Introduction

FLU-ACE® for Boilers

FLU-ACE® for Dryers

DRY-REX™

Gem® Condensate Return System

Thermal-AUD™

ThermalOZOMAX™

Other Solutions

White Papers

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Solutions

FLU-ACE® FOR BOILER EXHAUSTS & HOT WASTE GAS

	Thermal Energy was contracted by Johnson Controls to design and implement a FLU-ACE® heat recovery system for CAMCO’s new dryer manufacturing facility in Montreal. It recovers heat from the “E-coat” system for building and process heating. It also benefits the environment by significantly reducing pollutants such as carbon dioxide and volatile organic compounds (VOCs).

FLU-ACE® technology greatly improves the fuel efficiency of boiler operations, provides a significant return on investment, and reduces environmental emissions. Up to 90% of the heat normally lost through boiler flue gas stack emissions is recycled by FLU-ACE®. This is possible because the FLU-ACE® unit’s unique direct contact (gas/liquid) design enables optimal recovery of both sensible and latent heat, even in widely varying operating conditions.

Win your fight to reduce energy and production costs:

• Reduce energy consumption on gas, oil and biomass burners by 15% to 35%;
• Reduce greenhouse gases and other emissions commensurate to fossil fuel reductions;
• Enjoy full payback on your FLU-ACE® investment in one to three years... and continued savings throughout the unit’s 20 year plus operational life;
• Achieve typical water temperatures of up to 63°C/145°F (up to 82°C/ 180°F) with alternate design);
• Recover 200% to 300% more heat than conventional recuperator and economizer systems … heat readily usable for process water and air heating;
• Recover and condense between 70% and 90% of the water vapor normally vented in the exhaust gas... providing water for recycling to process;
• Achieve both efficient heat recovery and effective pollution control with one cost-effective FLU-ACE® unit.

Thermal Energy International Inc. offers industry a winning solution to escalating energy costs.

FLU-ACE® provides an excellent source of heat at ideal temperatures for Thermal Energy’s low temperature Dry-Rex™ biomass drying systems.

In many cases, with clean fuels, the hot water can also be used directly in the process or boiler plant without any need for additional heat exchangers.

Electronic controls give FLU-ACE® optimum automated performance and “fail-safe” operation.
As a side effect of valuable heat recovery, FLU-ACE® provides you with a substantial environmental bonus... it reduces pollutant emissions by an amount equal to or greater than the percentage of energy saved.

FLU-ACE®, Thermal Energy’s winning solution for your bottom line and the environment.

Achieve energy consumption savings of up to 35%

How FLU-ACE® works to cut energy costs

1. Conventional heat recovery technologies require a dedicated piece of equipment for each boiler exhaust – not with FLU-ACE.
2. The varying flow of fl ue gases emitted from multiple boilers can be efficiently processed by a single FLU-ACE®. This means a lower initial investment, lower operating costs and a higher return on investment with FLU-ACE®. FLU-ACE® will have an ongoing positive effect on
   your bottom line throughout its long operating life (20+years in most applications).
3. The FLU-ACE® unit’s unique internal structure ensures maximum condensing heat and mass transfer. It also enables an unobstructed flow of liquids and gases through the tower, guaranteeing virtually continuous operation with limited downtime.
4. FLU-ACE® is equipped with a variable speed, induced draft fan at the tower outlet. The fan automatically maintains the optimum flue gas static pressure set point at the tower inlet preventing interference with upstream processes.
5. Hot water is produced when boiler flue gases are cooled and water vapor is condensed in the FLU-ACE®.
6. The hot water (at up to 63°C/145°F) accumulates in the receiver where it is chemically treated to neutralize acids and remove suspended solids if required.
7. FLU-ACE® uses variable speed pumps to keep the temperature of the hot primary water leaving the receiver at the desired level.
8. Control valves regulate distribution of the primary water to the heat exchangers.
9. Heat can be transferred to secondary water for direct process water heating or boiler make-up heating.
10. Heat can be transferred to secondary glycol fluid for direct plant makeup air heating, boiler combustion air preheating.
11. FLU-ACE® can alsos be used to provide heat to Thermal energy’s low temperature Dry-Rex™ biomass dryer for turning biomass feed stock into high-efficiency biofuel.