Engineering Equipment India designs and manufactures Shell and Tube Waste heat recovery boilers. Waste heat recovery is reusing the heat, which is usually exhausted into the environment after the process completion or chemical reaction. Waste heat recovery boiler is designed to recover heat from the waste exhaust gas, heat from DG exhaust, furnace exhaust heat, Klin exhaust heat, incinerator exhaust heat. The waste heat recovered can be utilized to produce steam, hot air or hot water for preheating boiler feed water or process water or preheating of combustion air and space heating.

The large quantity of hot flue gases is generated from Boilers, Kilns, Ovens, Furnaces, Gas turbine exhaust, DG exhaust, Cement kiln exhaust, Sponge iron kiln exhaust, and Fired heaters exhaust. Heat can be lost to the atmosphere at all or any stages of the process because of the inefficient generation of heat, the transmission of energy or improper final use of energy. If some of this waste heat could be recovered, a considerable amount of primary fuel could be saved. In any heat recovery process, it is essential to know the amount of heat recoverable and also how it can be used. Waste-heat recovery boilers are always placed downstream of other items of process equipment, the operating conditions of the Heat Exchanger will always be affected by the conditions in the upstream equipment.

Usually higher the temperature, higher the quality and more cost-effective is the heat recovery. The temperature range of waste gases from industrial process equipment is as follows:

  • DG exhaust &  Gas engine exhaust heat: 480 deg C to 600 deg C,
  • Sponge iron kiln exhaust heat: 950 deg C,
  • Cement kiln exhaust: 650 deg C to 800 deg C,
  • Metal refineries: 700 deg C – 1200 deg C,
  • Glass melting furnace: 1000 deg C – 1600 deg C,
  • Solid waste incinerators: 650 deg C– 1000 deg C,
  • Fume incinerators: 650 deg C– 1450 deg C.

The Shell and Tube waste heat recovery are best suited in the following applications:

  • Recovery of heat from the process steam condensate, distillation process or refrigeration or air conditioning systems,
  • Flue gas streams from the furnace,
  • Exhaust streams from furnaces, dryers, and stacks,
  • Engine coolants.

In waste heat recovery process, where oxygen content to the tune of 5-8% in the exhaust hot gas from DG sets, gas engine and gas turbine, a concept of supplementary firing (Duct firing) is introduced to raise the temperature of exhaust gas to around 1000 deg C to produce high-pressure steam. This steam is utilized in by the steam turbine to produce additional power. This process is called combined cycle. Cascade system of waste heat recovery is suggested to ensure that the maximum amount of heat is recovered at the highest potential. In the cascade system, waste heat recovery would be where the high temperature recovered would be utilized for air pre-heating and the low temperature recovered would be utilized for process feed water heating or steam raising.

The purpose of Waste heat recovery is to minimize the amount of heat wasted in various industrial processes and also to reduce the fuel consumption which leads to a reduction in the production of Flue gas.

Waste heat recovery also reduces pollution levels. Growing concerns about climate change and the negative impact of carbon emissions have encouraged many companies to look for methods to reduce the emissions and for the production plants to implement operations that are environmentally friendly.

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Medium to be heated- water/ gas/ air/ oil, pressure, temperature, flow of the medium
Heating medium- steam/ hot water/ thermic fluid- pressure and temperature