Aspropyrgos Greece

A new heat exchanger – without changes to the existing plant.

For the U-3100 refinery unit at the Aspropyrgos industrial complex, the operator once again relies on Kablitz. Having already supplied an air preheater for the unit in 2017, Kablitz was commissioned in 2025 to replace the existing heat exchanger and delivered it in 2026.

The replacement posed special requirements: the new air preheater had to match the existing system exactly in dimensions, connections and design details. Only then could the new component be installed in the same position without fundamentally changing or extensively converting the existing plant.

For the operator this meant one thing above all: a modern replacement with as little intervention in the existing infrastructure as possible.

Precisely planned. Accurately manufactured. Directly interchangeable.

Kablitz designed and manufactured a static air preheater with finned plates, precisely matched to the existing installation conditions. The heat exchanger uses the heat contained in the flue gas to warm the combustion air: flue gas with an inlet temperature of up to 420 °C can preheat the combustion air to up to 360 °C.

Efficiency from existing energy

Less energy loss. More from every process.

By preheating the combustion air, the operator can improve the efficiency of its process furnaces while reducing fuel consumption. Waste heat that would otherwise be lost becomes an important part of more efficient plant operation – a comparatively simple measure with a direct impact on energy efficiency.

A project built on trust

When a customer comes back, it speaks for the solution.

Kablitz already supplied an air preheater for the U-3100 unit in 2017. Eight years later, the operator once again chose Kablitz and commissioned the replacement of the heat exchanger. The project shows that Kablitz not only develops new plants but also supports existing plants over the long term and supplies suitable replacement solutions.

The Kablitz scope of supply

Everything from a single source – from engineering to delivery to site.

• EngineeringDesign and construction of the new air preheater
• ManufacturingProduction of the heat exchanger precisely matched to the existing plant
• Testing & paintingQuality inspection and appropriate surface treatment
• DeliveryTransport and provision for installation on site
• Spare partsSpare parts for commissioning, start-up and two years of operation

Keep using existing infrastructure – and become more efficient.

With the new air preheater, the existing plant can continue to operate without fundamental changes.

• Exact-fit replacementThe new heat exchanger was designed to fit the existing position exactly.
• Higher energy efficiencyThe heat of the flue gas is recovered and used to preheat the combustion air.
• Lower fuel consumptionThe preheated combustion air supports more efficient operation of the process furnaces.
• Minimal interventionThe replacement can be carried out without fundamentally changing the existing plant structure.
• Long-standing partnershipAfter the first delivery in 2017, the customer once again trusts Kablitz with the replacement in 2026.