R&D Hardware

Technical Overview

To remove dissolved foreign substances (chemical) and suspended foreign substances, we use automatic tube washing for chemical and 4 stage filtration for physical purposes.

  • Step 1

    Abandoned high-temperature waste water has suspended and dissolved foreign matters

  • Step 2

    Removes suspended matter (physical) through 4-Stage filtration device

  • Step 3

    Automatically apply chemicals when pressure and efficiency deteriorate and execute tube washing - Dissolve foreign matter (chemical)

  • Step 4

    High temperature waste water type with suspended foreign matter and dissolved foreign matter removed

Technical Details

To remove dissolved foreign substances (chemical) and suspended foreign substances, we use automatic tube washing for chemical and 4 stage filtration for physical purposes

  • Removing dissolved foreign substances
    - automatic tube washing

    - In the dyeing process, Sodium Hydroxide(NaOH) which dissolves the fabric results dissolved contaminants in waste water

    - Periodic automatic tube washing system operation through the custom-built unit installed in the product when the efficiency of facility operation pressure and heat exchange efficiency is detected at all times

    - Maintaining heat exchange rate, energy saving data storage and heat exchange efficiency

    - Improved chemical resistance by using tube washing chemical containing corrosion inhibitor

  • Removing suspended foreign substances
    – 4 Stage Filtration

    - Centrifugal (Stage 1) and Centripetal (Stage 2) Cyclone Technology

    - 6mm SUS Ball Micro Filtration (Stage 3 and 4) Technology

    - Automated filtration / backwash and discharge automatically from high-boiling particles to fine particles in succession without short-circuiting

In the conventional method, the manager checked the facility daily and calculated the pressure value and the temperature efficiency, and directly operated the valve manually and washed pipes using glacial acetic acid. But now, the system is built so that the machine can be automatically backwashed accordingly.

Automatic Tube Washing Flow Chart

  • - Automatically switching to tube washing operation when heat exchange efficiency decreases
  • - System automatically switches to normal operation after completion of automatic tube washing
  • - Automated tube washing after automatic drainage of wastewater inside heat exchanger
  • - Automatically proceeding from heat exchange efficiency judgment to cleaning completion and normal operation

Test Operation after Installation Ensaver, 9/5/2016 Operation Report

첫 가동 시
Temperature Efficiency Analysis
Avg. Waste Water
Inlet Temperature : 60℃
Avg. Clear Water
Inlet Temperature : 26.3℃
Avg. Temperature Efficiency : 83.3%
Avg. Waste Water
Outlet Temperature : 34.9℃
Avg. Clear Water
Outlet Temperature : 54.4℃

※ Temperature Efficiency = (Clear Water Outlet Temp - Clear Water Inlet Temp) ÷ ((Waste Water Inlet Temp – Clear Water Inlet)

Temperature Efficiency Before/After Tube Washing

Date of Tube Washing Division Unit Before After
11/1/2016 19:00 ~ 22:00 Period 10/31 17:00 ~ 11/1 17:00 11/1 22:00 ~ 11/2 16:00
Avg. Waste Water Inlet Temp 62.5 63.7
Avg. Clear Water Inlet Temp 19.0 18.2
Avg. Clear Water Outlet Te 54.7 56.7
Avg. Temp Efficiency % 81.7 83.1

- Temp efficiency decreased by 1.5% in 2 months after installation

- Temp efficiency increased from 81.7% to 83.1% after tube washing

Economic Effect

Division Before After Expectation
Industrial water supply temp. (annual avg) 20℃ 40℃ Hot water generating effect of 20 ℃
Bunker C Oil Usage , 480 ㎘/year 480 ㎘/year 409 ㎘/year 71 ㎘/year
Recovered Calories 0 Gcal/year 668 Gcal/year recovering 667 Gcal/year
Bunker C Oil Price 284,100 USD/year 241,800 USD/year reducing 42,300 USD/year
Tonne of Oil Equivalent 478 TOE 407 TOE 71 TOE
GHG Emissions 1,441 tCO2/year 1,228 tCO2/year reducing 213 tCO2/year
Dyeing process time (Fabric input and discharge) 430 minutes 380 minutes shortening 50 minutes, productivity increased by 11%
Electricity savings expected (dyeing machine circulation pump) 198,483 KW/year 175,547 KW/year 22,936KW/year, 2479 USD/year

- Economical effect such as reduction of about 42,400 USD and reduction of 213tCO2 by recovering 668Gcal of heat annually from 300 tons / day of high temperature wastewater discharged to the wastewater treatment plant without recovery

Certified Test Certificate

Authentication Overview
Certification Body Korean Register of Shipping
Authentication procedure
  • 1. Exam date: November 17, 2016
  • 2. Test items
    1) Energy saving and calculation of CO2 reduction amount
    ① Energy savings (MWh converted to Kcal)
    ② Reduced amount of fuel used (applicable lower calorific value of applicable fuel)
    ③ Fuel saving amount (Applicable area, measurement unit price)
    ④ Reduction of CO2 (applicable CO2 emission factor)
  • 2. Heat exchange efficiency calculation
    (Fresh water outlet temperature - fresh water inlet temperature) ÷ (wastewater inlet temperature - fresh water inlet temperature)
Certification Result 1: Fuel saving and CO2 reduction certification
ItemSection meter reading calories saved fuel savings savings CO2 reduction
MWh Kcal tCO2
Installation (Aug-Nov. 17 2016) 193.80 166,668,000 17,806 11,681,005 53.47
Annual Calorie Report
(Aug - Oct 2016)
148.68 127,864,800 13,661 8,961,465 41.02
Monthly Calorie Report
Nov. 1 ~ 16)
44.99 38,691,400 4,134 2,711,705 12.41
Daily Calorie Report
(Nov. 17 ~ 13)
1.50 1,290,000 138 90,410 0.41
Certification Result 2: Heat exchange efficiency = average heat exchange efficiency 83.88%
Section start end duration (minutes: second) average of clear water inlet temperature clear water outlet average temperature waste water inlet average temperature Section average temperature efficiency
1 13:23:25 13:24:25 01:00 17 ℃ 63.6 ℃ 73 ℃ 83.21%
2 13:36:00 13:48:45 12:45 17 ℃ 61.5 ℃ 69.3 ℃ 85.09%
3 13:49:15 13:52:50 03:35 16.7 ℃ 59.5 ℃ 68 ℃ 83.43%
4 14:06:10 14:07:25 01:15 17 ℃ 59.3 ℃ 68.1 ℃ 82.78%
5 14:07:55 14:10:30 02:35 16.8 ℃ 61.8 ℃ 70.9 ℃ 83.18%