Condensing Heat Exchangers

Harnessing the power of sensible and latent exhaust heat recovery for even greater energy savings.

All exhaust heat exchangers operate in the exhaust stream of a boiler or other industrial combustion process. The waste heat gases from fuel combustion are channeled through the exchanger. A heat sink liquid to absorb heat, flows through spiral finned tubes that line the inside of the heat exchanger. Exhaust heat is conducted through the fin tube raising the heat sink temperature while lowering the overall exhaust gas temperature.

Condensing Heat Exchangers

A more effective means of exhaust heat transfer is a condensing heat exchanger. It utilizes a colder heat sink with a greater entering temperature difference than exhaust stream gases. A heat sink of lower temperature absorbs sensible heat change in temperature, better than one of higher temperature. More importantly, the colder heat sink forces a "chemical reaction" of condensation within the exchanger. Microscopic water droplets start to form as the exhaust flows around the finned tube, cooling the gases to a 132°F dew point or below. Droplets grow in size on the tubing to form streams of running water. Hydrogen contained in the exhaust gases condenses into water transferring its latent energy to the heat sink. This gas to liquid transformation releases roughly 1,000 BTUs of heat for every pound of water created. Capturing both sensible heat and latent heat drastically increases overall exhaust heat recovery efficiency.

Cain Industries has dedicated years of research and development to create condensing heat exchangers that perform consistently in the most brutal of exhaust heat environments. Designed, engineered and hand-built in the USA to operate reliably for decades, this cost saving heat recovery method significantly reduces the fuel required to maintain boiler output as waste heat is transferred back into feedwater or makeup water... Saving energy and eliminating related pollution!

A two-stage condensing heat exchanger allows heat transfer for two independent heat sinks. Each of the combined exchangers can be engineered for different heat recovery yields.

We manufacture condensing heat exchangers for steam boilers, hot water boilers and most natural gas combustion applications where a cold water heat sink is prevalent. All condensation is safely captured and drained away from the exchanger, protecting the boiler or other combustion source. Heat sinks consist of boiler feedwater, makeup water, hot water return, hot water storage tank, condensate tank, swimming pool and other types of process water.

Contact Cain Industries today for the best in sensible and latent exhaust heat recovery! We'll calculate the exact performance of installed equipment with minimal end user input.

We guarantee the performance of every condensing heat exchanger we build!

CXL | Single Stage Condensing Heat Exchanger

CXL | Single Stage Condensing Heat Exchanger

The CXL Single Stage Condensing Heat Exchanger is specifically designed to recover sensible heat from within the exhaust and, more importantly, to also recover additional valuable latent heat as the exhaust is condensed. Typically the recovered heat will be transferred to the cold makeup or process water, thereby increasing the overall efficiency and lowering the fuel demand. As the exhaust temperature is dramatically reduced to 120°F to 170°F, resulting condensation is safely captured and drained from the economizer and away from the boiler.

Combustion Sources
Steam boilers, hot water boilers, and hot oil heaters with inputs up to 250,000,000 BTU/hr. (natural gas fired)

Boiler Exhaust Application
Capacity: up to 250,000 lb/hr steam
Entering Gas Temps: 300°F to 800°F
Heat Sink Types: makeup water and process water

Features
  • Internal expansion design
  • Mounting flanges for bolting to mating flanges/adapters
  • Condensate drain catch ring assembly
  • 12 gauge stainless steel exterior
  • Stainless steel interior
  • 2" factory insulation
  • Removable access doors
  • Stainless steel bypass
  • Stainless steel header manifold for high liquid flow
  • Compression fittings between finned tubes and the liquid manifolds for easy tube removal that requires no welding

DXL | Two Stage Condensing Heat Exchanger

DXL | Two Stage Condensing Heat Exchanger

The DXL Two Stage Condensing Heat Exchanger is specifically designed to recover sensible heat from within the exhaust and, more importantly, to also recover additional valuable latent heat as the exhaust is condensed. What makes the DXL Boiler Economizer unique is that it recovers heat in two stages. The first stage will preheat boiler feedwater and the second stage will preheat boiler makeup water. Final exhaust temperatures leaving typically range from 120°F to 170°F. This recovered heat will be transferred to feedwater and makeup water, thereby increasing the overall efficiency and lowering the fuel demand.

Combustion Sources
Steam boilers, hot water boilers, and hot oil heaters with inputs up to 250,000,000 BTU/hr. (natural gas fired)

Boiler Exhaust Application
Capacity: up to 250,000 lb/hr steam
Entering Gas Temps: 300°F to 800°F
Heat Sink Types: boiler feedwater, makeup water, hot water return, hot water storage tank, condensate tank, process water

Features
  • Internal expansion design
  • Mounting flanges for bolting to mating flanges/adapters
  • Condensate drain catch ring assembly
  • 12 gauge stainless steel exterior
  • Stainless steel interior
  • 2" factory insulation
  • Removable access doors
  • Stainless steel bypass
  • Stainless steel header manifold for high liquid flow
  • Compression fittings between finned tubes and the liquid manifolds for easy tube removal that requires no welding