency and increasing lubricating oil consumption.
- Bath Waste Heat Recovery Unit
- Installed below the drain outlet, the outer casing is fitted onto the drain pipe through the installation head, and a sealing ring is provided to prevent leakage.
- Built-in filter screen for easy cleaning of debris.
Precautions
- Safety Protection: Protective covers should be installed on high-temperature parts to prevent burns. - Regular maintenance: Clean accumulated dust, check seals, monitor corrosion to ensure long-term efficient operation.