Accepted Manuscript

Title: Design and economic analysis of a flue gas condenser to recovery latent
heat from exhaust flue gas

Author: Meryem Terhan, Kemal Comakli

PII: S1359-4311(16)00013-2
DOI: http://dx.doi.org/doi: 10.1016/j.applthermaleng.2015.12.122
Reference: ATE 7536

To appear in: Applied Thermal Engineering

Received date: 23-6-2015

Accepted date: 25-12-2015

Please cite this article as: Meryem Terhan, Kemal Comakli, Design and economic analysis of a
flue gas condenser to recovery latent heat from exhaust flue gas, Applied Thermal Engineering
(2016), http://dx.doi.org/doi: 10.1016/j.applthermaleng.2015.12.122.

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Design and economic analysis of a flue gas condenser to recovery latent heat from
exhaust flue gas

Meryem Terhana,*, Kemal Comaklib

a
Department of Mechanical Engineeering, Engineering and Arhitecture Faculty, Kafkas University, 36100, Kars, Turkey
b
Department of Mechanical Engineeering, Engineering Faculty, Ataturk University, 25240, Erzurum, Turkey

*Corresponding author. Tel: +905071502835

Email adresses: meryembalcin83@hotmail.com (M.Terhan), kcomakli@atauni.edu.tr (K.Comakli)

Highlights

 Water vapour condensation was investigated in flue gas condenser

 A waste heat recovery unit was designed theoretically for natural-gas fired boilers.

 In the design calculations one-dimensional Finite Different Method was used.

 The economic analysis was done to predict payback period of the unit.

Abstract

In this study, we examined the event of condensing water vapour in flue gas in order to recovery the

latent heat that is carried by exhaust flue gas in 60 MW natural-gas fired district heating system of

an university. With this, we aimed to design theoretically a waste heat recovery unit and make an

economic analysis of it. For this study, actual operation data of the system were taken. In the desing

calculations of flue gas condenser, we used one-dimensional Finite Different Method and made a

computer programme. According to calculation results, exhaust flue gas temperature can be

decreased to 40 °C with a flue gas condenser that has 80 m2 surface area and is made of 316 quality

stainless steel horizontal plain tube bundles. Annual fuel saving was calculated as $ 407396.16 with

Annual Equivalent Analysis Method.

Keywords: recovery of latent heat loss from flue gas, flue gas condenser, economical analysis

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1. Introduction

Recently because of biological and environmental reasons, using natural gas in boilers has become

more common. As this clean fuel, compared to other fuels, has more hydrogen than carbon, there is

more water vapour in exhaust flue gas accompanied by latent heat. So, to recovery the latent heat

from flue gas in order to increase the thermal efficiency of boiler is very important for natural gas

fired boilers [1]. The flue gas that is taken from 1 m3 natural gas theoretically contains 1.5 kg water

vapour and 3.6 MJ latent heat. The amount of latent heat loss of the exhaust flue gas from gas fired

boilers is very high. If we recovery sensible and latent heat at the same time, total energy efficiency

can be increased about 10% [2].

The maximum heat in complete combustion is obtained at an excess air ratio of 1. The efficiency of

each energy plants depend on its own ambient conditions, and ideal amount of heat is not constant.

Flue gas temperature is always above ambient temperature [3]. Waste heat of the flue gases for

energy plants usually consists 15-40% of the fuel’s heat content. In a traditional boiler, exhaust flue

gas exit temperature is generally higher than 150 °C. In condensing natural gas-fired boilers we can

decrease the flue gas exit temperature to 40-50 °C, condense the water vapour and recovery the

latent heat in flue gas. In such condition, thermal efficiency of the boiler increases extremely. In

that boilers, energy savings is about 15% and there is a corresponding reduction in CO 2 emissions.

