Dakota, Illinois
Berner Foods
A condensing HeatSponge economizer delivered a reported $135,000 utility rebate and more than $80,000 in annual fuel savings.
Representative: Meilner MechanicalRead the original PDFHeatSponge in the field
Engineered for the application. Proven in service.
Explore documented energy savings and a gallery of installed economizers, from compact boiler rooms to large industrial heat-recovery systems.
Documented results
Case studies
Download the original project reports for installation details and reported utility savings.
Chicago, Illinois
Art Institute of Chicago
Horizontal economizers were fitted into a constrained boiler room. The project reported a $154,000 utility rebate and more than $90,000 in annual fuel savings.
Representative: Meilner MechanicalRead the original PDFFor recent project updates, visit Boilerroom Equipment on LinkedIn .
Field gallery
Installed HeatSponge systems
Select any photo to see its full-size original.
01
Two-stage economizers
Staged recovery uses a conventional first stage and a condensing second stage when a suitable cold-water heat sink is available. These installations show several arrangements for performance, service access, and boiler-room fit.
SBS/UB-TITAN
Side-by-side internal three-pass gas flow with a remote condensate sump. The unbalanced arrangement provides more heating surface in the second stage.
SBS-BOSS
A larger side-by-side arrangement with an offset second stage for access and downward gas flow through the condensing section.
SPLIT-TITAN
Compact, cost-conscious two-stage installations, including units downstream of low-NOx SCR systems.
02
Single-stage HeatSponge
BOSS, MAGNUM, SUPER, TITAN, and COLOSSUS economizers serve conventional boiler feedwater heat-recovery applications. Designs can use carbon steel or application-specific stainless steel materials.
Single-stage HeatSponge installation
Three views of conventional single-stage HeatSponge economizers, showing the installed arrangement, stainless steel exterior and connected ductwork. These economizers are unique as they are bottom vertical inlet, top horizontal outlet, with an integral bypass damper installed at a Veterans Administration hospital.
Installed economizers
03
Type III condensing systems
The internal three-pass gas path supports condensing heat recovery while routing condensate to a separate sump away from the boiler. The design is evaluated against each boiler's available draft and water conditions.
MAGNUM-11 Type III
04
SHORTY coiled economizers
SHORTY economizers serve smaller boilers, generally under 300 HP. Replaceable compression-fit coils and stainless steel flue-gas-exposed components support long-term serviceability.
SHORTY-4 · Typically 150–300 HP
SHORTY-2 · Typically 80–150 HP
05
Custom & engineered installations
Site constraints often determine the arrangement. These projects include horizontal economizers, cogeneration heat recovery, and equipment fitted around emissions controls.
Low-headroom feedwater economizers
Low-headroom feedwater economizers installed on packaged coiled watertube boilers.
Horizontal TITAN installation
Two 800 HP boiler economizers engineered for a tight boiler room.
Cogeneration at a dairy facility
Two-stage heat recovery from a 5 MW combustion turbine serves boiler feedwater and an absorption chiller water loop.
College waste-heat boiler installation
A sequence showing custom feedwater economizers fitted to combustion-turbine waste-heat boilers.
Downstream of SCR
A horizontal boiler feedwater economizer fitted between an SCR system and the flue.
06
Rainmaker condensing recovery
Rainmaker applications recover sensible and latent heat from boiler exhaust for hot-water and process loads. The casing arrangement is selected around gas connections, drainage, available space, and access.
Type I
Downward gas flow to an induced-draft fan at a European medical facility, integrated with a direct-contact water-heating system.
Type II
Roof-mounted make-up-water preheat at a beverage facility, with downward gas flow and access doors for inspection.
Type IIIa
An internal three-pass arrangement with an isolated sump; the optional modulating bypass damper supports outlet-temperature control and standby oil firing.
Type IIIa installation
Six views of this Type IIIa Rainmaker above the boiler, showing its installed arrangement, stainless casing and connected ductwork.
07
Beyond the boiler room
A training display and a piece of HeatSponge company history.
HeatSponge show unit
A HeatSponge mounted to a cutaway firetube boiler display built by Ware Inc.
HeatSponge stock car
The HeatSponge late-model stock car driven by company founder Vince Sands, shown in several paint schemes.
Your next project
Bring us the operating conditions.
Boiler capacity, water temperatures, exhaust conditions, and the available installation envelope give us a useful starting point.