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The utilization of residual heat energy from the exhaust gas downstream of the dust filter at fossil-fired power stations offers a variety of convincing customer benefits, such as
Due to these advantages and its relatively short return of investment periods, the technology of fluoropolymer-tubed heat exchangers for flue gas heat utilization is already installed in more than 150 reference plants ranging from 100 to 1000 MWel.
The technology of flue gas heat extraction was developed in Europe more than 30 years ago. It has been proven in practice and is increasingly being applied in Asia for new and existing plants. China and South Korea, for example, are currently undertaking major national programs to fulfil stricter air emission standards by using the energy of cooled raw gas for clean gas reheating. This technology along with its benefits can also support the installation of flue-gas desulphurization units at thermal power plants in India to implement the new environment norms.
Flue gas heat utilization at temperature of 200°C and below requires suitable heat exchanger materials due to the highly corrosive acidic environment. In the past, high-nickel alloys have been used as tube material of such flue gas heat exchangers, but their service lifespan was often not more than only few years. In contrast, flue gas heat exchanger with tubes made of fluoropolymer demonstrates at least five times longer operation reliability thanks to chemical inertness and non-sticky surface properties of the fluoropolymer material. This technology was firstly developed in 1980’s in Germany and has been proven over the last decades offering a wide spectrum of flue gas heat utilization possibilities to power plant operators.
One possibility is the use of thermal energy extracted upstream of the desulphurization unit to re-heat the clean gas before entering the stack for reasons of corrosion protection as well as aerosol and plume avoidance. Traditionally, the technology of rotary-type gas-gas heaters (Ljungström design) is commonly used for this purpose, yet with plenty of problems, such as
Due to these disadvantages the plant operators in China and South Korea replace the existing Ljungström-type gas-gas heaters by non-leakage heat exchangers with fluoropolymer tubes. Considering the latest commitments in India on air pollution reduction and water savings, the power plant operators can already foresee the non-leakage gas-gas heater instead of the regenerative one and avoid the Chinese and Korean mistakes in advance.
The second possibility of flue gas heat utilization comprises a fluoropolymer-tubed cooler that extracts flue gas heat after the dust filter and transfers it via an intermediate water loop to preheat boiler combustion air or feedwater. In these heat recovery systems, the following benefits are reached:
Who should attend:
Oleg Bos | Director Proposal Management | Wallstein Ingenieur GmbH
Oleg Bos is a Director Proposal Management at Wallstein Ingenieur GmbH, where he coordinates a team specializing in development and proposal of technical solutions for heat exchange systems in fossil-fired power plants, waste-to-energy and biomass plants. Mr. Bos started his professional path at Wallstein as a Proposal Engineer in the same field 5 years ago right after attaining a master’s degree in Power Engineering of the Brandenburg University of Technology Cottbus-Senftenberg, that together allowed him to gather a deep knowledge of energy generation technologies and its related improvement solutions.
Andreas Deese | Senior Sales Engineer | Wallstein Ingenieur GmbH
Andreas Deese is Senior Sales Engineer at the Wallstein Ingenieur GmbH. He is responsible for the sales of heat utilization systems. Before joining WIG in 2017, Mr. Deese held leadership positions as MD at Bilfinger Babcock (Thailand), a specialist for corrosion resistant heat exchanger. He holds a Diplom Ingenieur in process engineering from the university of applied sciences Niederrhein, Germany
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