Heat Transfer & Combustion

Fired Heaters

Gasco supplies Fired Heaters to API 560 and ISO 13705 and proprietary Gasco forced draft convective designs.

Gasco, being both a combustion and heat transfer company, is uniquely placed to achieve the best possible outcomes with respect to high thermal efficiencies, low emission, reliable operation and state-of-the-art Burner Management Systems (BMS) to NFPA, IEC and other codes.

Gasco can supply cylindrical or box cabin type direct fired heaters, equipped with low NOx natural draft or forced draft burners.

To increase efficiency, preheating of combustion air can be achieved by adding a variety of air preheater exchangers.

A typical API 560 Fired Heater would consist of a:

  • Radiant Section
  • Convective Section
  • Stack
  • Burners
  • Fuel Skid
  • Control System

With the demand for ever increasing safety and reliability levels Gasco can design and supply BMS to IEC 61508 Programmable Electronic Safety Systems. We can also provide a basic hard wired system up to SIL 3.

Gasco convective heaters rely on forced convection heating only, are compact and can achieve thermal efficiency of 90per cent using convective heat transfer.

Fired Heater Upgrades for Existing Units
Gasco has upgraded old existing heaters to improve efficiency, safety and emissions using the latest PLC based BMS and NOx reduction technology.


Water Bath Heaters

Water Bath Heaters are Indirect Fired Type Heaters usually designed to API 12K, these devices are traditionally used to heat natural gas and oil. The main application for Indirect Fired Water Bath Heaters is to heat high pressure gas prior to pressure reduction.

A water bath heater works by submersing a process coil into a heated bath solution, which then indirectly heats the process liquids and gasses to create energy.

For gas well heads and pipelines, a large reduction in pressure will cause a significant drop in temperature of the gas. This is known as the Joule-Thompson effect, with a loss of temperature of approximately 5°C for each 1000kPa reduction in pressure.

Subzero temperatures will often occur if preheating is not applied. Full zero temperatures can result in embrittlement of piping and fittings, formation of ice and the formation of hydrates within the pipe with a potential for blockage of filters and regulator/valve seats.

For this reason, heating with a Water Bath Heater is commonly applied before pressure reduction of natural gas.

Heating of gas before gas engines in turbines is another application to avoid liquids and aerosols being injected into engines and turbines.

Another application is heating of high sulphur gas to avoid elemental sulphur deposition at regulator stations and in final engine/turbine pressure cuts.

Water Bath Heaters can also be used for heating:

  • Crude Oil
  • Vaporizing and superheating LPG & LNG
  • Regeneration Gas Heating
  • Heat Transfer Fluids
  • Heat sensitive gas and fluids
  • Amine Reboilers
  • TEG Reboilers

A typical water bath heater consists of an insulated shell, removable process coil, removable fire tube, stack burner, gas train and control system.

Gasco options include:

  • Natural Draft Burners
  • Forced Draft Burners
  • Pneumatic Gas Control
  • Electric (Electronic) Control
  • Remote Monitoring
  • Redundancy for Burners, Valve Trains, Controls
  • Photo Voltaic or Thermoelectric 24V Systems
  • Process Coil Inspections Service to AS/NZS 3788:2006

Gasco can also supply complete gas conditioning skids consisting of Water Bath Heater, Pressure Reduction, Filter Coalescer and Metering.


Regenerative Thermal Oxidizer

One of today’s most widely accepted air pollution control technologies across industry is a regenerative thermal oxidizer, commonly referred to as a RTO.

They are very versatile and extremely efficient – heat recovery efficiency can reach 95%. This is achieved through the storage of heat by ceramic media. In some applications, the use of catalyst with the ceramic media helps allow oxidation at reduced temperatures resulting in even lower operating costs. Regenerative Thermal Oxidizers are ideal in low VOC concentrations and during long continuous operations.

Industries that may require a Regenerative Thermal Oxidizer Adhesive Coating, Aerospace Painting, Air Strippers, Ammonia Streams, Automotive, Bakeries, Food Processing, Chemical Processing, Coil Coating, Co Destruction, Ethylene Oxide, Film Coating, Flexographic Printing, Flexible Packaging, Foil Coating, Formaldehyde, Graphic Arts, Heat-Offset Printing, Laminating, Metal Decorating, Paint Finishing Plastics, Expanded Foam, Petrochemicals, Phenolic Resins, Pulp & Paper, Processing Refinery Off-Gas, Rendering, Spray Coating, Tank Vent, Tape Coating, Tube Coating.

