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Utilities company USG

Heat recovery through the acid dew point from flue gas of an incinerator resulted in an energy recovery of 5,300 kW.

HeatMatrix polymer economiser customer reference at USG industrial utilities
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HeatMatrix polymer economiser customer reference at USG industrial utilities

By-pass configuration maximizes reliability

5,300 kW heat recovered

Corrosion resistant solution

Reduce the carbon footprint

USG is a utilities provider at an industrial chemicals park. They want to decrease the carbon footprint of their operations by reducing flue gas temperatures. Heat recovery was challenging because of the corrosive nature of the flue gas from the incinerator. USG wanted to recover heat from their flue gas and use it for boiler feed water preheating.

Sulphuric acid problems prevented additional heat recovery

To handle the corrosivity of the flue gas a HeatMatrix polymer economiser was selected. The flue gas heat is used to warm up boiler feed water. The flue gas is cooled through the acid dew point inside the heat exchanger. After leaving the heat exchanger it is sent back to the stack. The whole installation was connected as a bypass to the existing duct with a dedicated extraction fan. The heat recovery system can operate completely independent. The reliability of the main process is not impacted.

Corrosion free heat recovery

After the HeatMatrix polymer economiser was installed, the flue gas was cooled to 85-90ºC. No corrosion issues were observed. The system can be operated completely independing from the main process. Heat recovery can be at full or partial load depending on the heat requirements and the steam balance on the chemical park. 

Specifications

Solution has a duty of 5290 kW
Flue gas flow 240,000 kg/hr
Temperature flue gas flow 157 °C
SO2 concentration 2.5 mg/Nm3 SO2
Installed heat exchanger HeatMatrix Polymer Economiser
Process flow diagram (PFD) of a HeatMatrix polymer economiser installed on an Incinerator

Corrosion free heat recovery

"Potential corrosion problems limited us to further reduce our CO2 emissions. With the HeatMatrix polymer economiser this challenge is solved. There is no operational impact on our main processes, thanks to the cleverly engineered by-pass installation."
Eric BloemenProcess Engineer, USG Industrial Utilities
Eric Bloemen

For more than 10 years we design and deliver heat recovery systems for industrial factories

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Want to recover more heat, just like USG Industrial Utilities?

Our process engineers assess the technical feasibility of additional heat recovery on your incinerator, or any other thermal process. Your potential reduction in CO2 emissions, energy consumption and costs is determined by our experts.

  • Analysis of process data of your incinerator
  • Minimal input data required
  • Business case on your savings potential
HeatMatrix technical assessment of heat recovery on a Regenerative Thermal Oxidizer (RTO) or Incinerator
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