Fujia Group’s 20MW Waste Heat Recovery Project

In 2017, HTAC successfully delivered a high-performance air-cooled condenser (ACC) for a 20MW waste heat recovery project at the Dalian Fujia Group Co., Ltd. facility in Dalian, China. Designed to handle harsh environmental conditions, including temperatures as low as -20°C, the ACC featured advanced flat tube technology and a flow rate of 193.2 T/H, ensuring optimized performance and durability. This project showcases HTAC's expertise in engineering innovative cooling solutions for industrial applications.

Client and Project Background

End Client:

Dalian Fujia Group Co., Ltd., a leading industrial enterprise in China, required an efficient cooling solution for its waste heat recovery project. The plant aimed to convert waste heat into power, improving energy efficiency and reducing environmental impact.

Project Location:

Dalian, a coastal city in northeastern China, experiences harsh winters, with temperatures dropping as low as -20°C. The cooling system had to be designed to withstand these extreme conditions while maintaining reliable performance.

Project Scope:

HTAC was tasked with designing and delivering an air-cooled condenser (ACC) capable of:

• Efficiently condensing steam from waste heat recovery.

• Handling a flow rate of 193.2 T/H.

• Operating reliably in extremely low temperatures.

HTAC’s Solution: Advanced Air-Cooled Condenser (ACC)

HTAC provided a custom-engineered ACC that met the client’s operational and environmental requirements. The solution featured innovative flat tube technology, robust construction, and advanced thermal design.

Key Features of the ACC

1. Flat Tube Technology

• The ACC utilized flat tube heat exchangers, ensuring efficient heat transfer and minimal pressure drop.

• Flat tubes also reduce fouling and improve airflow distribution, enhancing overall performance.

2. High Flow Rate Capability (193.2 T/H)

• The system was designed to handle a high steam flow rate of 193.2 tons per hour, ensuring sufficient cooling capacity for the waste heat recovery process.

3. Extreme Cold Weather Design

• The ACC was engineered to operate reliably at temperatures as low as -20°C, making it suitable for Dalian’s harsh winter climate.

• Anti-freezing measures, including heat tracing and insulation, were integrated to prevent operational disruptions.

4. Environmental Benefits

• By eliminating the need for water in the cooling process, the ACC minimized water consumption and reduced the environmental footprint of the plant.

5. Durable Construction

• The ACC was built using high-quality materials resistant to corrosion and thermal stress, ensuring a long service life even under demanding conditions.

Results and Performance

Since its commissioning in 2017, the ACC has delivered exceptional results for the Dalian Fujia Group’s waste heat recovery project:

1. Efficient Steam Condensation

• The ACC effectively condensed the high steam flow rate of 193.2 T/H, enabling the 20MW plant to operate at optimal efficiency.

2. Reliable Cold Weather Operation

• Despite Dalian’s harsh winters, the ACC has maintained consistent performance, demonstrating its robust design for sub-zero temperatures.

3. Reduced Environmental Impact

• By using air for cooling instead of water, the system significantly reduced water usage, aligning with the plant’s sustainability goals.

4. Cost Savings

• The ACC’s efficient design minimized maintenance and operational costs, providing long-term economic benefits to the client.

Client Feedback

The Dalian Fujia Group expressed high satisfaction with HTAC’s solution, highlighting the ACC’s reliability, efficiency, and ability to perform under extreme conditions. The project demonstrated HTAC’s capability to deliver customized solutions that meet the unique challenges of industrial waste heat recovery systems.

Conclusion

HTAC’s air-cooled condenser for Dalian Fujia Group’s 20MW waste heat recovery project exemplifies the company’s expertise in designing advanced cooling solutions for challenging environments. By leveraging flat tube technology, robust engineering, and a focus on sustainability, HTAC delivered an ACC that met the client’s operational needs while reducing environmental impact.

For more information about HTAC’s air-cooled condensers and customized cooling solutions, contact us today to discuss how we can meet your project requirements.