flue and exhaust gas heat exchangers - bomat · 03 bomat ceramic heat exchangers. benefit from...

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FLUE AND EXHAUST GAS HEAT EXCHANGERS

PRODUCT RANGE

02

SAVES MORE.GIVES

MORE.MAKES MORE OF ENERGY.

ENERGY DEMAND WITH

GAS –15%*

The energy consumption of gas boilers can be reduced by up to 15 % through the use of BOMAT fl ue gas heat exchangers.

ENERGY DEMAND WITH

OIL –10%*

In the case of oil fi red systems, BOMAT fl ue gas heat exchangers can cut energy consumption by up to 10 %. Heat is extracted from the fl ue gas and condensing technology utilises the condensation energy of the water vapour contained in the gas.

EMISSIONS OF

CO2 –15%*

By saving energy, CO2 is also reduced. The greater the energy saving, the greater the resultant reduction in CO2 emissions.

EMISSIONS OF

ACID –60%*

* Compared to conventional boilers.

Sulphur and sulphur compounds contained in the fuel react during combustion with the oxygen present in the air and the water vapour in the fl ue gas, creating sulphurous acid (acid rain). In a BOMAT heat exchanger, the acidic fl ue gas condenses.

03

BOMAT CERAMIC HEAT EXCHANGERS.BENEFIT FROM EFFICIENT SOLUTIONS PROVIDED BY A MARKET LEADER.

SIMPLY BETTER: THE BOMAT PROFI THERM SERIES

BOMAT fl ue gas heat exchangers cool the fl ue gases to below their dew point. The thermal energy and latent heat of condensation in the fl ue gas are extracted and passed to the water heating cycle. Condensing technology with corrosion-free heat exchangers from BOMAT.

Problem: environmental pollutionMany fuels contain acidifying elements (such as sulphur)

that form an aggressive vapour of acid mixed with

water when burnt. In conventional heat generators this

acidic vapour from combustion is expelled in the fl ue

gas through the chimney into the environment, where it

condenses and falls to the ground through precipitation

(acid rain). This harms fl ora and fauna and can even be

detrimental to buildings. In metal-based condensing heat

exchangers, the condensate can become contaminated

as the acids from combustion may cause small particles

(metal ions) to be dissolved from the metal surfaces.

These particles pass into the condensate and then into

the environment and food chain through the waste

water. Some of these metal ions consist of heavy metals

such as chromium, nickel, etc., that pose risks to health

and cannot be satisfactorily absorbed by even the best

waste water treatment plants.

Solution: BOMAT ecology and …The ceramic pipes used in BOMAT heat exchangers off er

high thermal conductivity and an exceptionally long

service life. They are also completely acid-resistant, so

that any condensate created is metal-free.

… economy in perfect harmonyCondensing technology cools the fl ue gas in heat

exchangers until it condenses. This releases heat, which

is passed to the heating water. Fuel consumption and

operating costs are substantially reduced.

Less in, more outNow with even be� er energy utilisation, BOMAT is at

the cu� ing edge of advanced heating technology, off ering

investments that are often repaid in just three years.

BOMAT quality can be summed up in three words:

Made in Germany.

04

BOMAT: SUCCESS AND EXPERIENCE SINCE 1982.VERSATILE IN USE AND IMPRESSIVELY EFFICIENT.

Today, BOMAT fl ue and exhaust gas heat exchangers are

in use in a wide variety of applications.

These include Heating technology

Whether in domestic boilers for the family home or

large heating installations for hotels, hospitals or

municipal buildings, energy consumption is reduced

with BOMAT fl ue gas heat exchangers.

CHP (combined heat and power) unitsCombustion engines wastefully release hot exhaust

gases into the environment.

OEM (original equipment manufacturers)BOMAT supplies corrosion-free fl ue gas heat

exchangers to many leading boiler manufacturers.

Industrial systemsWith BOMAT fl ue gas heat exchangers, waste heat

from any source can be recovered – be it a furnace, a

powder coating facility or a steam boiler. By installing

a BOMAT fl ue gas heat exchanger, the heat from

combustion in the fl ue gases is extracted and passed

into the plant's heating circuit.

LOW CO2 EMISSIONS

NO HOT FLUE GASES

Optimum energy utilisation with very li� le loss.Condensing technology pioneer BOMAT is the only company

to use patented ceramic heat exchangers. These ensure that condensate is free of harmful substances and resist even sulphurous acids throughout their long service life. Moreover, the condensate produced serves to clean the heat exchanger (SELF-CLEANING EFFECT).

PATENTED CERAMIC HEAT EXCHANGERS: LAST LONGER AND PROTECT THE ENVIRONMENT

2%

7%

0

2

4

6

8

10

12

14

16

6%2%2

2%

05

REDUCE YOUR FUEL COSTS BY UP TO 15 %!

Up to 80 % of condensation heat from the fl ue gas is recovered. Taking oil boilers as an example, this results in combustion effi ciency levels of up to 106 % (net calorifi c value).Sensible heat loss Latent heat loss Cooling losses

Energy gain

12%

CHP AND BIOGAS PLANTS

BOMAT exhaust gas heat exchangers signifi cantly improve the thermal effi ciency of CHP units. With these corrosion-free ceramic heat exchangers it is even possible to make use of the exhaust gases from the combustion of sewer gas.

LARGE AND SMALL HEATING SYSTEMS

Tailored solutions for apartment buildings, residential complexes, public buildings, sports facilities and hotels. For boilers up to and above 2200 kW, BOMAT Profi therm units can be individually matched to each installation, and will naturally demonstrate an extremely high level of effi ciency.

INDUSTRIAL SYSTEMS

Commercial and industrial enterprises often produce large volumes of fl ue and exhaust gases that usually pass into the environment unused. For such facilities, BOMAT off ers individually tailored solutions for heat recovery from these gases.

WITHCONDENSING TECHNOLOGY

WITHOUT CONDENSINGTECHNOLOGY

"Energy is a precious resource and its value will continue to increase.The price we ourselves and our environment will pay for it in the future depends on our investment decisions today.Energy saving BOMAT condensing technology pays for itself in every respect. We invite you to try it and see for yourself."Gerhard Schneider (Managing Director) and Rolf Bommer (Company Founder)

06

BOMAT HAS OFFERED ENVIRONMENTALLY RESPONSIBLE HEAT RECOVERY SOLUTIONS SINCE 1982. THE RESULTS OF OUR EXPERIENCE ARE PLAIN TO SEE. HERE ARE A FEW EXAMPLES:

OVER 75,000SUCCESSFUL PROJECTS.

07

REFERENCES. CHP (NATURAL GAS).

Birkle clinic (Überlingen)Sokratherm CHP unit utilising condensing technology

Heat generator: Sokratherm GG50 CHP unit

Exhaust gas heat exchanger: AWR G 1522 for CHP unit

Year of manufacture: 2012

Heat recovery per year: Approx. 88,000 kWh

CO2 reduction per year: Approx. 17,600 kg

r Estimated payback period less than 3 YEARS.

Cornelis van Spronsen landscaping (Westoverledingen)Natural gas CHP unit utilising condensing technology

Heat generator: MTU BGS 301-438

Exhaust gas heat exchanger: AWR 2G 1064 for CHP unit





Klinikum am Weissenhof (Weinsberg)Sokratherm CHP unit utilising condensing technology

Heat generator: Sokratherm GG 237 CHP unit






Schlossbergkellerei GmbH (Althengstett)Sokratherm CHP unit utilising condensing technology

Heat generator: Sokratherm GG50 CHP unit






08

REFERENCES. BIOGAS / SEWER GAS.

