Recuperator / Economizer Manufacturer for Industrial Furnaces

Therm process Engineering Pvt. Ltd. designs and supplies recuperators for waste heat recovery on industrial furnaces. A recuperator sits in the flue duct between the furnace and the chimney. Combustion air passes through it and picks up heat from the outgoing flue gases before reaching the burners. Therm process states its recuperators can recover 60-70% of the waste heat and preheat combustion air to 150-500°C. They are available in single-pass, multi-pass, underground, overhead, hair-pin and radiation designs. Share your furnace and flue gas data for a recuperator proposal.

What Is a Recuperator?

A recuperator is a heat exchanger that recovers heat from furnace flue gases and transfers it to incoming combustion air. The two streams flow through separate passages and never mix. Heat moves through the walls of the tubes or channels between them.

Flue gases leaving a reheating or heat treatment furnace are very hot. Without recovery, that heat goes straight up the chimney. Preheating combustion air means the burner needs less fuel to reach the same flame temperature. Preheated air is one of the most effective ways to cut fuel consumption on fuel-fired furnaces.

Recuperators are designed as counter-flow, with air and gas moving in opposite directions for maximum heat transfer, or cross-flow. The choice depends on flue gas temperature, available space and duct layout.

The term economizer is often used for heat recovery equipment of this kind. On furnaces, it refers to the same aim: recovering flue gas energy that would otherwise be lost.

Therm process Recuperators

Therm process designs and supplies high-performance recuperators for waste heat recovery on various types of industrial furnaces. The recuperator is a special-purpose counter-flow or cross-flow energy recovery heat exchanger, installed in the flue duct between the furnace and the chimney.

Designs available:

• Single-pass recuperators
• Double / two-pass recuperators
• Four-pass recuperators
• Hair-pin type recuperators
• Radiation type recuperators
• Underground recuperators (in the flue duct below floor level)
• Overhead recuperators

Because Therm process also designs the burners and combustion blowers, the recuperator, burners and air system can be matched. Burners are rated for preheated air, and the blower is sized for the added pressure drop.

Technical Specifications

Parameter	Specification
Function	Waste heat recovery; combustion air preheating
Location	Flue duct between furnace and chimney
Flow Arrangement	Counter flow or cross flow
Waste Heat Recovery	60-70% of waste heat (Therm process stated)
Air Preheat Temperature	150-500°C (Therm process stated)
Designs	Single pass, double/two pass, four pass, hair-pin, radiation, underground, overhead
Applications	Reheating, forging, heat treatment and other fuel-fired furnaces
Sizing	As per flue gas volume, temperature and air requirement

Key Features

• Multiple designs to suit flue gas temperature and layout.
• Counter-flow or cross-flow configurations.
• Air preheat up to 500°C.
• Underground or overhead installation options.
• Matched to burners and blowers from the same supplier.
• Suitable for new furnaces and retrofits.

How a Recuperator Works

• Flue gas exit Hot flue gas leaves the furnace into the flue duct.
• Heat exchange Gas passes over or through the recuperator elements.
• Air path Combustion air from the blower flows through the separate air passages.
• Preheating Heat transfers through the walls from flue gas to air.
• Burner supply Preheated air goes to the burners.
• Exhaust Cooler flue gas continues to the chimney

Applications

• Billet reheating furnaces in rolling mills.
• Forging furnaces
• Heat treatment and annealing furnaces.
• Other fuel-fired industrial furnaces with significant flue gas heat.

Industries Served

• Steel rolling and re-rolling mills
• Forging
• Heat treatment
• Aluminium and non-ferrous processing

Benefits

• Lower fuel consumption through preheated combustion air.
• Higher flame temperature for faster heating.
• Reduced chimney heat loss.
• Retrofit option for existing furnaces.
• Better overall furnace efficiency.

Custom Recuperator Solutions

• Furnace type and capacity
• Fuel and firing rate
• Flue gas volume and temperature
• Required air preheat temperature
• Available duct space (underground or overhead)
• Existing blower and burner data (for retrofit)

Why Choose Thermprocess?

• Since 1997, Mumbai.
• Recuperators designed alongside burners and furnaces.
• Wide design range for different layouts.
• ISO 9001 & ISO 14001 certified, as stated by the company.

Related Therm process Products

• Industrial Burners
• Combustion Blower
• Reheat Furnace
• Forging Furnace
• Furnace Profiling

Frequently Asked Questions

Q1. What is a recuperator in a furnace?
A recuperator is a heat exchanger in the flue duct between the furnace and chimney. It transfers heat from outgoing flue gases to incoming combustion air.
Q2. How much heat can a recuperator recover?
Therm process states its recuperators can recover 60-70% of the waste heat and preheat combustion air to between 150 and 500°C. Actual results depend on flue gas conditions and design.
Q3. What types of recuperators does Therm process make?
Therm process supplies single-pass, double/two-pass, four-pass, hair-pin, radiation, underground and overhead recuperators.
Q4. What is the difference between counter-flow and cross-flow recuperators?
In counter-flow, air and flue gas move in opposite directions, giving higher heat transfer. In cross-flow, they move at right angles, which can suit certain duct layouts.
Q5. Can a recuperator be added to an existing furnace?
Yes. Recuperators can be retrofitted. Burners and combustion blowers may need to be checked or upgraded for preheated air.

Cut Furnace Fuel Cost with Waste Heat Recovery

Share your furnace, fuel and flue gas data. Therm process will propose a recuperator matched to your burners and layout.

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