Economisers & Flue Gas Coolers

Economisers and flue gas coolers enable the waste heat generated by boilers and other industrial processes to be captured and reused for a range of applications, resulting in improved efficiency, reduced fuel consumption, lower emissions and operating costs.

We design and fabricate economisers in our factory in Wakefield, where we’ve been manufacturing since 1845, when our founder Edward Green invented the world’s first economiser. All of our products are bespoke to meet our customers’ specific needs and operational requirements.

What They Are

Economisers & Flue Gas Coolers

Economisers in steam power plants are designed to capture waste heat from boiler flue gas and transfer it to the boiler feedwater. This process increases the feedwater temperature, reducing the required energy input needed to achieve the rated boiler output.

Similarly, flue gas coolers perform a comparable function, though the heated water is utilised for various plant applications rather than being evaporated in the boiler.

To mitigate risks of corrosion and ensure long-term performance, we prioritise the careful design and selection of construction materials.

Where They Are Used

Power stations, including fossil fuel fired, waste-to-energy, and biomass plants,

Enhance efficiency with Green’s economisers and flue gas coolers, enabling increased electricity generation or reduced fuel consumption. Industrial facilities such as pulp and paper mills, steel plants, chemical manufacturers, and food processors leverage our economisers to preheat water, producing hot water or steam for applications like drying ovens, kilns, heating, sterilisation, cooking, and on-site electricity generation. Surplus electricity can also be exported to the grid, creating an additional revenue stream.

Our Design & Manufacture

We design and manufacture economisers and flue gas coolers as fully assembled units, including casings and headers, tailored for seamless integration into new-build projects. These units are designed for easy installation using mobile cranes and are typically constructed to EN or ASME standards with the following specifications:

Water Pressure: 10–320 bar
Water Flowrate: 10–2800 t/h
Thermal Duty: 1–100 MW
Tube Length: Up to 20m
Module Size (WxLxH): From 1m x 3m x 1m to 6m x 20m x 4m
Module Weight: 15–150 tonnes
*Custom sizes can be accommodated—please reach out with specific requirements.

Coils

We provide both single and double coils, designed for seamless assembly into existing casings on-site.

This is typically necessary when existing tubes require replacement due to failures or when a redesign is needed to enhance performance.

Our team can design and manufacture replacement coils with customised tube pitch and fin designs, ensuring full compatibility with existing casings.

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