Flue Gas Heat Economizer waste heat recovery
Flue Gas Heat Economizer waste heat recovery
Flue Gas Heat Economizer – Waste Heat Recovery System for Hot Dip Galvanizing
The flue gas heat economizer is ahot dip galvanizing equipmentdesigned specifically forhot dip galvanizing plants. It captures residual heat from the galvanizing furnace flue gas before it is released into the atmosphere, and reuses that thermal energy to heat the flux (pre-treatment solvent) tank — reducing fuel consumption and lowering the plant's overall energy costs.
In a typical hot dip galvanizing line, flue gas leaves the heating furnace at temperatures of around 350–400°C, carrying a large amount of recoverable thermal energy that would otherwise be released into the atmosphere. Our waste heat recovery system extracts this energy through a corrosion-resistant tube heat exchanger mounted directly on the furnace flue, converting it into usable hot water for process heating.
Key Benefits
High heat recovery efficiency— flue gas heat exchangersof this type typically recover 50–70% of the available waste heat in the furnace exhaust
Lower fuel and energy costs— recovered heat reduces or eliminates the need for separate fuel/electric heating of the flux tank, cutting auxiliary energy consumption
Reasonable payback period— industrial flue gas heat recovery systems generally pay back their investment within 2–5 years, depending on furnace size, fuel cost, and operating hours
Reduced emissions— less auxiliary fuel burned means lower CO₂ and flue gas emissions, supporting environmental compliance
Stable process temperature— maintains flux tank temperature at 65°C ± 5°C automatically via closed-loop temperature control
Corrosion-resistant design— components are built to withstand the acidic, zinc-particle-laden flue gas environment typical of galvanizing lines
Waste-heat Utilization Unit
Components:Tube heat exchanger, PP radiator, Expansion Tank, Hot water circulation Pump, Water softener, pipe fittings, Temperature control system, Electric control cabinet
How It Works
The tubular heat exchanger is installed directly on the galvanizing furnace flue, where flue gas heat-exchange temperature reaches 90–100°C at the exchanger surface.
The hot water circulation pump draws heated water from the exchanger into an expansion tank, which buffers pressure and volume changes in the closed-loop system.
Hot water then flows into the PP radiator, where heat is transferred to the flux (pretreatment solvent) tank.
A temperature control system continuously monitors and regulates flow, keeping the solvent tank at a stable 65°C ± 5°C without manual adjustment.
A water softener protects the system from scale buildup, extending equipment service life and maintaining heat-transfer efficiency over time.
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