Modern condensing natural gas fired boilers are designed to recover the waste heat by use of

suitable materials to avoid corrosion of the wet heat transfer surfaces. Highly corrosion-resistant

material is required for condensing boiler manufacture. When the natural gas is used in boilers as a

fuel, mole fraction of water vapour in combustion products is a high value like 20%. This fraction is

lower in other fuel types. The higher the water vapour content of flue gas, the more latent heat can

be recovered, and the thermal efficiency of the boiler can be more improved. Besides, operating

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Page 2 of 23
cost of gas fired boilers is more expensive compared to coal fired boilers. As a results, it is more

suitable to condense the water vapour and recovery the latent heat in gas fired boilers [4-5].

Boilers generally can lose 20% of combustion energy with flue gas and thanks to flue gas

condensers they can recovery 50% of this loss energy according to operating conditions [6]. Flue

gas condensers are heat exchangers that recovery the flue gas heat loss coming out from stacks. In

this system, flue gas temperature is decreased to the lower point of water vapour dew point

temperature. Sensible and latent heat is recovered from flue gas and thermal efficiency of the boiler

increases observably. The usage of flue gas condenser in gas fired systems are more common.

Because, compared to other fuels, condensing in natural gas is less corrossive and moist amount in

combustion products is more. Corrossion on surface of condensing heat exchanger is an important

problem and stainless steel, teflon coated and glass heat exchangers must be use for this [7].

In a condensing heat exchanger, heat transfer is accompanied by mass transfer. Early studies

showed that heat transfer coefficient is higher in convective-condensation combining compared to

non-condensing situation, but lower than pure water vapour condensation. Water vapour

condensation situation in the presence of non-condensing gases is different than pure water vapour

condensation [4].

Colburn and Hougen developed main transport equality for water vapour condensation in the

presence of non-condensing gases. According to this, when the temperature of wall is lower than

dew point temperature of water vapour, on the surface of tube water condensing occurs and as a

result of diffusion of water from flue gas to liquid- vapour interface. Sensible heat is transferred

from flue gas to liquid-vapour interface, in addition to this, latent heat is transferred from

condensing water vapour. Heat transfer to cold water side is total of sensible and latent heat [8].

Levy et al. [9] studied condensing heat exchanger usage to recovery heat from flue gas in a power

plant. In their study, the flue gas can be cooled to below 40 ºC. Jeong et al. [8] generated an analitic

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Page 3 of 23
model of heat and mass processes in flue gas condensing heat exchanger system to develop to

predict heat transferred from flue gas to cold water. They used a pilot scale heat exchanger to show

validity of the analitic model. Experimental results showed a very good harmony with the analitic

model results. Hill [10] made the design of heat recovering systems for a plant in his thesis study.

For this plant, a lot of heat recovery systems were thought and a condensing economizer desing was

made. Chen et al. [5] in their studies made feasibility of a single flow shell and tube condenser heat

exchanger design that will be added to a 40 MW large scale district heat system. Chantana and

Kumar [11] made an experimental and theoretical study in order to examine the condensing of

water vapour for flue gas from natural gas fired boiler system. They designed a theoretical model

from heat and mass transfer similarities to study on the characteristics of mass and heat transfer

when the water vapour condensed in the presence of air low inlet water vapour mass mole fraction.

Li et al. [12] developed a mathematical model to examine the condensation of water vapour in the

presence of non-condensing gases in condensing process. The results of the model showed good

qualitative agreement with the experimental data.

