Controlled Flue Gas Cooling & Waste Heat Exchanger Solutions

GE’s waste heat recovery plant solutions aren’t just a way to cut costs and lower emissions, they allow you to recover more energy than you ever thought possible—contributing to a more successful, profitable plant.

Our waste heat exchange technology can cut your costs by:

  • Helping you achieve fuel savings for captive power/steam generator through feedwater preheating
  • Reducing your specific energy consumption for producing steel, and reducing maintenance costs for the quench tower
  • Increasing captive power plant efficiency with the most advanced flue gas energy recovery technology 

And lower emissions standards by:

  • Lowering emissions of SOx, NOX and CO2 through reduced fuel consumption
  • Increasing your captive power plant’s energy efficiency
  • Reducing your energy consumption per ton of steel produced
  • Minimizing your plant’s environmental load

…all using heat recovery solutions which seamlessly integrates with your existing installation. Our waste heat recovery technology have been proven in other industries to recover up to 30% in previously lost energy.


Want to learn how your iron & steel plant can benefit from waste energy solutions?

Discover how today 

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Waste Heat Exchanger: How it works

See step-by-step how our waste heat exchanger integrates with your existing equipment to save on operating costs.

  1. Hot flue gas from the furnace is routed through the heat exchanger (HEX) and cooled in a controlled way
  2. Through this controlled flue gas cooling, dioxin formations are eliminated
  3. Energy is transferred from flue gas to water
  4. The recovered flue gas water is routed to existing boiler feedwater preheater or district heating applications
  5. Dust accumulation is prevented by a proprietary cleaning mechanism that continuously removes dust from tubes, preventing build-up
  6. The quenching tower cools flue gas quickly to minimize the release of harmful gases. With HEX technology, the use of a quench tower can be reduced, minimizing both maintenance time and costs
  7. The cooled flue gas is routed to de-dusting equipment


For more details on this process and how it can help you recover valuable energy, please contact GE power today


Recover and reuse waste heat

Improving your plant economics isn’t easy. Here are some results we’ve seen across the iron & steel industry.

To combat the price of iron and steel, we want to help you lower your operating expenses. In the ferro-alloy and ferro-silicon industries we helped improve the economics of the smelter operation with a recovery of up to 30% of the original electrical feed to the smelters.

Other details include:

  • The melting energy used in the installation amounted to 70 MWel
  • Recovering heat from the smelting exhaust produces 20 MWel. of electricity for internal use (representing recovery of up to 28% of the smelter’s energy consumption)
  • In many cases, the payback of the waste heat is proportional to the cost of alternative power production