Design of a Steam Turbine Exhaust Duct for a Waste-to-Energy Plant in Europe
Project summary
3 experts
6 months
England
Energy
Project description
Our team designed a 4.8-meter diameter steam turbine exhaust duct (ACC duct) for SPIG-GMAB, a European leader in air-cooled condenser design. The project was part of the construction of a new waste-to-energy facility and required expertise in piping engineering, plant layout, and finite element analysis (FEA).
The duct had to withstand thermal loads, environmental stresses (snow and wind), and mechanical constraints (differential foundation settlements). As such, it represented one of the most challenging piping systems within the facility.
A waste-to-energy project delivered with SPIG-GMAB
As a recognized specialist in air-cooled condensers, SPIG-GMAB entrusted fortil with the design of this duct as part of their new waste-to-energy project. Ensuring the reliable transfer of steam between the turbine and the condenser was a critical element in guaranteeing the plant’s overall efficiency in converting waste → energy → electricity.
Project description
Our engineering team designed a 4.8-meter diameter steam turbine exhaust duct (ACC duct) for SPIG-GMAB, a European leader in air-cooled condenser design. The project was part of the construction of a new waste-to-energy facility and required expertise in piping engineering, plant layout, and finite element analysis (FEA).
The duct had to withstand thermal loads, environmental stresses (snow and wind), and mechanical constraints (differential foundation settlements). As such, it represented one of the most challenging piping systems within the facility.
A waste-to-energy project delivered with SPIG-GMAB
As a recognized specialist in air-cooled condensers, SPIG-GMAB entrusted fortil with the design of this duct as part of their new waste-to-energy project. Ensuring the reliable transfer of steam between the turbine and the condenser was a critical element in guaranteeing the plant’s overall efficiency in converting waste → energy → electricity.
Engineering Expertise Applied
Piping engineering for waste-to-energy plants
In a waste-to-energy plant, piping design is essential to ensure safe and efficient transfer of high-temperature steam.
The duct engineered in this project transports saturated steam at 150°C and 70 mbar absolute pressure (vacuum) from the turbine to the air-cooled condenser, where it is condensed at the end of the water/steam cycle.
Our piping engineer defined the materials, wall thicknesses, stiffeners, and supports required to ensure both mechanical integrity and long-term reliability, building on a preliminary flexibility analysis. The design also integrates metallic expansion joints and spring boxes to absorb thermal and mechanical stresses.
Plant Layout & 3D Integration
Beyond the piping itself, the project demanded strong plant layout expertise to integrate the duct into the facility as a whole.
A 3D model was developed to optimize space and anticipate interactions with surrounding equipment. Coordination was carried out with the turbine supplier, the condenser vendor, the structural engineer, and the EPC contractor—allowing us to foresee and resolve constraints related to manufacturing, transport, and on-site assembly.
Finite element analysis (FEA) for mechanical reliability
Given the large scale and demanding conditions, the project relied on advanced finite element analysis (FEA). Dedicated simulations were performed on the T-spool and supports to validate robustness under operational loads, particularly under vacuum, completing the flexibility study.
Driving Waste-to-Energy Performance
This project demonstrates how fortil’s combined expertise in piping, plant layout, and structural analysis directly supports the performance and efficiency of waste-to-energy facilities.
For industrial clients such as SPIG-GMAB, partnering with an integrated engineering firm offers clear advantages:
- Accelerated design timelines
- Compliance with international codes and standards
- Optimized and reliable energy performance
Why choose fortil for your waste-to-energy projects?
Piping Engineering Expertise
We design complex steam and process networks that operate under high thermal and mechanical stress.
Proven Track Record in Large Industrial Projects
With strong expertise across the entire Waste-to-Energy value chain—process, piping, plant layout, structures, automation, and boilers—we support clients from concept to commissioning.
Supporting the Energy Transition
This project is fully aligned with fortil’s mission: supporting industrial stakeholders in the energy transition and in the development of sustainable, high-performance solutions.
By combining technical expertise with extensive industrial experience, we help clients design, validate, and integrate critical equipment that powers the energy sector forward.
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