Recuperator

A recuperator is a type of heat exchanger that recovers thermal energy from a hot process stream and transfers it to a cooler incoming stream, with the two fluids not mixing. By reclaiming waste heat, recuperators reduce fuel consumption and associated emissions in a wide range of industrial and commercial systems.

In operation, heat is transferred across a solid wall or matrix separating the hot and cold fluids. Common forms include plate, tubular, and shell-and-tube configurations. Recupers are designed to maximize heat transfer while keeping pressure drops modest. They are often contrasted with regenerators, which store heat in a porous medium and operate in a cyclic, intermittent fashion rather than continuous direct exchange.

Applications of recuperators span power plants, refineries, chemical processing, steel and cement kilns, and HVAC systems. In gas turbines and other power-generation equipment, exhaust heat is used to preheat the incoming combustion air, improving overall efficiency. In industrial furnaces, recuperators preheat combustion air or process gases to save fuel.

Key performance factors include effectiveness (the actual heat transfer relative to the maximum possible) and pressure drop, which influence energy savings and system cost. Materials and design must tolerate high temperatures, pressure, and potential corrosion or fouling. Maintenance considerations focus on keeping heat transfer surfaces clean to sustain performance.

Recuperators form a core component of energy recovery strategies in thermal systems, contributing to reduced operating costs and lower environmental impact.