Flue Gas Condensation & Heat Recovery
Maximize boiler efficiency by recovering waste heat from flue gases using Thermax absorption heat pumps combined with SEGFlu scrubber technology. Reduce chimney temperatures from 150°C+ down to 15-25°C while capturing condensation energy for district heating networks.
Transform Waste Into Valuable Energy
Flue gas condensation is one of the most effective methods to increase overall boiler plant efficiency. By cooling exhaust gases below their dew point, we recover the latent heat of condensation — energy that would otherwise escape through the chimney.
Thermax absorption heat pumps, deployed in partnership with our Danish distributor SEG Energy and their proprietary SEGFlu flue gas scrubbers, provide a proven solution for this application across Scandinavia and Central Europe.
The system works by circulating cold water from the heat pump’s evaporator through the flue gas scrubber, cooling exhaust gases to near-ambient temperatures. The recovered energy preheats district heating return water, dramatically improving overall plant efficiency.
System Flow & Energy Recovery
A closed-loop system that extracts maximum energy from boiler exhaust while preheating district heating water.
Boiler Exhaust
Hot flue gases exit boiler at 150-180°C containing significant waste heat
Flue Gas Scrubber
SEGFlu scrubber cools gases with chilled water from heat pump evaporator
Condensation
Flue gas cooled to 15-25°C, recovering latent heat of water vapor condensation
District Heating
Recovered heat preheats return water from 45°C to 70-85°C before boiler
Why Flue Gas Condensation?
Efficiency Increase
Boost overall plant efficiency by 10-20% by capturing waste heat that would otherwise be lost through the chimney stack.
Fuel Savings
Significant reduction in fuel consumption as recovered heat reduces boiler firing requirements — rapid payback typically under 5 years.
Carbon Reduction
Lower emissions by reducing fuel burn — critical for meeting climate targets and regulatory requirements.
Continuous Operation
Designed for 8,000+ hours per year operation with minimal maintenance — proven reliability in demanding district heating applications.
Water Recovery
Condensed water from flue gases can be treated and returned to the boiler feedwater system, reducing makeup water requirements.
Biomass Compatible
Ideal for wood chip and biomass boilers where high moisture content in exhaust creates significant condensation potential.
Case Studies from Denmark
Thermax heat pumps deployed by SEG Energy across Danish district heating plants demonstrate exceptional performance and reliability.
Amager Bakke (ARC) Waste-to-Energy Plant
- 8 × Thermax absorption heat pumps
- 32 MW total cooling capacity
- Series configuration (2×4)
- Copenhagen district heating
Northern Europe’s largest flue gas condensation installation — one of world’s most innovative waste incineration plants.
Lemvig District Heating
- Thermax 5G3MC heat pump
- 900 kW cooling capacity
- Wood chip boiler heat source (115°C)
- Stainless steel evaporator
Chimney temperature reduced to 18°C, dramatically increasing boiler output and plant efficiency.
Vestervig District Heating
- Thermax LT10C heat pump
- 300 kW cooling capacity
- Chip boiler application
- Scrubber water at 12°C
Flue gas cooled to 12°C, maximizing condensation heat recovery and overall plant efficiency.
Egedal District Heating
- Thermax absorption heat pump
- Chip boiler (115°C drive heat)
- Chimney temp reduced to 25°C
- Complete SEG turnkey delivery
Most energy in flue gases recovered, significantly improving plant economics and carbon footprint.
Uppsala Waste Incineration
- 4 × SANYO/Thermax heat pumps
- 4.7 MW cooling capacity each
- Steam-driven configuration
- Flue gas condensation
One of Europe’s earliest large-scale flue gas condensation projects — proven 25+ year track record.
Eksjö Waste Heating Plant
- SANYO/Thermax 3.2 MW unit
- Hot water driven (incinerator)
- Flue gas condensation
- Pioneer installation
Nearly 40 years of continuous operation demonstrates exceptional longevity of absorption technology.
System Parameters
Maximize Your Boiler Efficiency
Our engineering team will design a custom flue gas condensation system for your district heating plant or industrial boiler.
Request Feasibility Study →