Nomenclature

A Heat transfer area, m2 Uo Overall heat transfer coefficient, W/m2 K

a, b, c Constants V Velocity, m/s
Cp-cw Spesific heat of cold water, kJ/kg K y Mole fraction
DH O-gas
2 Mass diffusivity of water vapor in flue gas, m2/s ylm Log-mean mole fraction difference of non-condensable gas
di İnner diameter of tube, m W Power, kW
do Outer diameter of tube, m Greek symbols
f Friction factor α Thermal diffusivity, m2/s
hcw Heat transfer coefficient of cold water side, W/m2 K ρ Density, kg/m3
hfg Heat transfer coefficient of flue gas side, W/m2 K μ Dynamic viscosity, kg/m s
i İnterest rate η Efficient
jheat Colburn j factor for heat transfer ζ Pressure drop coefficient
jmass Colburn j factor for mass transfer Subscripts
k Specific heat ratio avg Average
k Thermal conductivity, W/m K AEA Annual Equivalent Analysis
kD Convective mass transfer coefficient, m/s b Bulk
km Mass transfer coefficient of water vapor, kg/s m2 cw Cold water
Lx Length of the heat exchanger, m cd Condensation
Ly Width of the heat exchanger, m C Cost
LeH O-gas
2 Lewis number of water vapor in flue gas f Film
l Latent heat of water vapor, kJ/kg fg Flue gas
MH O 2 Molecular weight of water, kg/kmol F Income
Mng Molecular weight of non-condensing gas in flue gas, kg/kmol i Interface
ṁcw Mass flow rate of cold water, kg/s IC Investment cost
ṁfg Mass flow rate of flue gas, kg/s max Maximum
n Economic life MPP Monthly payback period
Nu Nusselt number ng Non-condensing gas
Ny Rows of tubes in the y direction tot Total
Nz Rows of tubes in the z direction v Vapour
P Pressure, Pa w Wall
Pr Prandtl number
Prs Prandtl number based on wall temperature
ri İnner radius of tube, m

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ro Outer radius of tube, m
R Resistance, K/kW
Re Reynolds number
Sc Schmidt number
St Stanton number
Stm Mass transfer Stanton number
Sy Seperation between rows y direction
Sz Seperation between rows z direction
T Temperature, °C

In this study we made the waste heat recovery unit design theoretically and ecomonic analysis to

recovery latent heat loss from exhaust flue gas in natural gas fired district heating system. Besides,

we aimed to save the fuel by using the recovered energy in the system as a source again. Designed

flue gas condenser consists of counter-cross flow U-shaped stainless steel tube bundles. Inside the

tubes cold water, on horizontal tube bundles flue gas flows from up to down. In heat exchanger it is

planned to condense the water vapour in flue gas by decreasing the temperature down the dew

point. In order to examine the condensing, we used finite differences method and discreted the cells

to one-dimensional during the tube flow, then we calculated step by step. So that, we calculated to

predict heat transfer rates, flue gas and water inlet and outlet temperatures, surface temperatures of

tube wall and interface temperatures of condensing part, mole fractions of water vapour and other

non-condensing gases in flue gas, and finally mass transfer parameters in each discrete cell. We

found heat transfer surface area, pressure drops of tube side and shell side, pump and fan powers

related to this. We made economic analysis in case of addition this unit to the system.

2. Theoretical analysis

Heat and mass transfer occurs when the condensation starts in a heat exchanger. So, classical heat

exchanger design methods became deficient in condensing part. Non–condensing part and

condensing part should be examined seperately in heat exchanger. Because, in non–condensing part

only heat transfer is efficient while heat and mass transfer is efficient in condensing part. Colburn

and Hougen developed main transfer equality for condensing in the presence of non-condensing

gases. Colburn and Hougen equation is given in Eq. (1). According to this, when the temperature of

wall is lower than dew point temperature, water condensation occurs. Consequently, water vapour

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Page 5 of 23
diffuses towards to liquid-vapour interface from flue gas. Water vapour in flue gas is in the form of

superheated steam at Tfg temperature. Sensible heat is transferred from flue gas to liquid–vapour

interface, additionally latent heat is transferred from condensed water vapour. Heat transfer to cold

water from flue gas is the total sensible and latent heat.

h fg  ( T fg  T i )  k m  l  ( y H b
 yH i
) U  ( T i  T cw ) (1)
2O 2O o

h fg
 ( T fg  T i )  k m  l  ( y H
2O b
 yH
2O i

)  dA  m cw  c p  cw  dT cw (2)

In the Eq. (1), Ti is interface temperature for condensing of water situations. l is latent evaporation

heat of water vapour. hfg and hcw are respectively heat transfer coefficients flue gas side and cold

water side. km is mass convective coefficient and, Uo is total heat transfer coefficient.

