Waste Heat Recovery Boilers

Waste Heat Recovery Steam Boiler

Industrial Steam Boilers - Noble Associates

Technical Data – Waste Heat Recovery Steam Boiler (WHRB)

Parameter          Typical Range / Specification

Boiler Type : Waste Heat Recovery Steam Boiler

Capacity : 150 kgh to 2 TPH (customizable)

Steam Pressure : 5 bar to 10 bar

Temperature : Saturated / Superheated (up to 520°C)

Heat Source : Gas Turbine Exhaust, Engine Exhaust, Furnace/Kiln Flue Gas

Fuel Consumption :Nil (utilizes waste heat only)

Exhaust Gas Temperature Inlet : 300°C – 1100°C

Outlet : 120°C – 180°C

Efficiency : Up to 85% (depending on gas composition & design)

Boiler Shell / Drum Plate : ASTM A516 Gr.60 

Tubes :  ASTM A192 

Applications : Power Plants, Cement Plants, Steel Mills, Chemical Industries, Refineries, CHP Systems

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Working Principle

Heat Source (Exhaust Gases):
High-temperature flue gases from processes such as gas turbines, furnaces, kilns, or diesel engines are directed into the WHRB.
Rather than being released directly into the atmosphere, these gases are passed through heat recovery equipment.

Heat Transfer:
Inside the WHRB, gases move across specially designed heat transfer surfaces such as tubes, economizers, and superheaters.
Here, their thermal energy is absorbed by feedwater flowing inside the tubes.

Steam Generation:
When the feedwater absorbs sufficient heat, it converts into saturated or superheated steam, depending on the system’s design.
The generated steam is then supplied either to turbines for power generation or to industrial processes for heating.

Exhaust:
Once the maximum possible heat has been extracted, the cooled gases are safely discharged into the atmosphere through a stack.
This ensures compliance with environmental norms.

Benefits

Firstly, it improves overall plant efficiency, achieving up to 30–40% energy recovery.

As a result, it reduces operating costs by minimizing fuel consumption.

Moreover, it is environmentally friendly, as it lowers CO₂ and other harmful emissions.

Finally, its compact design allows easy integration into existing industrial setups.

Maintenance Points

Heat Exchanger Cleaning: Regularly clean heat exchanger surfaces to remove dust, scale, and fouling. This practice ensures maximum heat transfer efficiency and extends equipment life.

Pipeline Inspection: Inspect gas and steam pipelines regularly to detect leaks, corrosion, or blockages. Moreover, timely inspections maintain smooth and safe operation.

Insulation Check: Check thermal insulation on ducts, pipes, and equipment to prevent unnecessary heat losses. In addition, proper insulation improves overall system efficiency.

Gasket & Seal Maintenance: Examine gaskets and seals carefully, and replace them promptly when worn out. Therefore, you can avoid costly leakages and downtime.

Instrument Calibration: Calibrate temperature, pressure, and flow sensors periodically. As a result, the system provides accurate monitoring and reliable performance.

Waste heat recovery steam Boiler Description

A Waste Heat Recovery Steam Boiler (WHRB) is an energy-efficient steam boiler that captures wasted heat from exhaust gases, flue gases, and other industrial processes. Instead of releasing high-temperature gases into the atmosphere, the heat recovery boiler reuses their thermal energy to produce steam. Industries use this steam for power generation, process heating, and production operations, which lowers energy costs and improves efficiency.

Major industries such as power plants, chemical factories, cement plants, steel mills, and gas turbine units widely adopt WHRB boilers because these facilities release large amounts of hot flue gases as byproducts. By installing a waste heat recovery steam boiler, industries reduce fuel consumption, cut greenhouse gas emissions, and achieve sustainable operations. As a result, companies benefit from lower operating costs, higher efficiency, and improved environmental performance.