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Blowdown Heat Recovery Systems for Boilers

HV Type Heat Recovery System

HV Type Heat Recovery System
Three different styles and twenty standard models are available to match a Madden blowdown Heat Recovery System to your boiler system for the best performance and the most economical return on investment. Look at these Madden results:
  • Recover 90% of the heat energy in continuous top blowdown that would be lost down the drain.
     
  • Reduce temperature of blowdown discharge to drain to meet statute limits.
     
  • Fast investment payback from fuel, cooling water and makeup water savings, Madden systems usually pay for themselves in less than 12 months.
     
  • Durable, time proven designs, built to take the punishment of continuous, 24 hour a day service for years.

Function

Hot, High pressure continuous blowdown water drained from the boiler, contains valuable heat energy. The continuous blowdown process helps control boiler water quality and operating efficiency by removing suspended and dissolved solids from the water in the boiler drum.

Recovery of up to 50% of the BTU's available may be accomplished by generating low pressure flash stream in a flash tank. This supply of stream can be used in boiler D/A tank or other low pressure steam applications. As the flash steam is generated, the blowdown condensate that remains is used to preheat the boiler feed water using a low pressure liquid heat exchanger. For smaller, lower pressure blowdown requirements, the HX Series heat recovery system utilize a higher pressure liquid to liquid heat exchanger without a flash tank to do the heat recovery job. The Madden sales representative will recommend the model you need to maximize your fuel savings potential.

Madden System Features

Type HX, HV and Type HC

HX type Heat Recovery

HX type Heat Recovery
 
  • The Type HX blowdown heat recovery systems are inexpensive, yet durable. The hot blowdown water passes through a self cleaning vertical heat exchanger coil. Fresh makeup water is the shell side counter flow cooling media. No flash steam is created in these simple heat exchangers. The Type HX are designed for blowdown flows up to 3,500 lbs. per hour from boilers up to 150 psi. ASME 150 psi shell construction. Copper or Stainless Steel coils available.
     
  • No Solids Buildup. All Madden systems are self flushing, designed to use gravity flow to continuously clean itself. They operate without becoming clogged or fouled with solids contained in the dirty blowdown water.
     
  • Low pressure heat exchangers in the Type HC and Type HV systems - this reduces stress on equipment and makes scale buildup unlikely on the

    HC type Heat Recovery

    HC type Heat Recovery
    cooling side of the heat exchanger tubes. This is because the temperature rise of the makeup water cooling medium will usually be no more than 20' Fahrenheit.
     
  • No Solids Buildup. All Madden systems are self flushing, designed to use gravity flow to continuously clean itself. They operate without becoming clogged or fouled with solids contained in the dirty blowdown water.
     
  • Type HC and Type HV systems Flash Tanks are designed for blowdown. Impact plates on the blowdown inlet create water droplets and turbulence to enlarge the surface and increase flashing. Adequate vessel volume produces clean steam without water carryover. Surface area and retention time are engineered to facilitate flashing. The Type HC and Type HV systems can be used on higher pressure boilers, up to 1,000 psi and more.

*Does your boiler room need a heat recovery system? Find out here with this helpful walkthrough*

Does your boiler room need a heat recovery system

Boiler Blowdown Heat Recovery Types

Model Number Capacity lbs/hour Description
HC40-150 4,000 Horizontal type, 304 SS U-tube type heat exchanger
HC80-150 8,000 Horizontal type, 304 SS U-tube type heat exchanger
HC120-150 12,000 Horizontal type, 304 SS U-tube type heat exchanger
HC160-150 16,000 Horizontal type, 304 SS U-tube type heat exchanger
HC200-150 20.,000 Horizontal type, 304 SS U-tube type heat exchanger
HC240-150 24,000 Horizontal type, 304 SS U-tube type heat exchanger
HC280-150 28,000 Horizontal type, 304 SS U-tube type heat exchanger
HC320-150 32,000 Horizontal type, 304 SS U-tube type heat exchanger
HC360-150 36,000 Horizontal type, 304 SS U-tube type heat exchanger
HC500-150 50,000 Horizontal type, 304 SS U-tube type heat exchanger
HV030A 3,000 Vertical type, copper coil heat exchanger
HV030B 3,000 Vertical type, 304 SS coil heat exchanger
HV050A 5,000 Vertical type, copper coil heat exchanger
HV050B 5,000 Vertical type, 304 SS coil heat exchanger
HV070A 7,000 Vertical type, copper coil heat exchanger
HV070B 7,000 Vertical type, 304 SS coil heat exchanger
HV090A 9,000 Vertical type, copper coil heat exchanger
HV090B 9,000 Vertical type, 304 SS coil heat exchanger
HV120A 12,000 Vertical type, copper coil heat exchanger
HV120B 12,000 Vertical type, 304 SS coil heat exchanger
HV150A 15,000 Vertical type, copper coil heat exchanger
HX400A 2,500 Vertical blowdown heat exchanger, copper coil
HX400B 2,000 Vertical blowdown heat exchanger, 304 SS coil
HX450A 3,00 Vertical blowdown heat exchanger, copper coil

Float Valve replacement in an HV heat recovery unit



Customize Your Boiler Heat Recovery SystemMadden Manufacturing HV boiler blowdown heat recovery system with external float control

Madden Manufacturing’s vertical and horizontal heat recovery system designs are mechanically actuated. These systems do not require programming or electrical wiring of any kind, all of the components are self-actuating. As with all of our products, the focus is on simplicity and quality which we believe translates to dependability and trust.

That said, there are numerous reasons you may want to tweak our design, or add ancillary equipment to these systems. On occasion we get requests to add connecting points to our systems so that end users can have the ability to send back information to their control system. Take temperature outputs for example. Madden Manufacturing’s standard boiler heat recovery system has a nameplate that also includes a temperature gauge panel. This includes (3) thermometers, one provides a reading on the drain temperature, another provides the cooling water inlet temperature, and the final one shows the cooling water exit temperature. These are all simple thermometers with temperature bulbs and 8 foot capillaries that allow for manual reading and display of these temperatures. Some engineers or end users prefer to add sister connections to all of these terminal points so that they can also send a temperature signal to their boiler room control system. No problem at all.

Another request we get from time to time is to change the heat recovery system’s level controller from an internal ball type float to an external controller. For this we often propose either a pneumatic level float control or simply an external ball type float with an electronic output signal to be used with an electronic ball type drain valve. 
Madden Manufacturing horizontal boiler blowdown heat recovery system with external level float controlWe often use either a Fisher pneumatic float control and drain, or a pairing of McDonnell Miller boiler level controller with a Honeywall electronic ball valve. Our standard designs allow for a more compact unit, especially with our vertical HV systems which take up only 2 square feet of floor space; but with external controllers you do get the added benefit of easier maintenance when the controller requires it. (Note: Madden float ball level controllers usually last 10+ years before any potential fouling or wear and tear would call for any kind of maintenance).

No matter the request, Madden Manufacturing is happy to help accommodate. If your boiler room is in need of valuable heat recovery, we would love to help work on a solution with you. Let’s start with our standard design and go from there.



To learn more about Blowdown Heat Recovery Systems for Boilers, click here to contact Madden Manufacturing today!

 
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