LNG Plant Acid Gas RTO
Gasco has broken new ground by supplying to Woodside an RTO for the destruction of BTEX in CO2 Acid Gas. The RTO, Process Fans, platforms and ladders have all been pre-assembled and shipped as a single module approximately 25m long x 15m wide x 10m high and weighing 270 tonnes. Additionaly two x 50m tall cyclone resistant stacks for exhaust and emergency bypass are included.


Thermal Oxidizers

Thermal Oxidiser’s (also known as thermal oxidizer, or thermal incinerator) are a process unit for air pollution control in many chemical plants that decomposes hazardous gases at a high temperature and releases them into the atmosphere.

Thermal Oxidisers are a class of pollution control devices that use the combustion process to destroy hydrocarbons, volatile organic compounds (VOC), Hydrogen Sulphide, and other compounds as well as smoke particles and odour, hence they are sometimes called afterburners, fume incinerators or tail gas incinerators.

Gasco Thermal Oxidisers can handle a wide range of process parameters including variable analysis waste flow rates, calorific values, temperature and oxygen content.

Features of our Thermal Oxidisers are their robust performance, ability to operate at high thermal efficiency and achieve up to >99.99 per cent destruction efficiency.

Gasco Thermal Oxidisers scope may include turnkey projects, designed to comply with our client’s specifications and environmental authority regulations.

We have supplied Thermal Oxidisers to the oil and gas, chemical, automotive, medical, pharmaceutical, food, minerals and metals industries.

Gasco Thermal Oxidisers include:

  • Simple Thermal Oxidisers without heat recovery
  • Thermal Oxidisers with heat recovery to process hot oil/water/steam, etc
  • Thermal Oxidisers with preheat of water gas steam (recuperative)
  • Catalytic Thermal Oxidiser
  • Regenerative Thermal Oxidiser – RTO

Heat from the exhaust of a Thermal Oxidiser can be recovered in a Waste Heat Recovery Unit, energy can be utilized in the form of heat transfer fluids – oil, water, air and to raise steam.

A Gasco RTO can provide average thermal efficiency of up to 95+% and use about 20 times less fuel than a TO with no heat recovery. In some applications the VOC present in the waste gas stream may enable the Gasco RTO to operate without any supplementary fuel gas (except at start up). Destruction efficiency of up to 99.5+% is achievable.


Hot Oil Heaters

Gasco designs and manufactures a range of Hot Oil Heaters: 100KW to 7,500KW gas-fired, 25KW to 1500KW electric.

The gas-fired heaters consist of two concentric helical coils which has the advantage of:

  • Compactness
  • High Efficiency
  • Low Thermal Mass

The dual helical coil design allows maximized heat transfer, minimises thermal stresses and prevents overheating. The coil design has the advantage that ensures high fluid velocities, low film temperatures and no accumulation of gases.

The burner can be selected to suit the application: the types of fuel – gas, oil, heavy oil, timber and turndown. The flame shape is carefully matched to the coil configuration. Typical efficiency with air preheating can range up to 88 per cent depending on thermal fluid outlet temperature, fuel, and atmospheric conditions.

Each heater has a pre-wired control panel that ensures safe and efficient operation of the heater.

As well as supplying heaters, we can provide skid mounted units that incorporate primary and secondary pumps, expansion tanks, stack and drain/fill tanks.There are a myriad of applications that are suitable for hot oil heating.

  • Gas Plant – Regeneration
  • Tank Heating – Bitumen, Wax, Emulsions
  • Reactor Heating – Chemical Industry, BioTech
  • Platen Presses – Timber Industry, Moulding
  • Hollow Flight Screws – Mineral Processing
  • Pipe Tracing – Heavy Fuel Oil, Bitumen, Wax
  • Ovens – Printing, Automotive
  • Extruders – Plastic
  • Fryers – Food
  • Calendar Rolls – Plastic, Film
  • Autoclaves – Aerospace, Rubber, Brick
  • Dryers – Timber, Food
  • Kilns – Timber

Gasco can supply a stand-alone heater or a total engineered package to suit any or all of the above applications. Turnkey bitumen heating is a specialty.


