HEAT RECOVERY SYSTEMS
Heat recuperartors harness the thermal energy generated by flue gases from solid, liquid, or gaseous fuels and transfer it to another fluid—typically the combustion air used within the same process.
Depending on the process and the temperature of the gases, heat transfer is achieved through:
Key benefits:
Improved energy efficiency
Reduced fuel consumption
Lower pollutant emissions
Return on investment within months
We ensure safe and specification-compliant installation, either through our own assembly teams or by providing technical supervision to local contractors.
In both cases, we guarantee adherence to technical and quality standards, coordinate functional tests, fine-tune key parameters, and train personnel for efficient and safe commissioning.
Technical Installation & Specialised Assembly
Functional Commissioning
Operational Training
We provide ongoing technical assistance post-commissioning. Our team offers preventive and corrective maintenance, fault diagnostics, remote support, scheduled inspections, and continuous optimisation.
All our services are backed by original Kalfrisa spare parts, ensuring full compatibility and performance.
Adaptive Preventive Maintenance
Rapid Corrective Maintenance
Post-Installation Optimisation
Actualizamos equipos y modernizamos instalaciones mediante retrofit y revamping, sustituyendo componentes obsoletos, mejorando el rendimiento térmico y adaptando los sistemas a nuevas normativas.
Estas intervenciones pueden implicar la renovación parcial o sustancial de la planta, según las necesidades del proyecto.
Revamping térmico, mecánico y estructural
Retrofit tecnológico funcional
Actualización o reacondicionamiento de cámaras, intercambiadores, aislamientos, conducciones, etc
Mejora de eficiencia y reducción de emisiones
We transform traditional installations through smart technologies and advanced connectivity.
Our solutions include industrial automation, real-time remote monitoring, and predictive maintenance analytics—integrating your plant into the Industry 4.0 digital environment to maximise efficiency, productivity, and operational control.
Advanced Automation of Thermal Processes
24/7 Remote Monitoring
Predictive Maintenance Using Data Analytics
We provide technical and regulatory assessments of your facilities, propose improvements, and support compliance with legal and sustainability standards.
As an industrial decarbonisation partner, we help reduce energy consumption and emissions, driving your operations towards a cleaner future.
Energy Efficiency & Emissions Audits
Technical & Economic Feasibility Studies
Regulatory Compliance Support
Thermal Decarbonisation Strategies
Emission & Operating Condition Measurements
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Convection heat recovery units
Convection recuperators enable heat transfer between a primary and secondary fluid using bundles of smooth steel tubes.
They can be supplied as standalone units for installation in horizontal (underground or overhead) or vertical (stack-mounted) flue gas ducts, or housed in internally lined casings for enhanced protection and durability.
Commonly used in steelworks, direct reduction processes, reheating furnaces, forging, heat treatment, and annealing.
Operating Parameters::
• Flue gas temperature: 600 – 1,000 °
• Flue gas flow rate: 2,000 – 500,000 Nm³/h
• Combustion air preheating: up to 700 °C
Key Benefits::
• Energy efficiency
• Maximum heat recovery
• Suitable for high-temperature processes
Heat exchangers
Heat exchangers enable thermal energy transfer between two fluids through convection.
They are ideal for applications where flue gas temperatures are moderate and where there is no suitable duct for installing tubular bundles.
Their compact design ensures fast and simple installation, easily adapting to different configurations with minimal system modifications.
Operating Parameters:
• Flue gas temperature: up to 600 °C.
• Flue gas flow rate: 600 – 20,000 Nm³/h.
• Combustion air preheating: up to 700 °C.
Key Benefits:
• Flexible installation
• Quick and easy assembly
• Efficient performance at moderate temperatures
Radiation heat recovery units
Radiation recuperators are particularly effective for preheating combustion air. Two main types are available:
– Double Jacket Design: Consists of two concentric cylinders where the secondary fluid flows between the inner and outer jackets. Installed in chimneys or flue gas outlets.
– Tube Basket Design: Replaces the inner jacket with an annular basket of tubes through which the air flows. Offers higher mechanical strength and more even air distribution, enhancing heat transfer under high pressure and thermal demands.
Operating Parameters:
• Flue gas temperature: 1,000 – 1,500 °C.
• Flue gas flow rate: 1,000 – 10,000 Nm³/h.
• Combustion air preheating: up to 700 °C.
Key Benefits:: • Fuel savings of up to 40%. • High durability. • Stable performance.
Catalogue
Discover how we can help you enhance the energy efficiency of your industrial processes.
Download our catalogue and explore our heat recovery solutions.