In order to calculate the mass transfer coefficient, we use Lewis analogue equation that defines the

relation between mass diffusion and heat transfer. Colburn J factor equations with applicable ranges

for heat and mass transfer are given as:

h
j heat  St  Pr   Pr 0 , 6  Pr  60
2/3 2/3
(3)
  cp V

kD
j mass  St m  Sc   Sc 0 , 6  Sc  3000
2/3 2/3
(4)
V

where h is convective heat transfer coefficient, and kD is mass diffusivity coefficient. Lewis

analogue is requires jheat=jmass. The final form of mass transfer coefficient is derived as, [13]:

H 2O
M ng
 y ng
 ng  (5)
M  y
H 2O H 2O

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Page 6 of 23
 k D   ng h fg  M H 2O
km   (6)
c p  fg  M  y lm  Le
2/3
y ng H 2 O  gas
H 2O

In the equations, ylm logaritmic mean mole fraction difference of non-condensing gas is calculated

as:

y ng  i  y ng  b
y lm  (7)
In ( y ng  i / y ng  b )

where yng-i is mole fraction in interface of non–condensing gases in flue gas; and yng-b is mole

fraction of non–condensing gases in bulk. Besides, Lewis number of water vapour in flue gas is

LeH O-gas calculated by the Eq. (8) .

2

Sc  fg
Le H 2 O  gas
  (8)
Pr DH  gas
2O

Antoine equation which gives the relation between temperature and saturated vapour pressure for

pure components mole fraction in interface of water vapour. In the equation Ptop, kPa and Ti; is in

the unit of °C [8].

b
exp( a  )
Ti  c
xH i
 a  16 , 262 b  3799 , 89 c  226 , 35 (9)
2O
Ptop

Theoretical analysis in this study was developed with the following assumptions and simplifications

[8-11].

 Steady state one dimensional flow.

 Countercurrent cross flow condensing heat exchanger.

 Two phase flow for the flue gas side and one phase flow for the cooling water side.

 Film condensation on the tube wall surface.

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Page 7 of 23
 Film thickness assumes as zero.

 No evaporation of water vapor and no chemical reactions.

 No heat loss to the environment from the heat exchanger

 Flue gas contains CO2(g), O2(g), N2(g) and H2O(g).

Necessary equations for calculating heat transfer coefficients on the cold water side and flue gas

side in the heat exchanger can be written as follows:

4  m cw
V cw  (10)
 cw    ( d i )
2

 cw  d i  V cw
Re  (11)
 cw

 0 , 023  Re  Pr Re  10000
0 ,8 0,4
Nu cw (12)

Heat transfer coefficient on the cold water side can be found with the Eq. (13) by calculating

Nusselt number according to the range of Re number. In Equation 12, Seider-Tate (1936)’s nusselt

number correlation is used for the water turbulent flow (Re>10000) inside a smooth circular tube.

Nu  k cw
h cw  cw
(13)
di

Width of heat exchanger,

Ly  N y
 S y
(14)

average speed of flue gas,

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Page 8 of 23
 m fg
V fg  avg

 fg
 Lx  Ly
(15)

maximum speed of flue gas,

.
1/ 2
 S 
2
 sy
S  d o    
y
  Sz 
2
 do V V  (16)
y
  2

 
fg  max fg  avg
S y
 do 

and reynolds number of flue gas side is calculated with the equations [6].

 fg
 do V fg  max
Re max
 (17)
 fg

  Pr Pr s 
0 , 63 0 , 25
 0 , 27  Re  Pr 1000  Re  2  10
0 , 36 5
Nu D max max (18)

Heat transfer coefficient on flue gas side is calculated with the Eq. (19). In Equation 18, Zukauskas

(1987)’s nusselt number correlation is used for flowing in-line arrangement on tube bundles Nz>16

and 3x104<Re<106 [14].

