Steam-to-Air Heat Pipe Heat Exchanger
Proven thermal performance for optimizing energy integration in industrial applications
Evolving process targets and decarbonisation goals mean today’s industrial plants must adopt forward-looking approaches toward energy integration. In energy-intensive industries such as petrochemical refining, power generation and non-ferrous metals production, precise thermal control, fuel efficiency and equipment reliability are critical in maintaining a sustainable and cost-effective operation.
One of the most effective ways of achieving these objectives is by revisiting how heat integration can be managed within the process, made possible through technologies such as Econotherm’s steam air heating system. By pre-heating combustion or process air with otherwise-unused or low-grade steam, operators can decrease primary energy inputs, enhance thermal stability and reduce emissions.
While approaches to air pre-heating vary across facilities, the opportunity to gain meaningful performance improvements is nearly universal.
At Econotherm, we have deep expertise in designing and manufacturing high-performance steam-to-air heat pipe
heat exchangers that provide reliable, energy-efficient performance for high-temperature industrial applications. We design our systems to avoid the limitations of conventional tubular steam air heaters, offering robust, low-maintenance solutions that will last.
Why choose steam-to-air heat pipe heat exchangers?
Multiple redundancy
Each heat pipe in the system operates independently. Single pipe failure is rare. Even when this occurs, the consequence on the operation is negligible since the unit can continue to operate safely. This differs from tubular designs where one tube failure often leads to total system shutdown.
Low failure rate
Unlike tubular systems that are prone to water hammer and vapour shocks, Econotherm's heat pipe steam air heaters eliminate these risks by condensing steam inside a sealed chamber, not a coil.
Easy, in-situ maintenance
Failed pipes can be quickly replaced in the field during routine shutdowns without uninstalling the entire unit. This drastically reduces downtime and maintenance costs. Commercially proven in-situ cleaning systems such as sonic horns or water jet spray systems can be installed to further reduce maintenance situations requiring downtime.
Superior heat transfer efficiency
Our heat pipes use two-phase heat transfer, achieving thermal conductivity up to 100,000 W/m-K — far exceeding copper or aluminum. Isothermal operation of the heat pipes prevents hot and cold spots from forming, ensures precise temperature control throughout the exchanger, and maximizes energy recovery.
Durable and corrosion-resistant
Econotherm’s solution is built from high-grade materials with thick-walled pipes, providing resistance to erosion and corrosion while ensuring a long service life.
Proven, long-term performance
Legacy heat pipe air preheaters (often referred to as “Q-Dot”) installed in the 1980s and 1990s are still operating today — some of which are now being refurbished by Econotherm. This track record speaks to the exceptional longevity of heat pipe-based designs.
Heat Pipe versus Tubular Steam Air Heaters
Attribute | Heat Pipe Steam Air Heater | Tubular Air Heater |
|---|---|---|
Cross-stream leakage | Zero throughout life | Increases over time |
Repairability | Excellent | Poor |
Corrosion resistance | High | Low |
Maintenance | Simple, on-site | Complex, often off-site |
Water hammer / vapour shock | Eliminated | Common |
Redundancy | Yes (independent pipes) | None |
Applications
Aluminum melting furnaces
Petrochemical-fired heaters
Power generation
Waste-to-energy
plants
Learn more
Discover how Econotherm’s proven, scalable and low-maintenance heat pipe technologies can transform your industrial processes. Contact us today to speak with an engineer or request a quote.