Exhaust Heat Recovery Case Studies

Application:

Hospital

Customer:

Oconomowoc Memorial Hospital

Oconomowoc, WI
USA
Heat Exchange Focus:

FCR - Fin Coil Recovery Series (3 units)

Installation consists of three Cain FCR-1L3816ALS heat transfer models. Each unit is recovering 408,000 BTUs per hour from its paired 300 HP steam boiler. The heat sink temperature of the boiler feedwater (22 GPM) is being raised from 227°F to 266°F by reducing the boiler exhaust gas temperature from 425°F to 302°F (12,553 SCFM).

Payback vs. Fuel Savings (per unit)
Unit Cost: $19,234
Payback: 16.2 Months
Annual ROI: 74%
Annual Fuel Savings: $14,231
Life Expectancy Fuel Savings: $284,620 (20 years)

Summary:
Oconomowoc Memorial Hospital is a 75-bed, general acute-care hospital. Built by the community in 1954, Oconomowoc Memorial has since grown to become one of the most exceptional community hospitals in the country. Cain heat recovery units are used to recover exhaust waste heat from steam boilers and preheat boiler feedwater. This results in reduced fuel costs for the hospital.

Application:

University

Customer:

California State University

Long Beach, CA
USA
Heat Exchange Focus:

EM - Energy Manager Series (10 units)

Installation consists of ten Cain EM-28 heat transfer models. Each unit is recovering 400,000 BTUs per hour from its paired 6,300,000 BTU hot water boiler. The heat sink temperature of the hot water return loop (30 GPM) is being raised from 160°F to 186°F by reducing the boiler exhaust gas temperature from 490°F to 300°F (1,750 SCFM).

Payback vs. Fuel Savings (per unit)
Unit Cost: $9,962
Payback: 8.6 Months
Annual ROI: 140%
Annual Fuel Savings: $13,924
Life Expectancy Fuel Savings: $278,480 (20 years)

Summary:
The California State University, Long Beach campus encompasses a total of 323 acres with 84 permanent buildings. 1,962 students live on campus in 18 residence halls. The ten Cain EM Series heat recovery units are used to recover exhaust waste heat from hot water boilers and preheat the hot water return loop. This results in reduced fuel costs for the university.

Application:

Museum

Customer:

The Chicago Museum of Science and Industry

Chicago, IL
USA
Heat Exchange Focus:

ESG1 - Exhaust Steam Generator Series

Installation consists of one Cain ESG1-820D17CSS steam generator model. The unit is recovering 3,467,000 BTUs per hour from a 1750 kW QSV91 engine. The heat sink of 3,573 PPH generated steam (40 PSIG) is produced by reducing the engine exhaust gas temperature from 941°F to 346°F (4,761 SCFM).

Payback vs. Fuel Savings (per unit)
Unit Cost: $101,802
Payback: 8.9 Months
Annual ROI: 134%
Annual Fuel Savings: $136,883
Life Expectancy Fuel Savings: $2,737,660 (20 years)

Summary:
The Museum of Science and Industry opened in 1933 and is visited by over two million people annually. It is the largest science museum housed in a single building (approx. 665,000 square feet) in the Western hemisphere. Heat recovered by the Cain Industries ESG1 is used for space heating and to run a 10,000 CFM desiccant humidifier.

Application:

Energy/Agriculture

Customer:

Innovative Energy Systems

Oakfield, NY
USA
Heat Exchange Focus:

HRSR - Heat Recovery Silencer Radial Series (7 units)

Installation consists of seven Cain HRSR-330C26SSP heat transfer models. Each unit is recovering 1,845,000 BTUs per hour from its paired Caterpillar 3516 engine. The heat sink temperature of hot water (300 GPM) is being raised from 180°F to 194°F by reducing the engine exhaust gas temperature from 922°F to 387°F (2,766 SCFM).