Nu D
k fg
h fg 
do
(19)

When the contamination factor and condensation film resistance are ignored, total heat transfer

coefficient can be found with the the Eq. (20). k in the equation, is thermal conductivity of heat

exchanger material [15].

1
U 
0
ro 1 r 
ro 1
(20)
   In  o  
 
ri h cw k  ri  h fg

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Page 9 of 23
It is necessary to know the lenght of total heat exchanger (Ltot) in order to calculate pressure drop

inside the tubes [15]. Pressure drop inside tubes of cold water flow can be obtained as:

2
L tot V cw
 Ptube  f     (21)
di 2

where, f is friction factor and different types of correlations can be found according to Re number

and turbulance flow. Von Karman and Nikuradse’s friction factor correlation for smooth circular

tubes can be expressed as, [15]:

 0 , 25
f  0 , 046  Re 3  10  Re  10
4 6
(22)

In Equation 22, von Karman and Nikuradse’s friction factor correlation is used for the turbulent

flow (3x104<Re<106) inside a smooth circular tube.

In order to defeat the pressure drop necessary pump power can be written as follows:

Q cw   Ptube
W pump
 (23)
 pump

where, Qcw is volumetric flow rate of the cold water, ɳpump is efficiency of pump and taken as 80%

[16].

Drop of pressure between inlet and outlet of flue gas, flowing on the tube bundles in the shell side

can be calculated with the given Eq. (24). ζ value given in the equation is pressure drop coefficient

and differs according to arrangement of tube bundles.

  V 
2
fg  avg
 Pshell     
fg

 
(24)
 2 

10
Page 10 of 23
 1
S Z   SY  S Z
2 2
(25)
4

For in-line arrangement :

0 ,5
S   0 ,5 (SY  d )
  2   Y  1  Re  NZ SY / d  S Z / d and  1, 0 (26)
 d)
'
 d  (S Z

Fan power, needed to defeat the pressure drop can be calculated as:

k 1
 
 P  k

m  c p  fg  T fg  inlet    out   1
fg
 P  
 in 
 
W fan
 (27)
 fan

where Tfg-inlet shows flue gas inlet temperature, Pout is the total of pressure drop and atmospheric

pressure. Pin is atmospheric pressure and k is spesific heat ratio. ɳfan is aspirator efficiency and taken

as 80% in this study [17].

In economic analysis, parameters that we need to compare are these.

• First investment cost

• Economic life

• Annual maintenance and operation costs

• Annual fuel saving (benefit)

• Junk income

• Interest rate

Annual equivalent worth analysis is prefered in this economic analysis study. In annual equivalent

worth analysis, the aim is to transform money to an equivalent uniform annual cost or benefit [18].

Annual equivalent benefit (AEB) is given in Eq. (28).

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Page 11 of 23
  t Fn
t
Cn  (1  i ) n  i
AEB       (28)
 n  1 1  i  1  i 
n n
 (1  i )  1
n
n 1

Monthly payback period is calculated with the Eq. (29). IC in the equation shows first investment

cost.

IC
MPP  (29)
AEB / 12

3. Materials and Methods

In the flue gas condenser’s design calculations, one-dimensional finite different method with

forward differencing and an iterative numerical scheme were used to governing equations based on

mass and energy balances for the boundary value problem. Zones of the heat exchanger are

discretized by dividing up the total tube area into cells and calculations from governing equations

are performed on each individual cell. Thus, calculated exit variables for the first cell are used as

the inlet variables to the next successive cell. The distance of cells is also minimum. Physical

properties like thermal conductivity, dynamic viscosity and density of flue gas or water, for inlet

and outlet boundaries of cell were taken tables in heat trasfer books at bulk temperature.

