Energy
Heat exchanger

BOSAL Energy has 20 years of experience in development, testing and production of highly effective heat exchangers. BOSAL Energy is part of the BOSAL group which was founded in 1923 in the Netherlands.

Expanding fast into advanced sustainable products

BOSAL Energy is determined to take a leading position in the emerging renewable energy markets and provides specific heat exchanger solutions for all emerging technologies which will play an increasing role in the near future, such as Solid Oxide Fuel Cell Technology (SOFC) or Solid Oxide Electrolysers (SOEC).

These high-temperature carbon-emission-reducing technologies will allow energy to be produced with higher efficiency than any other means, at any desired scale, making them very attractive for “fuel-to-power” applications such as:

  • Residential power and combined heat/power;
  • Commercial power and combined heat/power;
  • Distributed electricity generation for data centres, charging stations for BEV to name a few

And for “power-to-fuel” applications such as:

  • Green hydrogen manufacturing
  • Clean CO and ammonia production
  • Syngas and synfuel production
Energy

High effectiveness in very compact design

With the purpose to produce in an environmentally friendly way basic chemicals for the industry, or store in chemicals excess green electricity from photovoltaics and wind into a chemical energy form for later use.

Beside those new disruptive fuel cell based applications, BOSAL has many years of experience in µ-Gas Turbine applications with highly effective recuperators from 30kW to 150kW, but also have provided products that were employed in other high temperature applications like steam reformers, evaporators, and condensers, whereby we can also offer tubular heat exchangers.

BOSAL’s main competitive differentiator is our offering of fully welded thin foil heat exchangers which combine high effectiveness with low back pressure in very compact design.

Our heat exchangers work according to a primary heat exchange principle through a stack of thin foils, with a proprietary design resulting in a high surface density (more than 1.2 m2/litre) and a very “organised” transfer of heat, getting as close as possible to ideal thermodynamic heat transfer. More than 12 patents have been filed during the development of these cutting-edge components, whereas we use hydroforming techniques to manufacture our proprietary corrugated foils which are stress-free and uniform in thickness, the guarantee for long-lasting durability.

Our customers state that a very low pressure drop in combination with a small volume contributes to smaller and more efficient systems with positive impact of their OPEX. In other words the cost to produce a kilowatt of  electric power is lower in case of a SOFC or µGas turbine, the electricity needed to produce a kilogram of hydrogen gas is lower.

   
Energy

Benefits of BOSAL thin foil heat exchangers

  • High heat exchangers effectiveness: we have applications with up to 95% temperature transfer from one energy stream to the other. In other words, BOSAL preserves the quality of heat in your process so that you can do more with it.
  • Low back-pressure: you will need less power to feed our heat exchangers so have more power to do additional things with.
  • Compact design: Our modular plate design comes in four footprints from the size of a business card to an A3-page format. We stack them to cores which contain between eight and 400 cells, which enables us to size the heat exchangers to your precise specifications… and they all have one common characteristic: they are small, resulting in less thermal loss, less insulation costs, less weight, more space for something else.
  • Fully seal-tight welded assemblies: Our stainless steel/Inconel heat exchangers are fully welded with no use of seals nor gaskets. We use laser welding to achieve maximum precision and durability. Seal-tight for a lifetime.
Energy

Thoroughly tested high-performance products

Our R&D department has myriad digital tools that provide a virtual environment for simulation, prototyping, integration, and testing. In our state-of-the-art facility in Lummen, Belgium, our experienced technicians help you get the best out of our heat exchangers with durability and cost in mind. We have various test beds available whereby we can simulate specific customer process conditions.

   

Proven durability and long operational life

Some customers have been using our products for 20 years and they are still going strong. You can rely on high-performance heat exchangers that are designed with a life expectancy of 40,000 hours or more.

   
Steel

Only the best high-grade stainless steel materials

BOSAL uses only highest grade austenitic steel materials that withstand long term corrosion exposure. For the most demanding applications we offer products entirely made of nickel-chrome alloys (Inconel), for unparalleled thermal and corrosive resistance.

   

Customisation

Our products range from standard “catalogue” heat exchangers which cover applications between 500w and several hundreds of kilowatts.

But we do not stop there. Based on your precise specifications, we not only develop and build your integrated gas processing unit, including as many heat exchangers as necessary, but also can simulate and validate the resulting system for flow-uniformity, effectiveness, back-pressure, thermal strains at steady state, operating conditions, and thermal cycling behaviour.

Once past prototype validation, we can manufacture and supply pre-series of your desired gas processing unit. The next step would be further partnering with you in order to plan for mass production, whereby BOSAL will develop & commission a robotised manufacturing setup for your specific product, in any of BOSAL’s the 16 manufacturing locations across the globe.

   
Energy

Additional options & services

To increase the level of integration of your system, BOSAL’s thin foil heat exchangers  can be supplemented with a number of value-adding features:

  • Integrated catalytic oxidative coatings providing heat exchange and afterburning functionality of exhaust streams in one unit.
  • Integrated catalytic reductive coatings providing (steam) reforming functionality of hydrocarbon fuels inside our heat exchanger.
  • Aluminium protective coatings for improved corrosion resistance durability, and containment of chromium evaporation.
  • Integrated mixers: more complex units capable of steam reforming, gas mixing.
  • Burner components: integrate burner housing into heat exchanger assemblies.
  • Integrated probe location for temperature and pressure measurements.
  • Insulation services of heat exchangers and piping.