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14 Nov 2022

By-Cast Gas/Gas heat exchangers

BY-CAST Stand: 12.0.B10

Reduce CO2 emission in combination with a higher efficiency combustion process


By-Cast is your ultimate partner for achieving targets for lower CO2 emissions and energy savings. Moreover, a DEKA air preheater (APH) can cool to lower temperatures than other solutions. Hence our slogan: Efficiency makes your difference!


At By-Cast, our mission is to help you to reduce your ecological footprint by making combustion processes more efficient, performant and cost-effective. Since our company was founded nearly four decades ago, we have grown to become a world leader in the design, production, and maintenance of cast-iron (DEKA-type) and glass heat exchangers. All over the world, from Europe and Japan to Mexico, our heat exchangers are used in industrial boilers and fired heaters to preheat the combustion air before mixing it with fuel. In doing so we considerably increase the efficiency of the installation and recuperate energy that would otherwise be lost.

By-Cast develops fuel-saving products for large consumers of fossil fuels; this is the ideal solution for a smaller ecological footprint. A DEKA air preheater (APH) reduces fuel consumption in an industrial boiler by 10 to 25 percent. How is this done? By recovering and recycling heat from emission gases.


After the installation of an air preheater companies, also emit significantly less CO2.


Originally designed to withstand the harsh conditions of coal-fired boilers in power plants, our air preheaters have gained a proven track record of quality and durability in many processes, including industrial boilers firing fuel such as coal, gas, and oil, but also with less conventional fuels such as wood chips and municipal waste. Because of their design, our heat exchangers offer an unparalleled operational life span and an unbeatable total cost of ownership (TCO), further adding to their cost-effectiveness and

Green efficiency.


Air preheaters transfer heat from the flue gases of combustion processes to the air required for the combustion reaction. In doing so, they reduce the quantity of fuel required and thus increase the efficiency of the installation. The result is an optimal utilization of the waste heat. Depending on the desired inlet/outlet temperatures of the flue gases and their composition, a By-Cast air preheater will consist of cast-iron tubes only, glass tubes only, or a hybrid combination


Air preheaters that have been in service for more than 10 years are usually operating under conditions different from what they were originally designed for. This is largely because of the change in the fuel used in the process. In other words, the heat exchanger currently in use may not be the optimal solution for the current circumstances. By-Cast can assits you with the revamping of your existing APH installation. In such cases, By-Cast will carry out a performance study. An assessment of the condition of the heat exchanger will be made by comparing the calculated performance under current conditions to the actual measurements on site.


Since APH are attached to each other or to the structural steel of the module by bolts, they can be replaced individually, thus avoiding the replacement of an entire module or the complete air preheater. This constitutes a major advantage over our competitors.


Contact details

By-Cast N.V.

Kanaalweg 77

B-3980 Tessenderlo


Telephone : +32 13 662 651

E-mail : aph@by-cast.com

Website : www.by-cast.com


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