A waste heat recovery unit was designed theoretically to recovery latent heat loss from flue gas in

natural gas-fired district heating system. To achieve of this, flue gas exit temperature must be lower

than dew point temperature of water vapour in flue gas mixture. This unit consists equal capacity

three flue gas condensers (condensing economizers) for three boiler in the heating system, fans,

pumps and domestic hot water distribution pipes for residences. In Fig. 2, the unit’s diagram is

shown.

4. Results

12
Page 12 of 23
In the flue gas condenser’s design calculations, we use the following steps:

Step 1: The pipe was divided into one dimensional 750 cells in the axial direction. Flue gas inlet

and cold water outlet temperatures are known inlet boundary of first cell.

Step 2: In outlet boundary of first cell flue gas, cold water, wall temperature are calculated from the

governing equation balances the entalpy change of cold water and flue gas with convective heat

transfered from tube wall to the cold water and flue gas in non-condensing part. Calculated exit

variables for the first cell are used as the inlet variables to the next successive cell. In the non-

condensing part, heat transfer rates for each discrete cell, inlet and outlet temperatures of water, flue

gas and tube’s wall are calculated.

Step 3: In condensing-part, it is necessary to modify the equation using the Colburn-Hougen

relation and the wall temperature is replaced by the interface temperature. Firstly, the interface

temperature is assumed. Then, the new interface temperature is calculated from the Colburn-

Hougen Equation. If the new interface temperature is not equal to the old one, the iteration must be

repeated until the 0.1 K difference between of them.

Step 4: In the condensing part, for each discrete cell, water vapour in flue gas differences in mole

fraction of non-condensed gases and mass transfer relations are examined.

Step 5: For the next cells repeat this calculations until the final temperature of the flue gas is

reached.

Calculation results by using finite difference method from the inlet heat exchanger tube to the outlet

and changes of water and flue gas temperatures are shown in the Fig. 3. As seen in the figure, first

condensation starts on the breaking point of parabole.

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Page 13 of 23
A part of flue gas latent heat is recovered in the condensation presence and heat transfer increases,

mass transfer occurs. While water vapour in flue gas is transferred to liquid phase from gas phase,

mole fraction of water vapour in gas mixture decreases in the liquid-vapour interface. Mole fraction

of non-condensing gases in flue gases increases. In the Fig. 4, changes of water vapour and non-

condensing gases mole fraction with distance from the inlet in heat exchanger are shown.

In condensing part, interface temperatures are calculated for discrete each cell by using iteration. In

the Fig. 5, the changes of flue gas, water and interface temperatures through the tube in condensing

part can be seen.

Flue gas condenser desing was made to decrease the flue gas exit temperature about 40 °C. With

this recovered heat, we aimed to obtain domestic hot water for residences and provide fuel saving.

As the results of calculation, flue gas condenser consists of 34 mm external diameter and 1.2 mm

thickness U-shaped tube bundles. Tube material is 316 quality stainless steel, tube bundles are

surrounded by stainless steel sheet metal, and 10 cm thickness stone wool. It consists of 25 tubes on

y direction (width) and 30 tubes on z direction (height), total in-line arrangement 750 tubes (Fig. 6).

Surface area of the condenser is about 80 m2 and each tube length is 1 m. Distances between the

tubes are Sy and Sz equally 0.045 m in-line arrangement. Heat exchanger effectiveness and

condensation efficiency is respectively 0.79 and 17.80%. A part of heat exchanger design results is

shown in Tab. 1. Condensing heat exchanger of desing results are harmonious with the results

obtained by Cortina [4]. Height of the condenser is 3.55 m and pipes are replaced in the middle 1.35

m part of it. Condenser length is 1.2 m and width is 1.25 m. In Fig. 7, connection between boiler

and condenser is shown.

Hot water need for normal flat is 130 lt/h. Concurrent factor in these calculations is taken as 0.4.