Payback vs. Fuel Savings (per unit)
Unit Cost: $57,716
Payback: 8.3 Months
Annual ROI: 144%
Annual Fuel Savings: $83,006
Life Expectancy Fuel Savings: $1,660,120 (20 years)

Summary:
What began as a method of utilizing expendable landfill gas to produce energy has evolved into full-circle energy recycling for Innovative Energy Systems. The company generates and sells enough electricity to light a small city, and uses the heat captured by seven Cain heat recovery units to heat their 12.5 acre greenhouse, producing 5.5 million pounds of hot house tomatoes annually.

Application:

Mining

Customer:

Diavik Diamond Mine

Yellowknife, Northwest Territories
Canada
Heat Exchange Focus:

HRSR - Heat Recovery Silencer Radial Series (11 units)

Installation consists of eleven HRSR-472D24.7SSP heat transfer models. Each unit is recovering 6,799,000 BTUs per hour from its paired Caterpillar 3612 engine. The heat sink temperature of 60% ethylene glycol mixture (695 GPM) is being raised from 202°F to 221°F by reducing the engine exhaust gas temperature from 811°F to 400°F (10,742 SCFM).

Payback vs. Fuel Savings (per unit)
Unit Cost: $163,150
Payback: 2.1 Months
Annual ROI: 563%
Annual Fuel Savings: $917,860
Life Expectancy Fuel Savings: $18,357,200 (20 years)

Summary:
What began as a method of utilizing expendable landfill gas to produce energy has evolved into full-circle energy recycling for Innovative Energy Systems. The company generates and sells enough electricity to light a small city, and uses the heat captured by seven Cain heat recovery units to heat their 12.5 acre greenhouse, producing 5.5 million pounds of hot house tomatoes annually.

Application:

Sanitary Treatment

Customer:

Rock River Water Reclamation

Rockford, IL
USA
Heat Exchange Focus:

UTR1 - U-Tube Recovery 1 Series (3 units)

Installation consists of three Cain UTR1-605I18SSS heat transfer models. Each unit is recovering 1,363,000 BTUs per hour from its paired digester gas fired engine generator. The heat sink temperature of the glycol/water loop (280 GPM) is being raised from 210°F to 221°F by reducing the engine exhaust gas temperature from 852°F to 377°F (2,344 SCFM).

Payback vs. Fuel Savings (per unit)
Unit Cost: $27,620
Payback: 7.8 Months
Annual ROI: 153%
Annual Fuel Savings: $42,231
Life Expectancy Fuel Savings: $844,620 (20 years)

Summary:
The Rock River Water Reclamation District covers nearly 88 square miles of Winnebago County and serves over 250,000 people. During the treatment process, the anaerobic digester speeds up the breakdown of solid waste which produces methane gas. This gas is used as a fuel to operate 3 engine generators. The heat is recovered from the generator by Cain heat recovery units and is used to help heat the digester. The facility saves the district approximately $40,000 each month in electricity.

Application:

Ethanol Plant

Customer:

Utica Ethanol Plant

Utica, WI
USA
Heat Exchange Focus:

RTR - Rectangular Tube Recovery Series

Installation consists of one Cain RTR-166K25.7ALS heat transfer model. The unit is recovering 1,475,000 BTUs per hour from its paired 2,200 HP steam boiler. The heat sink temperature of the boiler feedwater (152 GPM) is being raised from 227°F to 247°F by reducing the boiler exhaust gas temperature from 367°F to 299°F (18,473 SCFM).

Payback vs. Fuel Savings (per unit)
Unit Cost: $37,902
Payback: 7.1 Months
Annual ROI: 168%
Annual Fuel Savings: $63,662
Life Expectancy Fuel Savings: $1,273,240 (20 years)

Summary:
Beginning production in 2003, Utica Energy, LLC became the 73rd ethanol plant operating in the USA. The plant has the capacity to store 3.5 million bushels of corn. In one day, Utica uses 42,000 kw/hr of electricity and 14,000 therms of natural gas. Utica is currently producing 52 million gallons of ethanol per year.