Buhl biogas plant (Dornhan-Kaltenhof)Cu� ing-edge agricultural technology with a biogas CHP unit

Heat generator: 550 kW CHP unit (el.)





r Payback period less than 3 years.

Erste Biogas Ocholt GmbH & Co. KG (Ocholt)Biogas CHP unit utilising condensing technology

Heat generator: Jenbacher JMS 312 GS-BL 625 kW el.






Wildeshausen wastewater treatment plant (Wildeshausen)Sewer gas CHP unit utilising condensing technology

Heat generator: enertec et124 SG MA CHP unit






Glatt wastewater treatment plant (Dornhan)Sewer gas CHP unit utilising condensing technology

Heat generator: PowerTherm 20 sewer gas CHP unit





r Payback period less than 3 YEARS.

09

REFERENCES. INDUSTRY.

AEW Allgäuer Emmentaler Werk e.G. (Kimratshofen)Cu� ing production costs with BOMAT condensing technology

Heat generator: Steam boiler

Flue gas heat exchanger: AWR 8G 1024-1200





Felder GmbH brazing and soldering (Oberhausen)Waste heat recovery from furnace system

Heat source: 2 metal-melting furnaces

each with 235 kW





r Estimated payback period less than 3 years.

PUK-WERKE KG factory (Schönecken)Waste heat recovery from galvanizing

Heat source: Galvanizing furnace

Exhaust gas heat exchanger: 2x AWR 5G 1024-600 for CHP unit

Year of manufacture: 2005 and 2009

Heat recovery per year: Approx. 400,000 kWh (for both plants)

CO2 reduction per year: Approx. 104,000 kg (for both plants)


Wutal AluminiumGuss GmbH (Stühlingen)Waste heat recovery from industrial process in aluminium foundry

Heat source (industrial): Aluminium melting process

Exhaust gas heat exchanger: 2 x AWR 7G 1046-1400


Heat recovery per year: Approx. 400,000 kWh (for both plants)

CO2 reduction per year: Approx. 80,000 kg (for both plants)


10

REFERENCES. STANDARD.

Riffelalp Resort Hotel (Zermatt)Flue gas heat for outdoor swimming pools

Heat generator: Oil boiler (550 kW)

Flue gas heat exchanger: AWR 6G 1024





Parkhotel St. Leonhard (Überlingen)Flue gas heat exchanger for an oil condensing system

Heat generator: Buderus oil boiler SE635 (280 kW)

Flue gas heat exchanger: AWR G 1064-350





Gasthof Lamm brewery (Abtsgmünd)Loos steam boiler with condensing technology

Heat generator: Loos steam boiler U-ND 500

Flue gas heat exchanger: AWR G 1064-350





Schöneck sports college (Karlsruhe)Three Buderus oil boilers utilising condensing technology

Heat generator: 3x Buderus GE515 (approx. 290 kW)

Flue gas heat exchanger: 3x AWR G 1064-350


Heat recovery per year: Approx. 180,000 kWh (for all three boilers)

CO2 reduction per year: Approx. 46,800 kg (for all three boilers)


11

COMPLETE SERVICE FROM THE ENERGY SPECIALISTS.CONSULTANCY, ENGINEERING AND IMPLEMENTATION: AS INDIVIDUAL AS YOUR PROJECT.

The BOMAT technical advisor: always looking out for unused potential.Condensing technology off ers a particularly high

potential for savings with medium-sized and large heat

generators. This is because less fuel often means annual

savings of the order of thousands of pounds, meaning

that a heat exchanger pays for itself relatively quickly.

BOMAT technical advisors are on hand right from the

start to assist you in engineering and project planning.

BOMAT PROFITHERM FOR LARGE BOILERS AND INDUSTRIAL PLANT

BOMAT Profi therm for large boilers and industrial plant achieved savings of 36,000 litres of fuel oil per year for a cheese production facility. The payback period here was less than two years.

Deutsches Zentrum für Luft- und Raumfahrt e. V. – DLR (Hardthausen)Viessmann oil boiler utilising condensing technology

Heat generator: Viessmann oil boiler

Flue gas heat exchanger: AWR 6G 1046-1200





FOR FURTHER REFERENCES, SEE OUR WEBSITE.

r www.bomat.de/references

12

BOMAT: OEM SUPPLIER TO BIG-NAME BRANDS.CUSTOM BOMAT FLUE AND EXHAUST GAS HEAT EXCHANGERS FOR OUR CUSTOMERS.

BRÖTJE

Task: To adapt a neutralising system to Brötje boilers. Over 25,000 units supplied!

BOSCH THERMOTECHNIK GMBH

Task: To adapt various BOMAT AWR units to Buderus boilers Output range: 17 – 400 kW Accessories range: Diverse neutralising systems

DE DIETRICH

Task: To develop a compact AWR unit to integrate and adapt for De Dietrich boilersOutput range: 16 – 350 kW

GIESE

Task: To adapt various AWR models to diff erent Giese CHP units

For more than 15 years we have supplied optimally designed heat exchangers to big-name manufacturers in Germany and abroad.Our development engineers pay particular a� ention

to the specifi c needs and requirements of our OEM

customers. Each manufacturer receives a customised

product for its heat generators.

Our customers' heat generators, fitted with BOMAT heat exchangers, attract attention for their exceptional energy efficiency.As the market leader for ceramic heat exchangers, one

requirement that we can easily satisfy is our customers'

demand for effi cient, low maintenance, durable products,

as well as maximum sustainability and economic viability.

OLYMP

Task: To adapt and develop various AWR models for diff erent Olymp boilersOutput range: 17 – 40 kW

RAPIDO-FERROLI

Task: To adapt 2 compact AWR units to Rapido-Ferroli boilers Output range: 17 – 40 kW

RIELLO

Task: To adapt various AWR models to Riello boilers Output range: 90 – 500 kW

SAINT ROCH

Task: To develop 2 very compact AWR models for integration into Saint Roch boilersOutput range: 17 – 40 kW

Since 2004 over 60,000 units have been producedAccessories range: Diverse neutralising systems

SENERTEC

Task: To develop a corrosion-resis-tant exhaust gas heat exchanger for CHP units driven by fuel oil and natural gas. Since 1999 over 18,000 units have been produced

13

OUR SUCCESSPROVES US RIGHT.

WEISHAUPT / PYROPAC

Task: To adapt AWR G 516 to Weishaupt boilersOutput range: 16 – 32 kW Accessories range: Safety systems, neutralising systems

WOLF

Task: To integrate various AWR into Wolf boilersOutput range: 17 – 250 kW Accessories range: Neutralising systems, safety systems

Accessories range: Neutralising systems

WEINMANN & SCHANZ

Heating and sanitation systems wholesaler:Neutralising systems, pumping stations and RNA main tenance packages

WALTER MEIER

Task: To adapt various AWR models to Walter Meier boilers.Output range: 45 – 1000 kW Accessories range: Diverse neutralising systems

JUST TELL US WHAT YOU NEED AND LET US FIND THE APPROPRIATE

SOLUTION – GUARANTEED.

think green

14

BOMAT CONDENSING TECHNOLOGY FOR CHP.LESS IN, MORE OUT.

Make better use of energy.Many conventional CHP units have a thermal effi ciency

of about 50 %. BOMAT recovers the condensation heat

contained in the exhaust gas as an additional source of

heat. The addition of BOMAT condensing technology

increases the thermal effi ciency by up to 10 %.

By investing in this technology, you are also helping

to protect the environment, as signifi cantly fewer

pollutants are expelled from the chimney.

