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Saudi Journal of Engineering and Technology (SJEAT)
Volume-11 | Issue-05 | 479-491
Original Research Article
Optimization of Heat Recovery Steam Generator (HRSG) for Reducing Exhaust Flue Gas Temperature
Benny Edet Okon, Oku Ekpenyong Nyong, Olusola David Fakorede, George Effiong Bassey, Samuel Oliver Effiom
Published : May 20, 2026
DOI : https://doi.org/10.36348/sjet.2026.v11i05.011
Abstract
This study presents the optimization of a Heat Recovery Steam Generator (HRSG) system with integrated low-temperature heat recovery to enhance thermal efficiency and promote sustainable energy utilization in a combined cycle gas turbine (CCGT) power plant. The research addresses key industrial challenges, including high exhaust flue gas temperatures (~200°C), dependence on electric heating, and underutilization of waste heat. A secondary heat exchanger (Preheater-2) is introduced downstream of the Make-Up Water Heater (MUWH) to reduce the flue gas exit temperature to 60°C while recovering energy for potable water heating. The system was modeled and optimized using Aspen Plus. Results show that the proposed configuration can offset approximately 550 units of 3 kW electric heaters, resulting in a daily energy saving of 11.55 MWh. Thermodynamic performance improved, with HRSG heat duty increasing from 2.546 MW to 3.711 MW and overall thermal efficiency rising from 61.25% to 64.76%. Sensitivity analysis identified an optimal potable water flow rate range of 60,000–70,000 kg/h, yielding stable outlet temperatures of about 80°C. Exergy analysis confirmed reduced system irreversibility. The low sulphur content of Nigerian natural gas supports safe low-temperature heat recovery without corrosion risk. The system offers a scalable solution for industrial waste heat recovery, with applications in process heating, domestic hot water generation, and energy cost reduction.
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