Gas Conditioning Equipment

Gas Conditioning and Control Skids
Gasco designs, fabricates, commissions and services an extensive range of Process Skids for Gas Conditioning and Oil Treatment including:

  •  Emergency shut down systems
  •  Filter coalescers
  •  Custody transfer metering with analysers
  •  Hot water heater/HX gas heating
  •  Water bath heaters API 12K
  •  Pressure reduction stations (a Gasco specialty)
  •  Black start heaters (electric/steam/hot water)
  •  Waste heat recovery for gas heating
  •  Total gas conditioning systems for power

Gasco designs and builds skid-mounted equipment to meet client needs as well as Australian and international standards including: AS1210 AS4140, ASME B31.3, API 12K, etc.

Gasco utilizes 3-D CAD systems to model layouts and enhance layout detail design. Equipment and piping are sized utilizing in-house computer programming and well-known proprietary software. Piping and flange loads are computer-calculated.

Instrumentation and controls are normally part of scope and skids are prewired and functionally factory acceptance tested (FAT) before leaving our workshop.

Multiple skids may be trial interconnected and tested before disassembly for transport. Additional features may include hot or cold insulation and heat tracing.

Gasco has supplied gas conditioning systems for power generation featuring GE, Rolls Royce, Pratt & Whitney and Siemens gas turbines as well as reciprocating engines.


Waste Heat Recovery / HRSG

Waste Heat Recovery systems utilise existing energy sources in order to efficiently generate thermal heat, process heat or electricity.

These systems reduce energy costs, provide carbon credits for emission trading systems and help the environment by reducing emissions.

Applications:
Gasco provides a comprehensive range of Waste Heat Recovery Systems for the following:

  • Gas Turbines
  • Gas and Diesel Engines
  • Thermal Oxidizers
  • Furnaces
  • Ovens

Gas Turbine heat recovery systems Gasco offers a complete turnkey plant comprising:

  • Inlet duct
  • Divertor valve
  • Divertor stack
  • Supplementary burner and controls
  • Waste Heat Recovery Unit
  • Exhaust Stack

Forms of Heat Recovery:
Heat Exchangers to heat thermal transfer fluids:

  • Thermal Oil
  • Hot Water
  • Water Gylcol
  • Steam

Heat Exchanger to:

  • Waste Gas Streams (Thermal Oxidizer)
  • Combustion Air (Fired Heaters and Thermal Oxidizers)
  • Make Up Air (Ovens and Furnaces)
  • Make Up Air – Space Heating

Gasco can provide for either individual pieces of equipment or supply a complete turnkey operating system for either a new application or modifying an existing plant.

Our range of services includes:

  • Survey/Analysis of existing systems
  • Engineering
  • Hardware
  • Hot Oil, Hot Water or Steam distribution systems
  • Erection
  • Commissioning
  • Turnkey Solutions
  • Heat Recovery Steam Generators HRSGs

Gasco is a licensee of ERK, Berlin, Germany for their world famous Corner Tube Heat Recovery and Steam Generators and Boilers.

To date over 6,000 ERK boilers, HRSGs and high temperature recuperators have been supplied worldwide.

HRSG – Heat Recovery Steam Generators
There are a form of waste heat recovery often applied to the exchange of gas turbines to recover energy as high pressure steam. Frequently the GT exhaust is augmented with additional heat input using supplementary firing using in-duct burners between GT and HRSG. HRSGs are usually used to provide steam to steam turbines for power generation. This is known as Close Cycle Power Generation (CCPG).


Heat Exchanger and Fin Fan Cooler

Our holding company has been fabricating heat exchangers, fin fan cooler and pressure vessel for major processing industries in Indonesia and overseas for more than 35 years. We offers fabrication of shell and tube heat exchanger, fin fan cooler, pressure vessel and other processing equipment manufactured in accordance with ASME Code Section 8 Division 1.

Enjoying our strong sourcing capabilities in combination with up to date know-how and state of the art production facilities, we are able to provide heat exchangers, air cooler and pressure vessel in a wide range of materials and operational conditions according to customer requirements and specification. Thousands of our factory’s product can be found in Oil Refineries, Chemical plants, Petro-Chemical plants, and Pulp and Paper Mills through out Indonesia.

These companies have come to rely on our reliability in proposals, fabrication, service, and commitment to on-time delivery of quality and cost effective heat exchangers and fin fan cooler.

We can perform virtually any heat exchanger/air cooler retubing or maintenance in the field or in one of our plants.