CHP heat exchangers: ceramic lasts longer.As a rule, conventional

exhaust gas heat exchangers

in CHP units are operated

above the condensation

limit. Nevertheless,

condensation may occur at

start-up or with low coolant

temperatures, resulting in corrosion inside the heat

exchanger. Where fuels containing sulphur are burnt (oil,

gas or biogas), sulphurous acid is produced. Depending on

the combustion temperature and catalysing technology

used, nitric acid may also form as a reaction with the

condensate and NOx. Nitric and sulphurous acids are

the causes of acid rain, and can even a� ack stainless

steel. Condensate that contains heavy metals may

also be produced. BOMAT utilises patented ceramic

heat exchangers that are 100 % corrosion-proof. These

devices produce contamination-free condensate and off er

an exceptionally long service life.

FOR ALL-PURPOSE USE WITH ANY OF THESE FUELS

Fuel oil Natural gas Sewer gas Biogas

Low pressure losses on the exhaust gas side

Fully corrosion-resistant

Short payback periods

15151515155555

SAMPLE CALCULATIONOF PAYBACK PERIOD.

CHP unit with approx. 8600 hours of

operation/year, including 4000 hours of

operation/year for heat recovery from the

exhaust gas heat exchanger.

Heat recovery yield: 115 kW

Water thermostat (on site)


Flow switch

Flow switch

District heating Drying Digester

Flue/exhaust gas STB

Flue/exhaust gas damper (on site)

BiogasCHP unit

Close 1)

Open 1) 2)Open 1)

Flue/exhaust gas damper (optional )

Return collector

Flow distributor

Condensing-compatible fl ue/exhaust pipe(stainless steel)

WTM

HK1 HK2 HK3

M M

AWR

AWR

Please note: The colder the return,

the higher the energy yield.

WATER SIDE CONNECTION INTO AN EXISTING BIOGAS PLANT.

EXHAUST GAS SIDE CONNECTION INTO AN EXISTING BIOGAS PLANT.

Biogas

CHP unit

1) The fl ue/exhaust gas

path must always be

open in one direction.

A CHP unit must not be

operated with dampers

closed.

2) This damper must

only be closed during

maintenance.

WMZ WMZ

BOMAT heat exchangers: simple to retrofit.BOMAT ceramic heat exchangers are simply fi � ed

between the exhaust pipes of the CHP unit. The heat

recovered is fed into the existing heating system or

used as process heat.

1004

1504

151215161522

35°C

50°C

65°C

1032

1064

2G 1032

4G 1024

3G 1032

2G 1064

6G 10247G 1024

8G 1046

3G 1064

10G 1024

6G 1046

8G 1046

10G 1046

400

350

300

250

225

200

175

150

125

100

1

2

10 20 30 40 50 70 100 200 300 400 500 700 1000 2000 3000 5000 7000

16

CHP NOMOGRAM.TO AID SELECTION OF EXHAUST GAS HEAT EXCHANGERS FOR CHP.

Co

olant tem

perature

For exhaust gas temperatures up to max. 250 °C only

AWR type:

Ex

haust gas temperature in °C

Exhaust gas mass fl ow rate in kg/h

CHP NOMOGRAMTO AID SELECTION OF EXHAUST GAS HEAT EXCHANGERS FOR CHP

17

List of information required.for designing condensing heat exchangers.In order for BOMAT to design a suitable heat exchanger, the following data is required:

Basis of calculationsFuel: Natural gas

Exhaust gas outlet temperature downstream of heat exchanger: 80 °C

Exhaust gas side pressure loss in AWR: < 10 mbar

Example 1

Exhaust gas mass flow rate in CHP unit: 70 kg/h

Exhaust gas temperature: 175 °C

Coolant temperature: 50 °C

» Heat exchanger selected: type 1032

Approximate calculation of sensible heating output of heat exchangerExhaust gas mass fl ow rate in kg/h × 0.0003 × (exhaust gas temperature – 80 °C)

Example 2:

3000 kg/h × 0.0003 × (225 °C – 80 °C) = 130.5 kW

Through condensation, the heating output may be increased by up to 50 %.

Fuel: Fuel oil, natural gas, biogas, sewer gas or ....

Exhaust gas mass flow rate in CHP unit: If the

exhaust gas mass fl ow rate is not known, the

volume fl ow may be provided instead, together with

the exhaust gas temperature

Exhaust gas temperature: Temperature of exhaust

gas at entry to BOMAT heat exchanger

Coolant temperature: The colder the coolant in the

heat exchanger, the higher the energy yield. In order to

exploit the condensing eff ect, the coolant temperature

must be below the dew point of the exhaust gas.

Maximum possible exhaust heat exchanger pressure loss: We usually design the exhaust gas

heat exchanger such that the pressure loss of the

heat exchanger on the exhaust gas side is less than

10 mbar.

Example 2

Exhaust gas mass flow rate in CHP unit: 3000 kg/h

Exhaust gas temperature: 225 °C

Coolant temperature: 35 °C

» Heat exchanger selected: type 8G 1046

If you would like us to provide individual calculations or designs, please contact us:

[email protected] T +49(0)7551.809970

F +49(0)7551.809971

18

THE BOMAT SOLUTION TO COMBUSTION ACIDS: NEUTRALISATION.HELP PROTECT THE ENVIRONMENT WITH OUR RNA SERIES.Condensate from condensing systems causes environmental pollution.For each litre of fuel oil, 0.8 l acidic condensate (diluted

acid) is created; per m³ natural gas this is about 1.5 l.

This acid causes immense damage to the environment

(e.g. acid rain).

RECOMMENDATION

Code of Practice ATV-DVWK-A 251 governs the use of neutralising systems for condensate from condensing boilers. In general, however, the use of a neutralising system is recommended for the treatment of condensate before it is introduced into public waste water systems.

Specifi cations of our neutralising and cleaning systems can be found on pages 32 – 33.

The solutionBOMAT RNA CLEANING AND NEUTRALISING SYSTEM

Acidic condensate damages drainage pipes.Many waste water and drainage pipes are made of

materials that are not acid-resistant in the long term

(e.g. concrete or grey cast iron). Acidic condensate from

a condensing system may a� ack these and even destroy

such pipes.

BOMAT has been producing cleaning and neutralising systems (RNA) for over 30 years. In that time over 40,000 units have been installed. These systems exhibit high reliability, a long service life and ease of maintenance.

RNA COMFORT This unit features a patented backfl ushing system to regenerate the neutralising granulate, removable fi lter baskets and removable pre-fi lters to assure simple maintenance, and an integrated siphon for a high level of safety. These RNA units can also be fi � ed with condensate pumps to overcome height diff erences.

19

BOMAT PROFITHERM UP TO 160 kW 20




BOMAT MINITHERM CHP SERIES 28

BOMAT PROFITHERM CHP SERIES 30

ACCESSORIES BOMAT NEUTRALISING SYSTEMS 32FOR HEATING AND INDUSTRY

BOMAT NEUTRALISING SYSTEMS 33FOR USE IN CHP PLANT

ENGINEERING INFORMATION 34

FLUE AND EXHAUST GAS HEAT EXCHANGERSSPECIFICATION

20

BOMAT PROFITHERM UP TO 160 kW COMBUSTION OUTPUT

BOMAT Profi therm up to 160 kW



Heat exchangers for flue gas heat recovery, for boilers with pressure-jet gas or oil burners (other applications on request). For water-side integration into dual circuit system or boiler return.

