Application: boiler flue gas treatment
Capacity: gas volume of the system is 40,000 m3/h, and the temperature is 40℃
Transformation technology: “REGLASS condensation phase change condensation” technology
The Sinopec Maoming Branch Waste Heat Recovery Project represents a milestone in industrial energy efficiency, marking the first application of a glass plate heat exchanger as the core of a waste heat recovery system in China’s petrochemical industry. In collaboration with Sinopec Maoming Branch, Ruichang Environmental Equipment provided its patented REGLASS glass plate heat exchanger, delivering a reliable and high-performance solution for the facility’s 2-million-ton-per-year residue oil hydrogenation unit. This collaboration highlights Ruichang’s expertise in designing, developing, and implementing customized heat recovery systems for demanding industrial applications.
Challenges and Retrofit Reasons
Prior to the retrofit, the unit employed finned-tube heat pipe exchangers, which, although capable of maintaining flue gas temperatures around 110°C and relatively high thermal efficiency, suffered from severe corrosion. This necessitated frequent replacement of heat tubes during annual maintenance, incurring substantial operational costs.
System Design and Implementation
To address these challenges, Ruichang designed and installed a glass plate heat exchanger system in December 2014, which officially began operation on January 19, 2015. The system was designed to process flue gas at 19,800 kg/h with a heat exchange load of 0.7 MW, providing both high efficiency and corrosion resistance under low-temperature flue gas conditions.
Operational Performance
Since commissioning, the REGLASS glass plate air preheater has demonstrated outstanding operational stability. During operation, the flue gas inlet temperature consistently ranged between 150–180°C, while the flue gas outlet temperature was maintained between 100–110°C. Under full design load, the outlet temperature could drop below 90°C, achieving maximum furnace efficiency of over 94%. Operators adjusted flue gas bypass and other parameters to maintain an outlet temperature above 100°C, ensuring a steady furnace efficiency around 93.5%.
Long-term Reliability and Maintenance
Long-term monitoring confirmed the durability and low-maintenance performance of the glass plate heat exchanger. No fouling, channel blockage, or corrosion was observed during operation. As part of the project evaluation, the heat exchange modules were removed in early 2016 to inspect their condition after one year of low-temperature operation. The modules remained intact, reflecting the excellent corrosion resistance and operational reliability of Ruichang’s patented design.
Calibration and Client Recognition
In 2017, the Changling Equipment Research Institute calibrated the system under operational conditions, recording a flue gas outlet temperature of 108.7°C and furnace efficiency of 94.06%. By the end of 2017, the glass plate heat exchanger technology had proven highly effective in improving furnace efficiency, earning formal acceptance from Sinopec Maoming Branch. The project received positive feedback from the client, and in December 2015, the technology was publicly recognized in an article published in the China Petrochemical News.
Project Significance
The Maoming project exemplifies Ruichang Environmental Equipment’s innovation, technical expertise, and commitment to sustainable industrial solutions. By replacing traditional heat exchangers with REGLASS glass plate technology, Ruichang has provided a cost-effective, high-efficiency, and long-lasting solution for industrial waste heat recovery, setting a benchmark for future applications in the petrochemical sector.
