CG Thermal has introduced three new standard economiser configurations designed to improve efficiency and reliability in sulfuric acid waste-heat systems.
The pre-configured designs are aimed at addressing a persistent bottleneck in sulfuric acid plants: recovering usable energy from high-temperature flue gas streams while mitigating corrosion in downstream equipment. According to the company, the new configurations are based on typical plant capacities, enabling faster project execution without the need for fully bespoke engineering in every case.
Economisers function as secondary heat exchangers within waste-heat boiler systems, capturing residual heat from flue gases – typically in the 260–315°C range – and using it to preheat boiler feedwater. This improves overall thermal efficiency and reduces energy losses through the stack.
Economisers designed to resist corrosion
CG Thermal said its designs incorporate several features intended to address common failure modes in conventional economisers, particularly in highly corrosive sulfuric acid environments. These include seal-welded tubes, pass-through tubesheet construction, and open louver arrangements that minimise stagnant zones where corrosion can initiate. The systems also use engineered flow ventilation within the return header to reduce acid condensation and external tube degradation.
The company emphasised that while the new standardised configurations enable quicker deployment, they can still be adapted to site-specific operating conditions. Fully custom economiser designs remain available for plants with more complex process requirements.
CG Thermal specialises in engineered heat transfer solutions for aggressive, high-temperature process streams, serving industries including chemicals, fertilisers and sulfuric acid production. Its portfolio includes high-temperature heat exchangers, corrosion-resistant materials and process system design capabilities aimed at improving plant reliability and uptime.
