Fintube Technologies, Inc.

Date: October 22, 2009

Sanat Shetty© United States Steel Corporation

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Fintube Technologies, Inc.

Steel Coil ServicesSteel Coil Services

• Coil slitting & processingCoil slitting & processing• Rod to fin stripRod to fin strip

TEKtube TEKtube • ERW Tube MillERW Tube Mill• X-ID® TubingX-ID® Tubing

Finned Products GroupFinned Products Group

• Kentube Finned Products - OKKentube Finned Products - OK• Aletas y Birlos – MexicoAletas y Birlos – Mexico

Kentube Engineered ProductsKentube Engineered Products

• DesignDesign• EngineeringEngineering• FabricationFabrication• Contract FabricationContract Fabrication

“Vertically Integrated Manufacturing for Reliability and Quality”

ISO certified for more than 10 years

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• Economizers– Rectangular– Cylindrical

• Tubular Air Heaters

• Steam Coil Air Heaters

• (Indirect fired) Super-heaters

• Waste Heat Recovery– Hot Oil / Thermal fluids– Glycol/Water

• Stool Coolers

• Feedwater Preheat Systems

• Tank heaters

• Accessories

– Safety Relief Valves

– Sootblowers

– Ductwork

Kentube Engineered Products Group

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Kentube Engineered Products– Industries Served

Process industries

Industrial applications

Other

Packaged Boilers

Utility boilers

Furnaces

Ovens

Kilns

Fired Heaters

Diesel Generators

• Chemical & petrochemical• Food & beverage• Paper• Pharmaceuticals / Fertilizer

• Hospitals• Schools• Laundries • Offshore Platforms

• Steel production• Equipment manufacturers• Textile industries

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• Recover energy that is other-wise being wasted.

• This energy has already been “ paid for ”.

• BENEFITS of HEAT RECOVERY– Higher efficiency– Lower Pollution (Thermal and emissions)– $$ saved

• Economics of heat recovery are dictated by capital and operating costs of the heat recovery equipment.

• SENSIBLE HEAT RECOVERY OR LATENT HEAT RECOVERY ALSO !

Fundamentals of Heat Recovery

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Rectangular Economizer

• Vertical or horizontal gas flow

• Size ranges to 1,000,000+ pph

• Operating pressures from 50 psig to supercritical

• Horizontal or vertical tube designs

• Can support large loads

• ASME Section I or VIII, Division I

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Rectangular Economizer

Outlet header

Finned tube bank

Return bends

Inlet header

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Cylindrical Economizer

• Built to Section I or VIII of the ASME code

• Vertical or horizontal gas flow

• From 400 hp to 100,000 pph designs

• Solid or serrated finned tubes

• Built-in soot-blowers

• Minimal transitions – Adapter plate or Rolled Angle Flanges

• Access door for inspection and cleaning

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Finning Configurations

FuelsSquare tube pitch with

Solid Finning (fpi)Staggered tube pitch with

Serrated Finning (fpi)Sootblowers

Recommended

Natural Gas Only N/A

Natural Gas with #2 oil backup (<2 wks/yr)Natural Gas with #2 or #4 backup

N/A

N/A

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5

4

No

No

No

Natural Gas with #5 or #6 Oil backup

#5 or #6 Oil

#2 or #4 Oil

Heavy Residual (Bunker C or Coal Tar)

N/A

4 - 5

3

N/A

Yes

Yes

Wood

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2.5

2

N/A

N/A

N/A

Yes

Yes

Yes

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Casing & Tubing

• Inner Casing Choices

– Carbon steel – Kentube Standard, Flue gas temperatures up to 800°F

– Corten – up to 1050°F

– 1-1/4 Chrome – up to 1250°F

– Stainless steel – up to 1500°F

– Internally lined for higher temperatures

• Outer Casing Choices

– Corrugated galvanized carbon steel

– Corrugated aluminum

– Flat outer casing

• Tube Types– Welded (Kentube Standard)– Seamless

• Tube Material– Carbon steel (Kentube

Standard)– Alloy

• High temperature– Stainless Steel

• High temperature• Resists oxygen pitting

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Corrosion Considerations

• OXYGEN CORROSION FROM UN-DEAERATED WATER• Oxygen removed adequately?

– Chemical / Mechanical /Thermal de-aeration– If not, we can use stainless steel tubes.– Minimum 180 F feed-water temperature, assuming atmospheric pre-heat (and Chemical

treatment) before we use Carbon steel tubes.

• ACID CORROSION FROM CONDENSATION OF SULFUR COMPOUNDS• Acid dew-point depends on sulfur content of fuel

• Stack temperature after economizer is dictated by acid-dew point.• Wall temperature is controlled by feed-water temperature

–Can deaerator pressure be increased?–Feedwater preheat system?

Fuel Lowest Econ Exit temperature

(◦F) (C)

Recommended minimum feed-water temp (◦F) (C)

Natural gas 260 F (126 C) 180 F (82 C)

# 2 Oil ( < 0.5% S) 300 – 325 F (149 C –163 C) 210 F (99 C)

#6 Oil ( ~ 2% S ) 350 F (177 C) 240 F (116 C)

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• Unit consists of bundle of straight tubes that are rolled into end tube-sheets.