Heat exchanger surface in corrosion-proof ceramic Height-adjustable feet Condensate drain Insulation White coated sheet steel casing Flue gas outlet with coupling Condensate hose AWR safety unit with 120 °C safety temperature limiter for fl ue pipe and 80 °C thermostat for heating water Cleaning apertures at fl ue gas connector and heat exchanger

FEATURES

Profitherm Product number

AWR G 314-22 Up to 22 kW* combustion output 94 510 00

Flue gas inlet: Dint 130

Flue gas outlet: DN 80 coupling

AWR G 514-45/D 150** Up to 45 kW* combustion output 94 709 00




Flue gas inlet: Dint 130Flue gas outlet: DN 125 coupling








Upright brackets are included for freestanding installation.

* Design basis: 200 °C fl ue gas inlet temperature, 70 °C fl ue gas outlet temperature, 40 °C average coolant temperature, Lambda 1.2. To optimise energy savings the water inlet temperature should be in the 30 – 40 °C range under operating conditions.

** Please note: The heat exchanger is mounted behind the boiler and must be sealed on site using fl ue gas sleeve gaskets. Freestanding installation is only possible if the requisite upright bracket set, product no. 90 790 00, is additionally ordered.

Accessories Product number

Upright bracket set for freestanding installation of heat exchangers 90 790 00

Flue widening adaptor from 180 to 200 mm (material: stainless steel) 80 093 00

Flue gas sleeve gasket Ø 130 92 369 00



Cleaning kit for AWR G 514-45 and AWR G 524-60 94 713 00

Cleaning kit for AWR G 1024-160 94 714 00

21

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20

30

40

50

60

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BOMAT Minitherm CHP series Accessories

Engineering information

FOOTPRINT AND CONNECTION DIMENSIONSBOMAT AWR G 314-22, G 514-45, G 524-60, G 1024-160 SERIES

* Note the neutralising system inlet height. ** Selectable; please specify when ordering.

All data is without guarantee. Subject to change without notice.

Profitherm AWR G 314-22 G 514-45 G 524-60 G 1024-160Boiler size (max. combustion output) kW 22 45 60 160

Water capacity litres 2.3 5.5 8.6 14

Flue gas HLSC, max. setting °C 120 120 120 120

Permissible operating pressure bar 3 3 3 3

Max. permiss. flue gas inlet temp. °C 250 250 250 250

Max. permiss. water outlet temp. °C 80 80 80 80

Max. permiss. flue pressure drop Pa 100 100 100 100

Weight kg 33 35 44 71

Dimensions (mm) A 482 640 650 1205

B 140 130 110 130

C 194 195 240 240

D min 690 655 695 730

D max 880 805 845 1180

E min 540 520 530 530

E max 730 670 680 880

F 220 240 270 270

G min 366 325 315 375

G max 556 475 465 725

H min 262 215 210 230

H max 452 365 360 580

Flue gas inlet I int.** 130 130/150 130/150 180

Flue gas outlet J int. (coupling) 80 125 125 160

Water connections K R1 (DN 25) R1 (DN 25) R1 (DN 25) R1 (DN 25)

L 120 65 55 55

M* min 155 155 155 155

M max 420 305 305 505

N Rc 1 (DN 25) – – –

Z 372 576 612 1171

Key1 Water inlet2 Water outlet3 Flue gas inlet *4 Flue gas outlet *5 Condensate outlet Dint 40 mm, condensate hose Dext 25 mm6 Insertable, height-adjustable foot; adjustment range 190 mm

(AWR 314), 150 mm (AWR 514 / 524), 350 mm (AWR 1024)7 Control panel with 120 °C high limit safety cut-out and max. 80 °C

heating water thermostat

* make connections free of weight and free of vibrations (for example with conduit pipes or compensators)

Keya AWR G 314-22b AWR G 514-45c AWR G 524-60d AWR G 1024-160

AWR G 314-22 AWR G 514-45

To ensure maximum operational reliability of the system, this combination should be checked prior to installation with the manufacturers of the burner, boiler and fl ue pipework. Particular a� ention should be paid to the pressure drop levels on the fl ue gas side of the boiler, AWR unit and fl ue gas path, and also to the burner fan pressure.

AWR G 524-60 AND G 1024-160

AWR G 314-22AWR G 524-60 AND G 1024-160AWR G 514-45

Pressure drop on water side

Pre

ssur

e dr

op

mba

r

Flow rate kg / h

Pressure drop on fl ue gas side

Pre

ssur

e dr

op

mba

r

Burner load, kW(at fl ue gas temp. = 160 °C; Lambda = 1.2)

BOMAT Profi therm CHP series

0.10

0.20

0.50

1.00

Product no.: 97 119 10 (27/15)

22





Heat exchangers for flue gas heat recovery, for boilers with pressure-jet gas or oil burners (other applications on request).

Ceramic heat exchanger Flow switch Deaerator Height-adjustable substructure Flue gas outlet in polypropylene with coupling Condensate drain incl. condensate hose Insulation White coated sheet steel casing Water connections Flue gas inlet with connector BOMAT safety control panel incl. 120 °C fl ue gas temperature limiter; AWR pump control with cable and plug

FEATURES











Accessories for industrial applications Product number

Flue gas fan specially designed for plant configuration On request

Speed controller for flue gas fan On request

Accessories for applications with flue gas inlet temperatures above 250 °C On request

Condensate pan made from stainless steel On request

Maintenance kit Product number

Maintenance kit for Profitherm AWR G 532-90, AWR G 1032-200, AWR G 1064-350 90 785 00

* Design basis: 200 °C fl ue gas inlet temperature, 70 °C fl ue gas outlet temperature, 40 °C average coolant temperature, Lambda 1.2. To optimise energy savings the water inlet temperature should be in the 30 – 40 °C range under operating conditions.




23

30

201000 5000 10000

405060

80

100

200

300

400500

100 500200

2

5

4

3

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Engineeringinformation


FOOTPRINT AND CONNECTION DIMENSIONSBOMAT AWR G 532-90, G 1032-200 AND G 1064-350 SERIES

* Other diameters on request. ** Note the neutralising system inlet height. *** Incl. adaptor to 25 mm.


Profitherm AWR G 532 G 1032 G 1064

Boiler size (max. combustion output) kW 90 200 350Water capacity litres 5.4 7.7 17.5Flue gas HLSC, max. setting °C 120 120 120Permissible operating pressure bar 3 3 3Max. permiss. flue gas inlet temp. °C 250 250 250Max. permiss. water outlet temp. °C 80 80 80Max. permiss. flue pressure drop Pa 100 100 100Weight kg 70 90 146Dimensions (mm) A 688 1188 1165

C 282 282 411D min 1300 1005 1218D max 1730 1205 1418E min 1062 785 988E max 1492 985 1188F 220 220 220G min 684 390 545G max 1113 590 745H min 389 220 355H max 816 420 555I* int. min 155 185 255J int. (coupling) 125 160 200K (connector) 25 40*** 40***

P 270 270 385M** min 293 155 259M max 723 355 459N 115 115 100

Key1 Rc 1 (DN 25) (water inlet with

fl ow switch 6 l/min.)2 Rc 1 (DN 25)

(water outlet with deaerator)

Keya AWR G 532-90b AWR G 1032-200c AWR G 1064-350

AWR G 532-90 AWR G 1032-200 AND G 1064-350

3 Flue gas inlet *4 Flue gas outlet * (can be

rotated on AWR G 532-90)5 Condensate outlet

Pressure drop on water sideP

ress

ure

dro

p m

bar

Flow rate kg/h


Pre

ssur

e dr

op

mba

r


0.05

0.10

0.20

0.500.60

Product no.: 97 122 10 (03/14)


24






Ceramic heat exchanger Flow switch Deaerator Height-adjustable substructure 3-fl ange* fl ue gas outlet in polypropylene Condensate drain incl. condensate hose Insulation White coated sheet steel casing Water connections 3-fl ange* fl ue gas inlet BOMAT safety control panel incl. 120 °C fl ue gas temperature limiter; AWR pump control with cable and plug

FEATURES


AWR 4G 1024-400 Up to 400 kW** combustion output 94 693 20

















Maintenance kits Product number

Maintenance kit for Profitherm AWR 4G 1024-400 to AWR 6G 1024-800 90 786 00

Maintenance kit for Profitherm AWR 7G 1024-1000 90 788 00

* Choice of connection options

** Design basis: 200 °C fl ue gas inlet temperature, 70 °C fl ue gas outlet temperature, 40 °C average coolant temperature, Lambda 1.2. To optimise energy savings the water inlet temperature should be in the 30-40 °C range under operating conditions.

