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Escher Division

Escher Recuperative Heat Exchangers
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Escher Recuperative Heat Exchangers

Our Escher Division designs and manufactures recuperative heat exchangers for use in iron-melting furnaces (cupolas) and glass-melting furnaces. Escher recuperators and coolers have been used since 1956 and have a worldwide reputation for quality.

The heat exchangers use dirty hot waste gases to heat cupola combustion air thus saving on purchased fuel.

Products

Flue Gas Cooler

Flue Gas Cooler
Flue Gas Cooler
Flue Gas Cooler
Flue Gas Cooler

The Flue Gas Cooler works much like a Recuperator and uses ambient air to cool waste gases from about 1100° F (the usual outlet temperature from a Recuperator) to a suitable temperature for fabric filters (340° - 450° F). The difference is that the ambient air from the cooler can be captured and used for multiple applications.

Since the cooling air does not mix with waste gases, the waste gas mass flow is not increased. In the cooler, the ambient air is raised in temperature to around 300° F and can be used for building space heating or materials drying. Construction is somewhat similar to the Recuperator but uses lower temperature capable materials, and no refractory.When cooled gases are at 430° F and above, the cooler is self cleaning. If the waste gases are cooled to less than 430° F, a cleaning system is generally used.

A feature of a forced air cooler system is that outlet waste gas temperatures can be automatically controlled to close limits by varying the flow of cooling air. This is especially useful for fabric filters where temperatures must be kept to a narrow band to prevent overheating of the filter material, and condensation if too low.

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Recuperater:

The Escher Recuperative Air Heater has been used since 1956 and has a worldwide reputation for quality. The Recuperater uses the waste heat in exhaust gases from a combustion process to preheat ambient air, which is then returned to the process significantly reducing the amount of coke and increasing the melt rate. In effect, the equipment recycles heat which would otherwise be lost from fuel utilizing equipment to atmosphere.

When heat is recovered by preheating combustion air, many benefits are obtained, the most common being: The overall efficiency of the process is increased, and fuel savings of approximately 30% are achieved. The combustion of fuel in the process takes place at a much higher temperature than when using cold combustion air and results in higher heat transfer to the product, and a lower temperature waste gas leaving the process.

Recuperater
Recuperater
Recuperater
Recuperater

In dirty waste gas applications, the Escher Recuperator has an average life expectancy exceeding 15 years with a return on investment in some cases of less than 3 years. This long life is attributed to several unique design characteristics:

Units are metallic with no internal refractory.

Units are vertically mounted and hung from spring supports.

Abrasion and dust build-up are minimal because all heat exchange surfaces are parallel to dirty gas flow. Hollow fins, each of which can move independently of the other, provide the majority of the surface for heat transfer between the air and hot gases.

We use a superior alloy on the fins which has better physical properties for higher temperatures. The Escher Recuperative Air Heater is capable of handling dirty waste gases without cleaning systems and can produce air preheats up to 1100° F.

A Recuperator can be used on iron-melting furnaces (cupolas), glass-melting furnaces, thermal oxidizers, and kilns. We service our units by providing replacement parts, making onsite visits for start-ups or troubleshooting, and offering ROI analyses for companies considering use of recuperative systems.

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PROJECTS

Weichai Power Ltd. in China

Cupola Melt System
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Cupola Melt System

This is a Turn Key Contract to engineer, install and commission a new state-of-the-art 45 ton/hour cupola melt system with new controls and equipment to meet U.S. MACT standards for cupola and emission-control technology.

Ward Manufacturing

Hot Blast Cupola and Emission System
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Hot Blast Cupola and Emission System

This was a Turn Key Contract to engineer and install a new hot blast cupola and emission system.

OUR CUPOLA TEAM

Our Escher Division works in conjunction with several well-known companies to produce turnkey packages for Cupola Systems.

Our partnership grew out of the rumblings about the iron-and-steel foundry MACT standards enacted in 2003. Through synergies, we can offer a more complete system to customers. This unique partnership has lead Escher to numerous projects.

Listed below are a few of our loyal customers:

  • General Motors PowerTrain
  • United States Pipe & Foundry Co. (2)
  • US Foundry & Mfg.
  • Griffin Pipe Products (3)
  • East Jordon Iron Works
  • Dexter Foundry
  • Carlton Iron Works
  • McWane Cast Iron Pipe Co.
  • American Brass & Iron Co.
  • Ward Mfg.
  • Neenah Foundry (2)
  • Gunite Foundry
  • Tyler Pipe
  • Atlantic States Cast Iron Pipe Co.
  • Union Foundry Co.
  • Honda
  • Weichai Power, China
  • Roxul, Canada
  • Chapman Technology, Australia
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