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BOILER STACK ECONOMIZER:
Boiler Stack Economizers use the heat remaining in boiler exhaust gases to reduce fuel requirement by preheating the water used in the washing. Recent increases in fuel costs have resulted in a renewed emphasis on the flue gas heat recovery. Direct contact condensing technology has overcome technological barriers, such as cold end corrosion and tubular scaling and fouling, resulting in a 200 to 300 percent increase in heat recovery increased efficiency, and significantly improved return on investment (ROI's). Today ROI's of 200 percent per year occur and ROI's of 50 percent per year are to be expected.

DIRECT CONTACT WATER HEATER:
Direct Contact Water Heaters use a gas burner which fires directly into the water. As it passes the combustion gases in counterflow, the water is heated and falls to the bottom of the tank where it is pumped to process. The temperature of exhaust gas are reduced to equal or less than the ambient temperature, thus eliminating any stack losses. Evaporation heat of combustion is captured and used. This system easily saves 30 percent of gas used to make hot water compared to a boiler steam heat exchanger water heater. The saving results by eliminating the losses of a boiler steam heat exchanger system, such as hot stack gasses, blowdown heat, radiation and convection losses of the boiler, steam pipe, condensate return pipe and tank and flash steam.

FLASH STEAM RECOVERY SYSTEM:
Each pound of condensate gives up approximately 144 BTU in the form of steam before it becomes water at 212ºF (100ºC). This surplus of 144 BTU becomes steam (flashes) and escapes from the vent of the condensate receiver. This represents 11.8 percent of the fuel consumed. This fuel is used to create the steam which is not used. All of this energy can be recovered with a Flash Steam Recovery Unit.