25

M

40J

I

GH

E

D

265

265

1250

68

0

100 500 1000

1

333

4 4 4

5

2

d

a

b

c





FOOTPRINT AND CONNECTION DIMENSIONSBOMAT AWR 4G 1024-400 TO AWR 7G 1024-1000 SERIES

* Note the neutralising system inlet height | All data is without guarantee. Subject to change without notice.

Profitherm AWR 4G 1024-400 5G 1024-600 6G 1024-800 7G 1024-1000

Boiler size (max. combustion output) kW 400 600 800 1000

Water capacity litres 32.5 40.5 48.5 56.5

Pressure drop on water side Kv 18 30 35 41

Flue gas HLSC, max. setting °C 120 120 120 120

Permissible operating pressure bar 3 3 3 3

Max. permiss. flue gas inlet temp. °C 250 250 250 250

Max. permiss. water outlet temp. °C 80 80 80 80

Max. permiss. flue pressure drop Pa 100 100 100 100

Weight kg 228 262 289 327

Dimensions (mm) D min 1550 1550 1550 1760

D max 1900 1900 1900 2160

E min 1114 1196 1278 1505

E max 1464 1546 1628 1905

G min 415 415 415 530

G max 765 765 765 730

H min 390 390 390 430

H max 740 740 740 830

I int. min 255 255 255 305

J int. (coupling) 250 250 250 315

M* min 285 285 285 285

M max 635 635 635 635

Key1 Rp 5/4 (water inlet with fl ow switch

and deaerator)2 Rp 5/4 (DN 32) (water outlet with

BDF valve)3 Flue gas inlet * (choice of position)4 Flue gas outlet * (choice of position)5 DN 40 condensate outlet

Note the neutralising system inlet height


Keya AWR 4G 1024-400b AWR 5G 1024-600c AWR 6G 1024-800d AWR 7G 1024-1000


Pre

ssur

e dr

op

mba

r


2.00

1.00

0.50

0.20

0.10

0.06

0.04

Product no.: 97 123 10 (27/15)

connector

26






Ceramic heat exchanger Flow switch Deaerator Height-adjustable substructure 3-fl ange* fl ue gas outlet in polypropylene Condensate drain incl. condensate hose Insulation White coated sheet steel casing Water connections 3-fl ange* fl ue gas inlet BOMAT safety control panel incl. 120 °C fl ue gas temperature limiter for fl ue pipe; AWR pump control with cable and plug

FEATURES




Flue gas outlet: DN 355 connector







Higher output ranges On request






Maintenance kit Product number

Maintenance kit for Profitherm AWR G 1046 series 90 787 00

* Choice of connection options

** Design basis: 200 °C fl ue gas inlet temperature, 70 °C fl ue gas outlet temperature, 40 °C average coolant temperature, Lambda 1.2. To optimise energy savings the water inlet temperature should be in the 30-40 °C range under operating conditions.

27

3

200 1000 2000

32

4 4

5

D

E

H

M

1000

3

14

815

J

I

1234290 9

2

114

0

92

2901

6

2

a

b

c

Pre

ssur

e dr

op

mba

r







* Note the neutralising system inlet height | All data is without guarantee. Subject to change without notice.

Profitherm AWR 6G 1046-1400 7G 1046-1800 8G 1046-2200

Boiler size (max. combustion output) kW 1400 1800 2200

Water capacity litres 98 112 127

Flue high limit safety cut-out (max.) °C 120 120 120

Permissible operating pressure max. bar 3 3 3

Max. permiss. flue gas inlet temp. °C 250 250 250

Max. permiss. water outlet temp. °C 80 80 80

Max. permiss. flue pressure drop Pa 100 100 100

Pressure drop on water side Kv 39 54 70

Weight kg 542 595 647

Water connection (fl. DIN 2365 / PN 6) DN 65 DN 65 DN 65

Dimensions (mm) D min 1995 1995 1995

D max 2355 2355 2355

E min 1515 1595 1675

E max 1875 1955 2035

H min 516 516 516

H max 876 876 876

I int. min 355 405 405

J int. (connector) 355 355 400

M min* 330 330 330

M max 690 690 690

Key1 Flange connection of water inlet to

deaerator2 Flange connection of water outlet to

BDF valve3 Flue gas inlet *

(Ø and position selectable)4 Flue gas outlet *

(Ø and position selectable)5 DN 40 condensate outlet

Note the neutralising system inlet height 6 Flow switch

(switching point: 12 l / min)


Keya AWR 6G 1046-1400b AWR 7G 1046-1800c AWR 8G 1046-2200

FOOTPRINT AND CONNECTION DIMENSIONSBOMAT AWR 6G 1046-1400 TO 8G 1046-2200 SERIES

Adj

ustm

ent

rang

e:

500

mm

Plan view shown without top cover

3.00

2.00

0.80

0.40

0.20

0.08

0.050.06

0.10

0.30

0.500.60

1.00

4.00

Product no.: 97 125 10 (21/14)

28

BOMAT MINITHERM CHP SERIESMinitherm exhaust gas heat exchangers for heat recovery from CHP units.

Rotatable exhaust gas inlet header* with cleaning cover and fl ange adaptor for diff erent exhaust pipe Ø Incl. protective cover Rotatable exhaust gas outlet bend with coupling and gasket to connect to exhaust pipe, incl. cleaning cover and condensate drain AWR safety unit, 230 V, with indicator lights, 80 °C temperature limiter for water temperature plus 120 °C high limit safety cut-out to protect exhaust pipe Cleaning brush for heat exchanger pipes 1.5 m condensate hose, DN 25** (plastic) with adaptor to DN 40 Welded mounting plate for height-adjustable base frame or wall fi xture (please order accessories separately)

FEATURES

Minitherm Product number

AWR G 1504 Flue gas inlet: Rp1 (DN 25) 99 614 20

AWR G 1012 Flue gas inlet: Ø selectable (see accessories) 94 650 00







Exhaust gas inlet connector, stainless steel, incl. M14 test port and gasketDN 50 (Ø 57x2.6)DN 65 (Ø 76x2.6)DN 80 (Ø 88.9x3.2)Ø 100 (Ø 104x2)Ø 125 (Ø 129x2)

80 160 6580 160 2580 160 4580 120 4080 130 40

DN 65 adaptor to DIN 2642 PN 10 flangeDN 80 adaptor to DIN 2642 PN 10 flange

80 160 75

80 160 85

Exhaust gas reducer DN 125 / DN 80 DN 125 / DN 110

95 634 10

95 634 00

Wall mounting bracket with swivel function (adjustable from 0 – 85°) for vertical or horizontal mounting of BOMAT AWR Minitherm; dimensions: 320x220x74

80 340 20

Base frame with swivel function (angle adjustable from 0 – 85°)for vertical or horizontal mounting of BOMAT AWR Minitherm; dimensions: 800x800x1720

Height adjustable:Vertical position: Exhaust gas outlet: min. 260 mm, max. 740 mmHorizontal position: Exhaust gas outlet: min. 465 mm, max. 1595 mm

79 380 50




On AWR G 1504:

* Rotatable in 90° increments – connector Rp1 (DN 25)

** DN 32 condensate hose

29

100

50

10

50 200 10000

20

200

1000 5000

2

A7

1

3

5

4

6

BC

D

EG

F

8

2

7

1

5

3

A

EG

F

8

6

4

BC

117 78

158

12

138

EG

F

10

6

7

9

11

D

C B

D

5

2

100 500

a

b

Pressure drop on exhaust gas side < 10 mbar. Maximum permissible exhaust gas sound pressure level 70 dB(A). Provide suitable protection on site if sound pressure is higher. All data is without guarantee. Subject to change without notice.

