Patented Air/Air cooler for an easy and quick change of the tube bundles.

In the past, we have also for the flue gas coolers and heat exchangers used old-fashioned technology that reliably fulfilled its tasks, but reached its limits in the area of wear and tear and also in maintenance. In the same order as we did with the combustion grate system we took a closer look at these problems and created a new type of flue gas cooler that is very easy to maintain.

But easy to maintain is not the only target what we had focused on.

The new design is long resistant against heat, abration and acids which is naturally dependent on selected materials.

Since the cooling circuit is shielded from the flue gas and the heat and thus energy transfer to the cooling air is due to the engineering enormous, it is nearly inevitable that this cooling air can be used further and thus the efficiency of a plant can be increased. 

Of course also the efficiency of an older, existing plant can be increased.

The design of the new cooler and the way it is implemented is both logical and consequent.

The cooler design is an air/air cooler. In the design, the flue gas and cooling air side are considered as independent systems.

One system, the flue gas side, must be resistant to heat, abrasion and corrosion and the other, the clean cooling air side, to sometimes enormous temperatures, depending on the design of the plant. We have also constructively implemented the thermal, mechanical problems that arise on the cooling air side.

Of course, the flue gas pipes are still exposed to a great deal of stress and their durability can be increased by using special steels, but they are still nothing more than wearing parts from a classical point of view.

If you take this problem into account, then you inevitably have to create a simple maintenance option, which we have implemented in our cooler.

The entire rear chamber part can be easily removed and the tube bundles can be replaced just as easily on their sliding frame. This significantly reduces downtime and keeps maintenance costs to a minimum.

The temperature ranges for the flue gas side are, depending on the design of the upstream plant, between 850 - 1200 °C and the cooling air side between 300 - 650 °C. 

Deviations are of course possible depending on the individual design of each plant.

Advantages of the new and patented cooler design:

• Easy to maintain.
• Long resistant against heat.
• Long resistant against acids.
• Long resistant against abration.
• Heat recovery via clean cooling air possible.
• No material attack of the secondary air cooling circuit by aggressive media.
• Long service life.

Execution possibilities:

Depending on the required flue gas quantity, the cooling system can be designed as single, double or triple cooling system. 
This means that the flue gases are split into one, two or three systems.
The system will be cooled by one or more fans, depending on the required cooling air capacity. 
This maintains the ease of maintenance.

Please note that each system requires an individual configuration. 
We always calculate your system individually according to your specifications and requirements.

Flue gas cooler 3 Flue gas cooler.pdf (2.21MB)

Flue gas cooler

3 Flue gas cooler.pdf (2.21MB)

Patented flue gas cooler AAC-202020000033.pdf (14.14MB)

Patented flue gas cooler

AAC-202020000033.pdf (14.14MB)

A useful guide to tendering International tender specification template.pdf (759.74KB)

A useful guide to tendering

International tender specification template.pdf (759.74KB)

An example air/air cooler for a first impression
Flue gas from combustion process	Please see also our example of a combustion furnace	Combustion furnaces 1 Combustion furnaces.pdf (1.07MB) Combustion furnaces 1 Combustion furnaces.pdf (1.07MB)
RDF (Refuse Derived Fuel) *	Mix of clinical waste, paper and fabric residues, polymers, other solid and sludgy waste fractions, like sewage sludge.	* only for sample
Flue gas cooler		Flue gas coolers 3 Flue gas cooler.pdf (2.21MB) Flue gas coolers 3 Flue gas cooler.pdf (2.21MB)
Materials
Casing plates	Heat resistant steel
Rear flue gas chamber	Heat resistant stainless steel
Tube bundle (tubes)	Special heat resistant stainless steel
Head plate inlet insulation	Heat resistant concrete and fibre
Head plate outlet	Heat resistant stainless steel
Front flue gas chamber	Special heat resistant stainless steel
Head plate inlet	Special heat resistant stainless steel
Support plates	Heat resistant stainless steel
Frame, outer parts	Mild steel
Housing insulation	Depending on the local requirements

A useful guide to tendering
International tender specification template.pdf (759.74KB)