Starting from a traditionally designed heat exchanger arrangement, a dual pressure and supplementary fired heat recovery steam generator (HRSG) has been examined according to a novel thermal design approach which features thermodynamic loss analyses being separately applied to individual components and to the thermal system as a whole. Basic Process Integration tools are employed in order to unveil the utility target. In addition recently developed analysis tools which are especially adapted to heat recovery equipment are introduced and then applied to the HRSG. Design modifications are identified which lead to an encouraging −8% reduction of heat exchange surface with respect to initial design while steam load and utility heat supply (by means of post-combustion) are kept unchanged. The design options are commented step by step and reflected against engineering feasibility as well as their overall economic impact.

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