Minitherm AWR G 1504 G 1012 G 1016 G 1022 G 1512 G 1516 G 1522

Water capacity litres 3.9 16 15 13 24 23 21

Weight kg 14 65.6 67 69.5 74.5 76.5 80

Dimensions (mm) A 1852 1605 1605 1605 2104 2104 2104

B 1692 1348 1348 1348 1848 1848 1848

C 1430 918 918 918 1418 1418 1418

D 90 192 192 192 192 192 192

E 317 591 591 591 596 596 596

F 290 470 470 470 470 470 470

G 147 457 457 457 457 457 457

Key1 Water inlet G 1 1/2 (DN 40)2 Water outlet G 1 1/2 (DN 40)3 Exhaust gas outlet *, rotatable

(coupling DN 125 PP)4 Exhaust gas inlet *, rotatable

(exhaust gas inlet connector = accessory)5 DN 40 condensate outlet6 AWR safety unit7 Mounting panel (for wall mounting

bracket or base frame = accessory)


FOOTPRINT AND CONNECTION DIMENSIONSBOMAT AWR G 1012 TO G 1522 SERIES

Exhaust pipe HLSC, max. se� ing 120 °C

Max. permiss. operating pressure 6 bar

Max. permiss. exhaust gas inlet temp. 250 °C

Max. permiss. water outlet temp. 85 °C

Max. permiss. exhaust pressure drop 5000 Pa

AWR G 1012 TO G 1022 AWR G 1504

AWR G 1512 TO G 1522

AWR SAFETY UNIT(ATB/TB 120 °C / 80 °C)

max. 85˚

Pre

ssur

e dr

op

mba

r

Flow rate kg/h

Pressure drop on water side





8 Cleaning aperture (2nd cleaning aperture at top under protective cover, but not on AWR G 1504)

9 Water inlet G 1/2 (DN 15)10 Water outlet G 1/2 (DN 15)11 DN 32 condensate outlet12 Exhaust gas inlet Rc1 (DN 25)13 Exhaust gas outlet (coupling

DN 80 PP)

Keya AWR G 1504b AWR G 1012 / G 1016 /

G 1022 / G 1516 / G 1522

Product no.: 97 585 11 (03/14)

30

BOMAT PROFITHERM CHP SERIESProfitherm exhaust gas heat exchanger for heat recovery from CHP units.

Exhaust gas inlet chamber made from stainless steel with cleaning cover and fl ange adaptor for various exhaust pipe Ø (accessory) Exhaust gas outlet chamber made from stainless steel with cleaning cover, condensate drain connector and fl ange adaptor for various exhaust pipe Ø (accessory) Modular condensing heat exchanger design with ceramic pipes Height-adjustable base frame Flow switch on coolant side Injection cleaning for easy manual maintenance (included) or pipe cleaning bank 1.5 m condensate hose, DN 25 (plastic) with adaptor to DN 40 Mineral wool insulation and powder-coated sheet steel casing Max. permissible exhaust gas sound pressure level 70 dB(A); provide suitable protection on site if sound pressure is higher

FEATURES




AWR 1032 Product number AWR 1064 Product number

AWR IG 1032 99 700 05 AWR IG 1064 99 672 50

AWR IIG 1032 99 700 10 AWR IIG 1064 99 672 30

AWR IIIG 1032 99 700 15 AWR IIIG 1064 99 672 40

Accessories AWR 1032 Product number AWR 1064 Product number

Cleaning bank, stainless steel, 3 spray pipes, DN 25 (R1) connector

90 751 70 Cleaning bank, stainless steel, 7 spray pipes, DN 25 (R1) connector

90 751 60

Industry safety control panel 96 804 00 Industry safety control panel 96 804 00

Exhaust gas inlet connector, incl. M14 test port and gasket

Exhaust gas inlet connector, incl. M14 test port and gasket

Stainless steel Ø 100 (Ø 104x2)Stainless steel Ø 125 (Ø 129x2)Stainless steel Ø 150 (Ø 154x2)

80 120 4080 130 4080 140 40

Stainless steel Ø 125 (Ø 129x2)Stainless steel Ø 150 (Ø 154x2)Stainless steel Ø 200 (Ø 204x2)Stainless steel Ø 250 (Ø 254x2)

80 120 1580 130 1580 140 1580 145 15

Exhaust gas outlet connector, incl. sensor well for exhaust gas HLSC and gasket

Exhaust gas outlet connector, incl. sensor well for exhaust gas HLSC and gasket

Stainless steel Ø 100 (Ø 104x2)Stainless steel Ø 125 (Ø 129x2)Stainless steel Ø 150 (Ø 154x2)

80 120 5080 130 5080 140 50

Stainless steel Ø 125 (Ø 129x2)Stainless steel Ø 150 (Ø 154x2)Stainless steel Ø 200 (Ø 204x2)Stainless steel Ø 250 (Ø 254x2)

80 120 2080 130 2080 140 2080 145 20

Exhaust gas outlet connector (plastic exhaust system), incl. sensor well for HLSC, gasket and retaining ring

Exhaust gas outlet connector (plastic exhaust system), incl. sensor well for HLSC, gasket and retaining ring

PPs coupling With DN 110 gasketWith DN 125 gasket

80 120 7080 130 70

PPs coupling With DN 125 gasketWith DN 150 gasketWith DN 200 gasket

80 120 9080 130 9080 140 90

Manifold kitAWR 2G 1032/1064AWR 3G 1032/1064

99 194 0599 194 15

Manifold kitAWR 2G 1032/1064AWR 3G 1032/1064

99 194 0099 194 10

b500

40

20

1000 5000 10000

30

506080

100

200

300

400

2

A

3

4

5

7

1

6

3

4

B

7

8

C

F

1000

MH

G

ED

a b

J

31

FOOTPRINT AND CONNECTION DIMENSIONSBOMAT AWR 1032 AND 1064 CHP SERIES

* 80 mm higher with cleaning bank ** On 1032 infi nitely height adjustable +200 mm ** On 1064 infi nitely height adjustable +175 mm

Maximum permissible exhaust gas sound pressure level 70 dB(A). Provide suitable protection on site if sound pressure is higher.


