MECS® OCAP™ Non-Welded Heat Exchanger
Our modular Open Channel Air Preheater (OCAP™) — like all MECS® heat exchangers — offers one of the most efficient and reliable heat recovery and air preheating solutions available for refinery, chemical, power and other industrial plants worldwide.
OCAP™ is a non-welded heat exchanger that increases the overall thermal efficiency of plant applications by recovering heat from hot gas streams, which may otherwise be stack-vented to atmosphere. The recovered heat from one gas stream is used to heat or preheat another, preparing it for use in other processes. Energy efficiency is optimized, yielding valuable process savings and boosting the cost-effectiveness of the plant.
MECS® acquired the OCAP™ Non-Welded Heat Exchanger technology from North Atlantic Technologies (NAT) in 1999. We are happy to provide quotations for new applications in addition to MECS/NAT replacement units. Backed by our extensive work with clients in the fertilizer, refining, non-ferrous metals, general chemicals, and coal gasification industries, dedicated MECS® engineers can custom-design and furnish an OCAP™ solution to meet your application needs, yielding optimum performance and energy efficiency.
A Modular Design for Optimal Flexibility
All MECS® gas-to-gas heat exchangers — including OCAP™ air preheaters — feature a compact, modular design and long service life. The units are shop-fabricated to ensure quality, and trucked as individual blocks or complete modules. With their compact size and weight, installation and field setup are much simpler than with conventional heat exchangers. The OCAP™ Non-Welded Heat Exchanger is available in both cross-flow and counter-flow configurations. Our modular approach enables us to offer one of the most flexible and efficient flow arrangements available, as well as the freedom to select appropriate materials of construction for each heat transfer zone. This modular approach also allows the unit to easily be expanded to accommodate future increases in capacity.
Unique Design Features and Distinct Advantages
The OCAP™ Non-Welded Heat Exchanger features a non-welded, "floating" plate pack contained within a rigid housing. This design permits thermal expansion and contraction with minimal stress on the unit’s components, to handle cycling applications with ease. A patented compression strip assembly provides a tight metal-to-metal seal. This design reduces stress and extends the life of the OCAP™ unit. Our uniquely constructed plates are nested together with directional ribs providing support throughout the plate pack to form the OCAP™ gas flow passages.
The OCAP™ Non-Welded Heat Exchanger design offers additional advantages over conventional exchangers:
- Generous plate clearances allow for ease of inspection
- Ability to inspect and clean both sides of the exchanger
- No tubes to vibrate or to cause acoustic resonance
- Floating plate pack to handle differential thermal expansion
- Rigid heavy-duty frame assembly for long service life
- Material "mix-and-match" construction
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High efficiency
Cold End Insulator™ Technology to Prevent Condensation
In certain cases, where the flue gas contains a significant amount of sulfur, the first pass (the "cold end" of the preheater) can be constructed to contain our proprietary Cold End Insulator™ (CEI) technology. This increases the heat transfer plate metal temperature in the cold corner of the air preheater, resulting in a condensation-free operation of the OCAP™ Non-Welded Heat Exchanger.
Our OCAP™ units provide reliability and durability in even the most difficult applications:
- Fired heaters
- Fume incineration
- DeNOx
- Boilers
- Incinerators
- Dryers
- Gas coolers
- Air preheating
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What solutions can our experts customize for your business?
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Build Skills with award
winning employee training
Reduce Employee Incident and Injury Rates
Transform your work culture, operations and profits
Increase Reliability With Clean Technologies
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Returns and Minimize WasteImprove Reliability and operability of alkylation technology
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Strategically manage energy and cut costs
Strategic and efficient energy management is key to business sustainability, and can deliver significant value. Our experts can customize the process and operational improvements that have worked for DuPont, as well as our proven cultural change methodologies, to help your organization get quick and lasting results. Our solutions help reduce energy costs, risks and carbon emissions, while strengthening operational excellence, profitability and competitive advantage.
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DuPont Asset Productivity consultants can help your organization optimize any aspect of your operating asset-base. Our integrated management processes and systems are designed to improve the cost productivity of your workforce, infrastructure and investments. Our expert consultants can customize our solutions to help you achieve new efficiency and effectiveness, improving your productivity, revenue, profits and operational excellence.
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Fortune 500 firms turn to Chris and his industry-leading team for multi-million dollar energy and operations efficiency solutions. Chris delivers results for businesses in the oil and gas, mining and metals, chemical, petrochemical, and manufacturing industries, and beyond.
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Proven Energy Efficiency Methods and Results
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DuPont Asset Productivity consultants can help your organization optimize any aspect of your operating asset-base. Our integrated management processes and systems are designed to improve the cost productivity of your workforce, infrastructure and investments. Our expert consultants can customize our solutions to help you achieve new efficiency and effectiveness, improving your productivity, revenue, profits and operational excellence.
Strategically manage energy and cut costs
Strategic and efficient energy management is key to business sustainability, and can deliver significant value. Our experts can customize the process and operational improvements that have worked for DuPont, as well as our proven cultural change methodologies, to help your organization get quick and lasting results. Our solutions help reduce energy costs, risks and carbon emissions, while strengthening operational excellence, profitability and competitive advantage.
