Exhaust Heat Recovery Systems

Boiler Economizer Systems • Gas & Diesel Cogeneration Systems • Fume Incineration Systems • Finned Tubing

The Cain Industries Family of Heat Recovery Systems

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Cain Industries Overview
Cain Industries is the leading designer and manufacturer of exhaust
waste heat recovery systems for the following markets: gas & diesel
cogeneration systems, boiler exhaust stack economizer systems,
and fume incineration systems.

Cain Industries has developed over 2,100 industrial heat transfer

models within its’ 14 product lines. These products integrate
seamlessly into any boiler exhaust, cogeneration exhaust, or
incineration exhaust system.

Cain Industries, Inc.

Headquarters
Germantown, WI
USA

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Cain Industries Product Markets
Boiler Economizer Systems
An extensive line of boiler exhaust economizers designed to recover
exhaust waste heat (Btu) typically lost through the stack to preheat boiler
feedwater, makeup water, process water, etc. for boilers ranging from
200,000 Btu input - 150,000 PPH steam.
Gas & Diesel Cogeneration Systems
Exhaust heat recovery for gas and diesel engines, gas turbines, and
micro turbine generator retrofit applications from 30Kw - 7Mw.
Fume Incineration Systems
Packaged fully automatic exhaust steam generators recovering large
volumes of exhaust waste heat from 600ºF - 1600ºF, producing primary
and/or secondary steam.
Finned Tubing
An abundant range of custom-fabricated, industrial grade finned tubing,
manufactured to meet stringent customer requirements.

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Boiler Economizer Systems Facts
Without Cain Economizer:
• Most boilers have a combustion efficiency of 78-82%.
• Boiler exhaust temperatures exiting into the atmosphere: 350º - 600º F.
• Stack energy loss is typically 18-22%.

With Cain Economizer:

• Efficiency is increased, reducing fuel costs. Average efficiency
increase is 4-7%.
• A portion of the stack loss is recovered and the energy (Btu) is returned
to the system to preheat water. Exhaust temperatures exiting to the
atmosphere are reduced to 150º - 300º F.
• Economizers operate with virtually no risk or maintenance.
• Average total turnkey payback: 12-18 months (annual Return on
Investment: 75-100%).

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Cain Boiler Economizer Advantages
• Stainless steel internal exhaust bypass
Provides for full emergency bypass, requiring no additional ductwork for
controlling stack corrosion, turn-down performance, and back pressure.
• Alfuse finned tubing
316L stainless steel tube with aluminum fins bonded to the tube. The
thermal conductivity of these fins is 3.4 times greater than carbon steel
fins and 9.8 times greater than 304 stainless steel fins.
• Individually removable finned tubes
No bulky/heavy tube rack.
• High quality, dual ferrule compression fittings
Connect each tube to the inlet and outlet header. Tube replacement
requires no welding.
• Hinged access door
Allows access to all of the finned tubes for replacement or cleaning. No
special equipment is needed to lift the door away from the economizer.

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Cain Economizer Product Lines
Cain Cylindrical Economizers:
• Compact
• Lightweight, providing ease of installation
• Hinged stainless steel access doors
• Stainless steel internal exhaust gas bypass

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Cain Economizer Product Lines
Cain Rectangular Economizers:
• Individually removable fin tubes
• Stainless steel interior shell
• Hinged full face access door
• Stainless steel internal exhaust gas bypass
• 10 gauge carbon steel, seal-welded exterior

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Boiler Economizer Applications
Steam Boiler with Continuous
Modulating Feedwater
Preheating boiler feedwater

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Boiler Economizer Applications
Steam Boiler with On/Off Feedwater
Preheating boiler feedwater

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Boiler Economizer Applications
Steam Boiler with 50% or More Make-up Water
Preheating make-up water

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Boiler Economizer Applications
Hot Water Boiler
Preheating return water loop

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Installation Before & After
BEFORE AFTER

BEFORE AFTER

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Case Study: Oconomowoc Hospital
Boiler: 300 HP Steam Boiler
Exhaust gas temp before economizer: 425º F
Exhaust gas temp after economizer: 302º F
Btu transferred into boiler feedwater: 408 MBtu/hr
Total cost installed: $24,200

Annual savings: $18,150

Simple payback: 18 months

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Cylindrical Economizer Installations

PRINTING FACILITY INDUSTRIAL LAUNDRY

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Cylindrical Economizer Installations

WASTEWATER MANUFACTURING
TREATMENT PLANT COMPANY

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Case Study: Dreyers Ice Cream Plant
Boiler: 500 HP Steam Boiler
Exhaust gas temp before economizer: 430º F
Exhaust gas temp after economizer: 305º F
Btu transferred into boiler feedwater: 631 MBtu/hr
Total cost installed: $23,280

Annual savings: $22,650

Simple payback: 12.5 months

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Rectangular Economizer Installations

ETHANOL PLANT PHARMACEUTICAL CO.

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Rectangular Economizer Installations

UNIVERSITY BREWERY

OUTDOOR INSTALLATION

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

 Economizer Proposal Process
1. Gather data: 2. Complete form: 3. Receive proposal:
Minimum criteria required for Simple Application Data Form Within 24 hours, includes:
potential boiler economizer available at www.cainind.com: • Quotation
application: • Performance & projected fuel savings
Complete basic information: • Equipment payback
• Stack Temperature • Boiler type and size • Economizer submittal & dimensions
i.e. 350º F • Fuel type • Flow diagram
• Hours of Operation • Exhaust gas data • Technical information
i.e. 8 hrs/day • Exhaust stack dimensions • Product literature
5 days/week • Inlet water temperature
50 weeks/year
(2000 hours)
• Fuel Cost
i.e. $ .90/therm

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

Summary - Boiler Economizer Systems
• Economizers reduce energy costs by recovering valuable BTU
exhausted out the stack.
• Typical Economizer applications: preheating boiler feedwater,
make-up water, hot water return loop.
• Average total turnkey payback: 12-18 months (annual ROI: 75-100%).

The Cain Industries Family of Boiler Economizers

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com

To request a free savings analysis/proposal:

800-558-8690
[email protected]
www.cainind.com
Boiler Economizer Systems • Gas & Diesel Cogeneration Systems
Fume Incineration Systems • Finned Tubing

“Manufacturing Waste Heat Transfer Products to Save Energy” www.cainind.com