Profitherm AWR IG 1032 IIG 1032 IIIG 1032 IG 1064 IIG 1064 IIIG 1064

Water capacity litres 7.7 15.4 23.5 17.5 35 52.5

Weight kg 90 153 216 146 248 350

Water connections R 1 (DN 25) R 1 (DN 25) R 1 (DN 25) R 1 1/4 (DN 32) R 5/4 (DN 32) R 5/4 (DN 32)

Dimensions (mm) A 1308 1308 1308 1448 1448 1448

B 1188 1188 1188 1165 1165 1165

C 288 288 288 500 500 500

D min 1130 1458 1758 1222 1560 1860

E** min* 882 1210 1510 955 1296 1596

F 220 220 220 220 220 220

G** min 520 848 1148 539 876 1176

H** min 353 377 377 339 376 376

I 125 125 125 250 250 250

J 125 125 125 250 250 250

K R 1 1/4 (DN 32) R 1 1/4 (DN 32) R 1 1/4 (DN 32) R 1 1/4 (DN 32) R 1 1/4 (DN 32) R 1 1/4 (DN 32)

M** min 244 244 244 204 204 204

Key1 Water inlet

(item 8 with fl ow switch)2 Water outlet3 Exhaust gas inlet * (choice of position)4 Exhaust gas outlet * (choice of position)5 Condensate outlet6 Insertable foot, height-adjustable7 Pipe cleaning bank (optional)


Keya AWR G 1032b AWR G 1064

Exhaust pipe HLSC, max. se� ing 120 °C

Max. permiss. operating pressure 3 bar

Max. permiss. exhaust gas inlet temp. 400 °C

Max. permiss. water outlet temp. 80 °C

Max. permiss. fl ue pressure drop 5000 Pa

AWR IG 1032 / 1064

AWR IIG 1032 / 1064

AWR IIIG 1032 / 1064

Pressure drop on water side (per pipe bank)

Pre

ssur

e dr

op

mba

r

Flow rate kg/h





Product no.: 97 126 10 (27/15)

32

ACCESSORIES BOMAT RNA CLEANING AND NEUTRALISING SYSTEMS FOR HEATING AND INDUSTRIAL APPLICATIONSThe acidifying elements contained in fuel oil or natural gas (e.g. sulphur) cause aggressive acids (such as sulphuric acid) to be formed during combustion and subsequent condensation. BOMAT neutralising and cleaning systems treat (neutralise) this acidic condensate so that it is suitable to be fed into the public waste water system. Note: In Germany, Code of Practice ATV-DVWK-A 251 regulates the discharge of condensate from combustion equipment. Acidic condensate from condensing systems can destroy waste water pipework.

Integral siphon Integral oil separator Replaceable absorber element for particle separation Large sedimentation volume for sludge se� ling Easy maintenance thanks to backfl ushing function and removable fi lter basket for neutralising granulate Compact construction and wide range of accessories

BENEFITS OF BOMAT RNA SYSTEMS

RNA Product number

RNA-Komfort oil/gas (up to 100 kW boiler output) with backflushing functionVessel with 2 connectors: Condensate inlet (bo� om), outlet (top), fi lter basket with granulate, fi lter foam, fast-coupling backfl ushing unit, cover with hole

Inlet height: 35 mm, outlet height: 115 mm

Dimensions: LxWxH 322 x 200 x 177 mm

Maintenance package

90 830 40

90 831 20

RNA-Komfort XL oil/gas (up to 500 kW boiler output) with backflushing functionVessel with 2 connectors: Condensate inlet (bo� om), outlet (top), fi lter basket with fi lter holder and granulate, fi lter foam, fast-coupling backfl ushing unit, cover

Inlet height: 45 mm, outlet height: 160 mm


Maintenance package

90 830 60

90 831 30

RNA-Komfort XL oil/gas (up to 500 kW boiler output) with backflushing function and integral condensate pumpVessel with connectors for condensate inlet (bo� om), fi lter basket with fi lter holder and granulate, fi lter foam, condensate pump (230 V/50 Hz with standard plug), fast-coupling backfl ushing unit, cover, incl. fl oat switch and potential-free fault indicator output (pump diagram on request), 192 l/h with 3 m delivery head

Inlet height: 45 mm


Maintenance package

90 830 50

90 831 30

Condensate pump with vesselIncl. fl oat switch and potential-free fault message output (pump diagram on request), 192 l/h with 3 m delivery head, 230 V/50 Hz with standard plug


90 730 20




33

ACCESSORIES BOMAT NEUTRALISING SYSTEMS FOR USE IN CHP PLANT

RNA Product number

Komfort SE CHP (max. condensate rate 6 l/h)1st condensate pre-cleaning stage with siphon eff ect* consisting of ves-sel with fi lter basket, activated charcoal fi lling, cover, undergravel fi lter, absorber, 2x connectors for condensate inlet and overfl ow in 2nd vessel

2nd neutralising stage, consisting of vessel with fi lter basket, granu-late fi lling, cover, 2x connectors ext. Ø 25 mm for condensate inlet and outlet. Fast-coupling fl ushing unit, incl. 150 mm connecting hose for the two vessels.


Maintenance package

90 840 00

90 831 10

RNA Maxi CHP (max. condensate rate 15 l/h)Vessel with cover, condensate inlet and outlet connectors, Dext. 25

1st se� lement chamber with siphon eff ect* for sedimentation of solid combustion products

2nd condensate pre-cleaning stage consisting of 2 clipped-in fi lter bas-kets with charcoal fi lling and undergravel fi lter

3rd neutralising stage, consisting of 2 clipped-in fi lter baskets with granulate fi lling, 2x fast-coupling fl ushing units

4th se� lement chamber with siphon eff ect


Maintenance package

90 850 00

90 831 40

* Siphon seal water height = 110 mm

Note: Since higher exhaust gas pressures may occur in CHP units, an additional siphon may have to be provided on site.


Condensate hose kit, consisting of:1.5 m NW 19 condensate hose1 adaptor DN 40 x 25DN 40 slide coupling2 adaptors DN 252 hose clamps

Condensate hoseNW 19, by the metre as required

Adaptor for condensate hoseNW 19 to DN 25

95 317 10

32 860 05

32 850 60

The acidifying elements contained in fuels (e.g. sulphur) cause aggressive acids (such as sulphurous acid) to be formed during combustion and subsequent condensation. Combustion engines release additional unburnt hydrocarbons into the exhaust system. These oil residues become separated during condensation and therefore enter the neutralising process. Activated charcoal absorbs unburnt hydrocarbons.





Condensate pre-cleaning stage with activated charcoal fi lling and undergravel fi lter Easy maintenance thanks to backfl ushing function and removable fi lter basket for neutralising granulate and activated charcoal Integral siphon with 110 mm seal water height (for higher exhaust gas pressures use a separate siphon)

BENEFITS OF BOMAT NEUTRALISING SYSTEMS

34

A1

A2

A3




BOMAT ENGINEERING INFORMATIONINTEGRATION OF FLUE AND EXHAUST GAS HEAT EXCHANGERS ON THE GAS SIDE

CHP unit / industrial application Bypass – same/existing fl ue/exhaust pipe


Flow switch

CHP unit

Heat generator

Close1)

Open1) Open 1) 2)

(optional fl ue/exhaust gas damper)


Flue/exhaust gas damper (on site)

Flue/exhaust gas ATB (on site)


Boiler / CHP unit Standard application

AWR

Boiler,CHP unit

Heat generator

Condensing-compatible fl ue/exhaust pipe(PPS or stainless steel)

Water thermostat (optional / on site)


Flow switch

Flue/exhaust gas ATB (optional / on site)

AWR

CHP unit / industrial application Bypass – separate/new fl ue/exhaust pipe

AWR

CHP unit

Heat generator

Flow switch

Close

Open





Flue/exhaust gas damper (on site) 1)

35

A4

A5





Industrial applicationBypass with fan – same/existing fl ue/exhaust pipe

Industrial applicationBypass with fan – separate/new fl ue/exhaust pipe

1) The fl ue/exhaust gas path must always be open in one direction. A CHP unit must not be operated with dampers closed.

