Project Overview
This project is located at a large thermal power plant in Vietnam. The original system was configured with a 450 t/h high-pressure coal-fired boiler. During the long-term operation of the boiler, the flue gas temperature was high, and the flue gas contained a large amount of recoverable low-grade thermal energy that was not effectively utilized, resulting in energy waste and increased operating costs and emissions pressure.
To improve overall energy utilization efficiency, reduce fuel consumption, and comply with energy conservation and emission reduction policies, the owner decided to implement a flue gas waste heat recovery upgrade project for the existing boiler system. AGICO provided a complete waste heat recovery system solution, key equipment configuration, and engineering implementation services for this project.
Technical Solution Description
Based on the boiler operating parameters, flue gas composition, and on-site conditions, AGICO conducted specialized heat balance calculations and process optimization design for the system. Without affecting the safe and stable operation of the original boiler, a high-efficiency flue gas waste heat recovery device was installed in the boiler’s tail flue gas area.
The main technical solutions include
Adding a corrosion-resistant flue gas waste heat exchanger system to the boiler's tail flue to recover sensible heat from high-temperature flue gas.
Installing a plate heat exchanger system to efficiently transfer the recovered heat to the feedwater system.
Utilizing a waste heat circulating water pump and an automatic control system to achieve stable, continuous, and automated system operation.
The recovered heat is primarily used to heat the raw water/feedwater system, reducing the amount of steam extracted from the boiler itself and improving overall thermal efficiency.
This solution effectively addresses the problem of direct discharge of high-temperature flue gas while avoiding adverse effects on the original boiler body and main system structure.
Core equipment configuration
Flue gas waste heat exchanger (high-temperature and corrosion-resistant design)
Plate heat exchanger system
Waste heat circulating water pump and piping system
Automatic control and safety interlock system
Associated flue modification and steel structure support
AGICO fully considered flue gas corrosiveness, long-term operational stability, and ease of maintenance during the equipment selection phase, ensuring the system is suitable for continuous operation in power plants.
Project Implementation Results
After the project was put into operation, the waste heat recovery system operated stably, and all technical indicators met the design expectations, resulting in significant energy savings:
The system recovers approximately 10.5 MW of heat annually, effectively utilizing the recoverable thermal energy in the boiler flue gas.
This translates to an annual saving of approximately 43,000 tons of steam, significantly reducing the system's reliance on main steam.
The annual comprehensive energy-saving economic benefit is approximately 15 billion Vietnamese Dong (VND), equivalent to approximately US$600,000, providing the power plant with continuous and quantifiable economic returns.
It effectively reduces fuel consumption and lowers the temperature of boiler flue gas emissions.
It improves the overall energy utilization efficiency and environmental performance of the power plant.
Through this flue gas waste heat recovery modification, the power plant has achieved simultaneous improvements in system energy efficiency and economic benefits without increasing fuel consumption or affecting the original boiler load operation, further enhancing the long-term operational value of the project.
AGICO's Support for the Waste Heat Recovery Project
As a supplier of comprehensive solutions for factory flue gas waste heat recovery and power generation, AGICO provided this project with one-stop services ranging from technical scheme design, key equipment configuration, and system integration to engineering implementation support. This helped the client achieve an overall improvement in energy utilization efficiency, continuous reduction in operating costs, and maximized utilization of industrial waste heat resources.
AGICO has been deeply involved in the waste heat recovery field for decades, possessing extensive experience in supplying waste heat recovery equipment, undertaking turnkey projects for waste heat power plants, and upgrading and retrofitting various waste heat recovery projects. We have provided high-quality equipment and services to customers in Southeast Asia, the Middle East, Africa, and Latin America. AGICO can customize comprehensive solutions for flue gas waste heat recovery and waste heat power generation based on different countries, industries, and boiler sizes. If you have any questions or needs, please feel free to contact us.