Recovered energy by cooling the flue gas to 40 °C can obtained hot water for 184 flat’s needs.

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Page 14 of 23
Economic life of the the unit is taken as 20 years. In these calculations, interest rate is 5%, daily

working hours to calculate annual operation costs of the pumps are 19 hours (yearly 6935 hours)

and the cost of electricity is $ 0.12/kWh. The heat recovery unit is consists equal capacity three flue

gas condensers (condensing economizers) for three boilers in the heating system, fans, pumps and

domestic hot water distribution pipes for residences. In economic analysis of the flue gas

condensers, tube material cost is taken as $ 8.78/m. Total investment cost of three flue gas

condenser is calculated as $ 19755. Although condensing heat recovery unit’s payback period is

varies depend on the system’s operation conditions, it usually about a year in the market. Payback

period was calculated as three months in our study, but these months in winter season. Therefore,

we can correct the payback period as about less than a year. In the Tab. 2 and Tab. 3, economic

analysis results of the unit are given.

5. Conclusions

The feasibility study of the waste heat recovery unit which is designed to be added a 60 MW natural

gas fired district heating system to recovery the heat loss of flue gas (16%) is done. Thanks to this

unit, hot water need of 184 flats is supplied. So that, 10.6% of fuel saving can be achived.

Designing flue gas condenser’s each one has 34 mm outer diameter and 1.2 mm wall thickness U-

shaped tube bundles. Tube material is 316 quality stainless steel. It consists of 25 pipes on y

direction (width) and 30 pipes on z direction (height), total 750 in-line tube bundle arrangement.

Required heat transfer surface area in order to decrease 158 °C inlet flue gas temperature to 40 °C is

calculated as 80 m². In economic analysis of the flue gas condensers, tube material cost is taken as $

8.78/m. Domestic hot water distribution system is consist of pipes, insulation of pipes and

circulation pumps. The unit’s first investment cost is $ 83711.16. According to annual equivalent

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Page 15 of 23
analysis method, annual fuel saving is calculated as $ 407396.16. The unit’s payback period is less

than 1 year.

Acknowledgment

The authors gratefully acknowledge that this work was financially supported by TUBITAK-BIDEB.

References

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[16] N. Goel, Design and performance analyses of condensing heat exchangers for recovering water
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Fig. 1. Condensation of a vapor in flue gas [11]

Fig. 2. Diagram of the heat recovery unit

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Fig 3. Changes of flue gas and water temperatures with distance from the inlet heat exchanger

Fig. 4. Changes of mole fractions with distance from the inlet condensation zone

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Fig. 5. Changes of temperatures with distance from the inlet condensation zone

Fig. 6. Views of flue gas condenser

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Fig. 7. Connection to boiler of flue gas condenser

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 Table 1. Design results of heat exchanger
Tube side-water Shell side-flue gas

Inlet Outlet Non-condensing zone Condensing zone

Tfg °C 60 10 158 51.33 51.33 40

ṁ kg/s 2.23 1.89

V m/s 1.76
2.65
Vmax m/s 7.20

Re 120238 11271

Nu 500.42 84.45

h W/m2.K 9505.02 77.75

do m 0.034 1x1.125x1.35

L m 750 625 125

k W/m.K 14.9

A m2 80 65 15

ΔP kPa 705.57 0.025

W kW 1.98 0.094

Table 2. Investment cost of the heat recovery unit

Investment Cost

Cost/m ($/m) Total Cost ($)

Flue gas condenser Tube material cost 8.78 19755.00

(SS 316) Manufacture cost 4.96 21471.68

Domestic hot water distribution system 42484.48

Table 3. Economic analysis results of the unit

Investment cost $ 83711.16

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Annual operation and maintenance cost $ 7375.8

Recurring cost $ 5279.48

Annual fuel saving (with Annual Equivalent Analysis) $ 407369.16

Economic life 20 years

Interest rate 0.05

Simple payback period 1 year

Discounted payback period 1 year

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