2) This damper must only be closed during maintenance.

Note: The images shown are intended as examples only and merely provide a greatly simplifi ed illustration.

ATB = Flue/exhaust gas temperature limiter HK = Heating circuitHT = High temperature heating circuitM = Motor/actuatorNT = Low temperature heating circuitSTB = High limit safety cut-out

Heat generator

AWR


Flue/exhaust gas STBFan

Flow switch



Hardening furnace,meltingfurnace, enamelling, etc. ...

El. fl ue/exhaust gas damper (on site)

Condensing-compatible fl ue/exhaust pipe(PPS or stainless steel)

AWR

Heat generator

Hardening furnace,meltingfurnace, enamelling, etc. ... Flow switch


Fan

El. fl ue/exhaust gas damper (on site)



36

W1

M M

W2

W3

M M

M M




BOMAT ENGINEERING INFORMATIONINTEGRATION OF FLUE AND EXHAUST GAS HEAT EXCHANGERS ON THE WATER SIDE

Main return is suitable for use of condensing technology

Connection to condensing-compatiblepartial mass flow

Using an external heating circuit

AWR

Boiler,CHP unit, ...

Heat generator

DHW heating

HK1 HK2

Flow switch


AWR

Heat generator


DHW heating

HT NT


AWR

Heat generator


DHW heating

Flow switch

HT HT

e.g. air heater


Flow switch

W4





The benefits are as follows: Bypass

If the fl ue gas heat exchanger is connected to the

bypass, the process heat source is not aff ected by

the heat exchanger being switched on/off .

Operational reliability

Regardless of whether heat is recovered, the heat

exchanger is serviced or faults occur, the operational

reliability of the process heat source is not aff ected.

Design

The fl ue gas heat exchanger is not sized according

to the amount of heat available in the fl ue gas, but

rather to the output of the heat consumer. This

allows long runtimes for the heat recovery system

and therefore economical operation.

Hydraulics

BOMAT fl ue gas heat exchangers can also supply

heat to an independent heating circuit separate from

the rest of the system. It is also possible to connect

heating circuits containing glycol, e.g. for pre-heating

stages of ventilation equipment, to BOMAT fl ue gas

heat exchangers (the colder the coolant through the

heat exchanger, the higher the energy yield).

Condensing technology and self-cleaning If the coolant temperature is below the dew point

of the fl ue gas, condensation occurs in the heat

exchanger. This results in increased heat recovery,

while the condensate also cleans the heat exchanger.

The use of waste heat from industrial processes is one of the most lucrative applications in the fi eld of energy

saving. BOMAT fl ue gas heat exchangers enable waste heat even from complex industrial processes to be

recovered and fed into the heating circuit.

37

ADDITIONAL BENEFIT

INDUSTRIAL AND PROCESS HEAT RECOVERY

Please note: The colder the return temperature at the heat exchanger inlet, the higher the energy yield

Note: The images shown are intended as examples only and merely provide a greatly simplifi ed illustration.

Connection to buffer/stratification cylinder

ATB = Flue/exhaust gas temperature limiter HK = Heating circuitHT = High temperature heating circuitM = Motor/actuatorNT = Low temperature heating circuitSTB = High limit safety cut-out

AWR


Heat generator

Flow switch


Buff er/stratifi cation cylinder

Cold water

Freshwater module

DHW

Heating system fl ow

Heating system return

38

108

106

104

102

100

98

96

9420 25 30 35 40 45 50 55 60 65 70 75




BOMATENGINEERING INFORMATION

Efficiency improvement In condensing and fl ue gas heat recovery systems,

the water-side temperature level at which the heat

exchanger is operated is decisive for effi ciency. The

colder the return (coolant mass fl ow), the be� er the

energy yield and the be� er the heat exchanger self-

cleaning eff ect that occurs as a result of condensation.

EFFICIENCY AS A FUNCTION OF COOLANT TEMPERATURE

EXAMPLE

A 100 kW boiler system has a combustion effi ciency without BOMAT heat exchanger of about 91 %.

With a BOMAT heat exchanger the effi ciency increases to 101 %.

The heat exchanger output is 100 kW x 10 % = 10 kW.

For a temperature diff erential between the heat exchanger fl ow and return of 10 K, the AWR pump must provide a mass fl ow rate of 861 kg/h.

Design of AWR pump The mass fl ow rate required to cool the fl ue gas heat

exchanger is calculated for a temperature diff erential

between the heat exchanger inlet and outlet of

5–10 K (standard applications).

The water-side pressure drop of the heat exchanger

can be found in the relevant datasheets.

The output of the fl ue gas heat exchanger can

be found from the effi ciency improvement of the

system; see diagram below.

The required minimum water volume of the heat

exchanger should be borne in mind when selecting

the pump.

Coolant temperature °C

Effi

cie

ncy

NC

V [%

]

Profitherm – oil fired Profitherm – gas fired

3939





BOMATENGINEERING INFORMATION

Condensing / flue pipes In heat generators that use condensing technology, the

fl ue gas is removed via a fl ue pipe. This fl ue pipe may be

drawn through an existing chimney or suitable shaft.

Flue pipes can also be fi � ed on the outer walls of the

building. Flue pipes must be pressure-tight, moisture-

resistant, corrosion-resistant and approved by the

building standards inspectorate. The connection from

the fl ue pipe to the heat exchanger must be free of any

loading or stress. Before installing the fl ue pipe, the

agreement of the senior fl ue gas inspector responsible

for the district should be obtained.

PressureBOMAT fl ue gas heat exchangers are normally operated

in overpressure on the fl ue gas side. All fl ue pipes must

be constructed so as to be pressure-tight.

Siting / installationBOMAT fl ue gas heat exchangers can, depending on

space requirements, also be installed beside or above

heat generators. The installation height should be

selected such that all condensate has a suffi cient fall to

fl ow into the neutralising unit and then into the waste

water system. If this is not possible, a condensate

pump (accessory) can be used.

Condensate drain The condensate drain between the BOMAT heat

exchanger and the neutralising system, and between

the neutralising system and the waste water network

must be routed with a constant fall. Any sagging of

pipes or hoses must be avoided as particles could se� le

there and cause eventual blockages. Depending on the

application (e.g. CHP), an additional siphon with a larger

seal water height should be provided.

Maintenance port When installing a BOMAT Profi therm fl ue gas heat

exchanger, ensure that the maintenance and inspection

ports are accessible.

Connecting line between heat generator and heat exchangerThe fl ue connection between the heat generator and

heat exchanger must be pressure-tight. Connection

points to bends, inspection ports, boiler fl ue outlets

and heat exchanger connectors must also be pressure-

tight (e.g. use conically sealing stainless steel pipe).

All joining elements must be free of loading or stress.

Suitable insulation must also be fi � ed to prevent heat

loss and condensate formation.

HOW CAN WE HELP YOU?WE LOOK FORWARD TO YOUR ENQUIRY.

Today, our fl ue and exhaust gas heat exchangers are in use in a wide range of industries.

We have the right solution for all applications and requirements.

JUST GET IN TOUCH WITH US.

r T +49 (0)75 51.80 99 70 r [email protected]

BOMAT is a member of the puren Group

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BOMAT Heiztechnik GmbH Zum Degenhardt 49

88662 Überlingen

Germany

P +49 (0)75 51.80 99 70

F +49 (0)75 51.80 99 71

[email protected]

www.bomat.de

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