Flexible exhaust gas waste heat recovery solutions

Waste heat is a valuable energy source and offers a unique opportunity to improve your operating economy and reduce your environmental footprint. It can be recovered from exhaust gases – the kind which come from engine and gas turbines or flue gas from industrial processes - and recovering this waste heat results in substantial energy cost savings and reduced CO₂ emissions.

Energy efficiency plays an increasingly important role in business, and waste heat recovery will ensure that the full energy content of the fuel will be utilized more efficiently instead of losing energy into the atmosphere. Waste heat recovery results in: 

• 15% improvement on fuel-to-electricity efficiency in combined cycle
• 95% improvement on plant efficiency in combined heat and power applications

Recovered waste heat can also be converted into:

• Electricity generation
• Hot water and/or steam generation which can in turn be utilized for
  
  • Process use
  • District cooling and heating
  • Fresh water generation
  • Cooling/heating system

The optimum mix of the above depends on the specific characteristics of the plant, the location, and the energy prices. We are happy to offer our expertise and vast experience related to waste heat recovery in order to help you evaluate the best possible solution to benefit your business.

Extensive know-how and decades of experience

Alfa Laval Aalborg has supplied over 1500 land-based waste heat recovery units to 100 countries from business entity Rauma, Finland.

Engine Waste Heat Recovery

Modern engine systems are considerably more efficient than their predecessors, yet much of the fuel energy is wasted as heat. By recapturing this energy and putting it to use, Alfa Laval reduces both fuel consumption and emissions.

Our waste heat recovery solutions for engine power applications secure excellent reliability and long-term high performance.

• Easy installation saves time & money
• Smart technology allows flexible operation, designed for frequent and quick ramp ups
• Effective operation with minimized capacity loss between off-service cleanings
• Vibration and pulsation resistant structure
• Compact design with flexibility for layout adaptation; perfect for retrofit installations as well

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Gas Turbine Waste Heat Recovery

Gas turbine plants are often designed for flexible operation. In both cogeneration and combined cycle applications, the entire system’s reactiveness to load changes is crucial. The faster the heat recovery steam generator (HRSG) can utilize the waste heat in the gas turbine’s exhaust gas, the higher the revenue of the plant.

Designed for fast start-ups and flexible operation, the Aalborg heat recovery solution optimized for gas turbine applications offers you a highly efficient system for sophisticated operation. Our compact and modular system is developed for quick installation and maximum uptime, and maintenance is scheduled to match the gas turbine overhauls. Our solutions enable you to start earning faster.

• Designed for fast start-ups and flexible operation
• Optimized footprint and compact customizable layout; perfect for retrofit installations as well
• Modular system design for reduced installation time and costs
• Flexible scope including concept development, engineering consulting and delivery including items from gas turbine outlet to exhaust gas stack

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Process Flue Gas Waste Heat Recovery

Industrial plants often waste remarkable amounts of heat. Capturing and utilizing this energy creates significant earning possibilities and a positive environmental impact. With the highly efficient Aalborg heat recovery solution optimized for process flue gas, you can recover and use the waste heat from your industrial plant. The increase in plant efficiency and reduction of emissions often result in payback time calculated in months rather than in years.

This valuable waste heat can be recovered and used for the plant’s own needs. These needs can vary from steel sheet cleaning and heating purposes, or heating up fuel and reducing wetness, hence improving the combustion in the kiln and its overall efficiency. However the recovered heat is used, it results in energy savings and improved sustainability.

• Increasing plant efficiency
• Tailored; beneficial especially in retrofit cases and easily integrated without effects to industrial process
• Flexible design & scope and engineering consulting
• Earning potential from free source of energy, selling heat to a neighbor plant or heat network

Steel process

Downstream steel processes, especially reheating furnaces, offer potential for flue gas waste heat recovery even after recuperation. Heat treatment furnaces also provide another source for heat recovery.

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Cement process

Cement processing is very energy intensive, where a majority of energy consumption is covered by thermal energy (75%), mainly in kiln fuel combustion. Main waste heat recovery opportunities provide hot flue gases from the preheater and hot vent air from the clinker cooler.