Waste Heat Recovery Boiler
Heat Source
Flue gases from sponge iron kilns, furnaces, or industrial exhaust
Capacity
5 TPH to 20 TPH
W.P
Up to 65 kg/cm²
Temperature
Up to 480°C (Superheated Steam)
Description
A Waste Heat Recovery Boiler (WHRB) is a water-tube type system designed to generate steam at the required pressure and temperature or hot water by capturing waste heat from industrial processes, particularly Steel, Cement, Petrochemcials & Refineries etc. In this system, hot flue gases flow over the tubes while water and steam circulate within them, ensuring efficient heat transfer. The boiler features a three-pass flue gas path consisting of a radiation section, screen section, and primary and secondary super heater in the first pass, a convection section in the second, and a convection section with an economizer in the third. This design maximizes heat recovery, enhances energy efficiency, reduces fuel consumption, and supports sustainable industrial operations.
PP Boilers’ Waste Heat Recovery Boilers are engineered to maximize energy recovery from high-temperature exhaust streams, converting wasted heat into usable thermal energy. Key design elements include:
- Water-Tube Configuration: Ensures efficient heat transfer and high steam generation capacity.
- Multi-Pass Flue Gas Flow: Three flue gas passes optimize heat absorption and recovery.
- Modular Sections: Radiation, screen, superheater, convection, and economizer sections for staged heat extraction.
- Customization: Tailored to integrate with specific industrial processes like sponge iron kilns, cement plants, or refineries.
Key Points
The Waste Heat Boiler produces steam at required pressure and temperature. The boiler proposed is of Water-Tube type with flue gases coming from the Sponge Iron Kiln flowing over the tubes while water and steam circulate within the tubes. The boiler consists of three flue gas passes. The Waste Heat Boiler consists of radiation section, Screen section and Super heater section in the first pass (duly divided into Primary super heater and Secondary Super-heater) at a temperature, a Convection section in the second pass and another convection section and an Economizer section in the third pass.
Industries : Sponge Iron Plant (150 TPD, 250 TPD, 350 TPD)
Capacity : 5 tph to 15 tph
Working Pressure. : 45 kg/cm2 to 65 kg/cm2
Temperature. : 440°C to 480°C
- Fuel-Free Steam Generation: Produces steam by utilizing waste heat from industrial processes—especially Sponge Iron Kilns—without the need for additional fuel.
- High Energy Efficiency: Converts waste heat into usable energy, significantly reducing overall fuel consumption and operational costs.
- Eco-Friendly Operation: Helps lower carbon emissions by capturing and reusing heat that would otherwise be wasted.
- Industry-Specific Design: Customized to suit industries like Sponge Iron Plants (150 TPD to 350 TPD), Cement Plants, Refineries, and similar high-heat operations.
- Cost Saving & Sustainable: Reduces dependency on primary fuels while supporting green energy goals and long-term operational savings.
- IBR Certified: Fully compliant with Indian Boiler Regulations for safety, quality, and environmental standards.
Salient Feature
- Water-Tube Construction: Ensures efficient heat transfer and enables high-pressure steam generation.
- Three-Pass Flue Gas Design: First Pass: Radiation section, screen section, and superheater (split into primary and secondary)
- Second Pass: Convection section
- Third Pass: Additional convection section and economizer
- Modular & Scalable Layout: Compact, sectional design for flexible installation and easy integration into existing systems.
- Capacity Range: Steam generation from 5 TPH to 15 TPH, with pressures up to 65 kg/cm² and temperatures up to 480°C.
- Durable & Low Maintenance: Made from high-grade materials, designed for long life and minimal downtime.
- High-Temperature Performance: Built to operate reliably under extreme temperature and pressure conditions.
- Automation Compatibility: Can be integrated with modern control systems (PLC/DCS) for real-time monitoring and efficient operation.
- Energy Efficiency: Converts waste heat into usable steam.
- Cost Savings: Reduces fuel dependency and operational expenses.
- Emission Reduction: Lowers carbon footprint by recycling heat.
- High-Pressure Steam: Generates steam up to 65 kg/cm² for power/process use.
- Durable Construction: Built to withstand extreme temperatures and pressures.
- Customizable: Tailored to specific industrial requirements.
- Low Maintenance: Robust design ensures long-term reliability.
- Compliance: Meets IBR and environmental regulations.