• Gas inside tubes or outside

• Vertical units have multiple shell side passes.

• Horizontal units have multiple tube side passes.

• Vibration baffles if needed.

• Completely seal welded casing.

• An integral expansion joint between the tube sheet and casing allows for differential growth between the tubes and shell.

Tubular Air Pre-Heaters

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Custom Designed Units

• Designs are based on Kentube's many years of experience designing and building air pre-heaters.

• Custom designed to meet specific design parameters by experienced engineers

• Sizes from as low as 25,000 pph of gas flow to hundreds of thousands of pph of gas flow, such as those used on utility boilers.

• Modular Construction.

• Installations with flue gas fromnatural gas, wood-burning,coal & pet coke burning boilers

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Design Information Needed – Air Pre-heaters

ITEM Required Needed COMMENTS

CONFIGURATION: XVertical, air or gas overHorizontal, air or gas over Default design - horizontal, gas over.

CONTROLLING EXIT X We have to know which exit temp. to TEMPERATURE GAS/AIR: design for - gas or air.

SPACE LIMITATIONS, X Generally, longer tubes less expensive.

FOULING CHARACTERISTICS: X Default gas resistance=.0200

EXIT FLOW DIRECTIONS X If specified, dictates number of passes.

GAS:temperature in Xpressure in X Default, (-10 in. gauge)allowable pressure drop XComposition X Minimum, require information on fuel

AIR OR SECOND GAS:temperature in Xpressure in X Default, (+25 in. gauge)allowable pressure drop Xmoisture content, if air X Default, 1.3% lb./lb.composition, if gas X Same as (GAS: composition) above

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Air Pre-Heater Configurations

Vertical Unit

Horizontal UnitVertical tubes with mixing between passes

Gas out

Gas in tube side

Air inshell side

Air out

Gas in tube side

Air inshell side

Gas out

Gas in shell side

Air in tube side

Air out

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Heat Recovery Units

• Heat recovered other than packaged boiler

• Heat transferred to possible other medium ( Thermal Oils / Glycol Water Systems, etc)

• May be high temperature

• Special design considerations

• We package duct-work, transitions, L&P, stack.

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FLAT COILS FOR LARGE FIELD ASSEMBLED ECONOMIZERS

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Stool Coolers

• Annealing Furnaces in sheet metal mills

• Water Cooled

• City Water Supply

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Fintube Engineered Products- Fabrication

• Quality Program– Kentube ISO certified : Travelers remain with unit from initial construction (Structural Shop)

• Fabrication Facilities ( NEW – OPENED IN JUNE 2008 )– 84,000 ft2

– Three (3) – 70 ft x 400 ft bays– Overhead cranes to lift– Portable jacks - 225 ton

• ASME Stamp Holder– Do not rely on “remote” stamp– Do not rely on a 3rd party fab shop’s stamp

• Experience – By far, industry leader

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Types of Finning

Kentube Finned Products Group

High Frequency Serrated High Frequency Solid Standard Frequency Serrated

Studs AeroSeg

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TEKtube Tubular Products Group

• TEKtube, started in 1989, is one of the largest producers of ERW carbon steel boiler tubes in North America, producing millions of feet each year.

• TEKtube has been ISO Certified since 1994 and is committed to producing a quality product

• SA-178-A, C, & D Tubing• A-513 Air Heater Tubing• A-423 Grade 1 {Corten} Tubing• X-ID Tubing made to SA-178 A• SA-214 Condenser Tubing

““Tektube Product Range”Tektube Product Range” ““Tektube Size Range”Tektube Size Range”

• Tube o.d. from 1.25”OD to 3.0” OD• Tube wall thickness from 0.065” to .210”• Lengths to 70’

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What is X-ID® ?

• X-ID is an internally enhanced tube.

• Tube augmentation (passive or active) techniques are used to increase the heat transfer rate.

• The augmentation in an X-ID tube is achieved by helical ribs on the inside of the tube.

• Ribs modify the behavior of the fluid flow leading to heat transfer augmentation.

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X-ID® Tube Applications

• Significantly higher heat transfer rates than plain tubes

• Increased unit efficiency

• Reduced unit size allows for significant cost savings on the overall heat exchanger

Firetube Boilers Tubular Air HeatersShell-and-Tube HX

TEKtube Tubular Products Group

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Quality

• ISO 9001:2000• Code Construction – Kentube holds our own code stamps. Based on

Customer Specifications, Kentube Products can comply with the following codes:

– ASME Section I, Power Boilers, “S” stamp holder ( also hold R stamp)– ASME Section VIII, Division I, Pressure Vessels, “U” stamp holder– ASME Section V, Nondestructive Examination– ASME Section IX, Welding and Brazing Qualifications– AWS D1.1, Structural Welding Code– American Institute of Steel Construction (AISC)– ASME B31.1, Power Piping– Uniform Building Code– International Building Code– ASCE 7-05, Minimum Design Loads for Building and Other Structures– P.E.D. (Pressure Equipment Directive) for the European Union

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“Heat Recovery Product Solutions” through technical expertise and technological innovations.

www.fintubetech.com

• High quality products

• Control all aspects

– Tubes

– Finning

– Fabrication

• Most accurate heat transfer correlations

• Truly an “Engineering” company

• Actively developing industry-leading technology

Summary