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Global Solutions Architect
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As one of our operations management experts, Garrett helps clients capitalize on energy and asset efficiencies, shrinking their footprint and costs. He's already helped save millions for oil and gas clients, as well as within DuPont facilities.
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Enhance operational performance and process safety
Our Operational Risk Management and Process Safety experts draw on over 40 years of DuPont experience in managing hazards at our own facilities. Our customized solutions can help prevent safety and environmental incidents, to preserve your business continuity, capitalization and right to operate, and – most importantly – to protect precious lives. In addition, our proven processes can boost cost efficiency, productivity and quality.
Reduce employee incident and injury rates
As a world safety leader, DuPont experts can help you implement organizational and individual change management processes that transform your safety culture. We help your organization foster a fully-integrated commitment to safety at all levels, with practices that strengthen leadership and reduce costs. Our solutions boost morale, performance and productivity, and most importantly, help send your workers home safely every night.
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Global Practice Leader
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Transfer knowledge and transform performance
Our experts offer a full range of integrated learning technologies and engaging content to help your workforce develop critical skills. From classroom training tools to e-learning solutions to tailored, on-site seminars, our blended learning solutions help you bring your organization closer to its employee-development goals. Our training experts help you assess, build, implement and extend your corporate training programs, as well as evaluate their effectiveness.
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As a world safety leader, DuPont experts can help you implement organizational and individual change management processes that transform your safety culture. We help your organization foster a fully-integrated commitment to safety at all levels, with practices that strengthen leadership and reduce costs. Our solutions boost morale, performance and productivity, and most importantly, help send your workers home safely every night.
Improve contractor safety and turnarounds
Our Contractor Safety Management experts implement the proven practices developed in DuPont capital projects, turnarounds and supplemental labor projects worldwide. We help business owners and contractor firms reduce contractor-related injuries, labor disruptions and capital losses. We can customize a solution for your organization that helps keep your contracted projects safe, on-time and on-budget.
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Transform your work culture, operations and profits
Each of our expert consultants acts as a catalyst for business transformation. We can customize our management best practices to lead your workplace and work culture to become safer, more efficient and more environmentally sustainable. Our solutions facilitate change and enhance leadership and organizational development to deliver world-class workplace safety, footprint reduction, operations and capital effectiveness, and unsurpassed energy efficiency.
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The Savings of Safety
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Increase reliability and lower costs with clean technologies
MECS® is the global leader in sulfuric acid plant design and technology licensing for the phosphate fertilizer, oil refining, metal smelting, and numerous other industries. Our expert engineers apply the combined experience MECS® and DuPont gained in building over 1,000 acid plants worldwide. MECS® offers solutions for a wide range of markets, including power, ferrous metals, cement, titanium dioxide, coal gasification, and chemical processes.
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Vice President
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Improve reliability and operability of alkylation technology
World-leading STRATCO® technology helps refiners safely produce cleaner-burning gasoline. We license sulfuric acid alkylation technology to oil refiners and customize solutions. Our technology experts can work with you to assess and determine the right solution for your refinery. We support you every step of the way, from proposal, technology evaluation, and design through equipment fabrication, startup, and training.
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INFORMATION & IDEAS
INFORMATION & IDEAS
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ZeCor® Alloy Packing Brochure
Read the product and offering brochure to learn more about the features and benefits of using our ZeCor® Alloy packing support system. -
DynaWave® Application: Cement Kilns
To get more information on improving removal efficiency and protection against corrosion in cement kilns, please read the full bulletin on DynaWave® wet gas scrubber applications. -
DynaWave® Reverse Jet Scrubber
Read the short brochure to learn more about the application, features and benefits of using our DynaWave® Reverse Jet Scrubbers. -
ZeCor® Alloy Tech Bulletin
Read the DuPont Sustainable Solutions (DSS) ZeCor® technical bulletin to learn more about our ZeCor® Alloy corrosion-resistant and high-performance metal. -
Acid Coolers Technical Brochure
Download the MECS® engineered alloy products technical bulletin to get more information on the benefits and uses of our innovative FilmGARD®-5 Anodic Protection System offering. -
MECS® UniFlo® Technical Bulletin
Read the MECS® UniFlo® acid distributor technical bulletin to learn more about the uses and benefits of our ZeCor®-Z and ZeCor®-310M corrosion-resistant family of alloys in this application. -
Ideas for a Better Cleanup
Read the full article in Sulphur Magazine for more information on how DynaWave® wet gas scrubbers can help lower operating costs, allow greater flexibility, and lower CO2 emissions. -
Zecor® Piping System Information
MECS® ZeCor®-Z piping systems set the leading standard on prevention of leaks. The ultra-low corrosion rate of ZeCor-Z results in reduced maintenance costs. Read the brochure to learn more. -
ZeCor® Alloy Brochure
Download the ZeCor® Alloy technical bulletin to get more information on the benefits and uses of our corrosion-resistant and high-performance metals. -
MECS® WavePak™ Brochure
Read the brochure to learn more about how our MECS® WavePak™ ceramic porcelain packing can help your business increase both performance and savings.