Waste Heat Recovery Boiler
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View Waste Heat Recovery Boiler as PDF for free.
More details
- Words: 6,581
- Pages: 28
WASTE HEAT RECOVERY SYSTEMS
Transparent Energy Systems Pvt. Ltd. Pune- 37. (INDIA) Tel : 020 – 4211347, Fax : 020 – 4212533. E-mail : [email protected] & [email protected]
INTRODUCTION Transparent has developed wide variety of superefficient Heat Recovery Systems for harnessing all types of waste heat, originating from various fuels and from different industrial sources. The Waste Heat Recovery Boilers are provided with Economizers which improve their thermal output and efficiency. Transparent superefficient Waste Heat Recovery Systems find ideal applications in Cogeneration Systems working on Reciprocating Engines and Gas Turbines.
Various sources of waste heat. ¾
¾ ¾ ¾
Exhaust heat recovery from Reciprocating Engine driven Gen-sets used for Captive Power Cogeneration and Independent Power Production. - Heavy fuel fired - Gas fired - Diesel fired Exhaust heat recovery from Gas Turbine exhaust. Jacket heat recovery from Engine Hot Waste Gases from - Scrap melting steel furnaces - Cement kilns - Industrial furnaces - Incinerators - Process Waste Gases
Converting into useful form Energy is consumed in various forms like steam, hot water, Chilling, refrigeration etc. at different places. Please refer next page for separate matrix to check different useful forms of energy to which this waste heat can be converted. Transparent has expertise in converting this waste energy into the most beneficial form of energy for any customer.
Various models of heat recovery systems
Transparent
has developed following wide range of ‘application specific designs and constructions’ of Waste Heat Recovery systems / HRSGs for above applications. Various designs of Waste Heat Recovery Systems are :
Recostar – FN Recostar – FI Recostar – S Recostar – WC Recostar – WCOF Recostar – WCRF Recostar – CC Recostar – PC Recostar – SCMP Recostar – JW
: Finned, Water tube, Non IBR. : Finned Water tube IBR. : Smoke tube IBR. : Bare Water tube, IBR. : Water tube, co-flow (concurrent flue-gas flows) IBR. : Water tube cross tube IBR. : Cylindrical coil type once through. : Pancake coil type once through. : Smoke tube, composite unfired plus fired type. : Engine jacket water heat recovery system
RECOSTAR FN Product Details Type
:
Finned Water Tube, Non IBR
Installation
:
Horizontal & Vertical, Indoor as well as Outdoor
Tube Orientation
:
Horizontal & Vertical
Fin Type
:
1) ‘L’ Type steel fins with full contact of fin base to tube 2) Integral extruded / rolled aluminium fins on C.S. tube.
Waste Gas Flow Direction
:
Horizontal/ Vertical (Upwards & Downwards)
Quality of Waste Gases
:
Normally clean dustfree gases
Acceptable dust in waste gases
:
Moderate dust level acceptable for vertical fin orientation with mechanized soot removing and collecting facility.
Type of heat recovery output
:
1) Steam–D & S / Superheated 3) Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot bulk powders, hot liquids, hot vapours.
Steam Pressure
:
Suitable for low as well as high pressure.
Steam Condition
:
Dry & saturated with external moisture separator. Superheated steam through provision of super-heater.
Water side circulation
:
Once through, forced circulation
Steam Water Separation
:
In external moisture separator
Waste Heat source suitability
:
Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Process heating, hot water generation, Thermic Fluid heating, whenever IBR installation is desired to be avoided.
Output capacity Possibilities
:
Single unit output upto approx. 600 kg/hr. Multiple units can generate proportionately higher outputs without mixing flue gases.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Automatic pneumatic cylinder operated travelling type steam jet or compressed air jet soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater
Typical lowest exhaust gas temp. at outlet of system
:
Gases generated by diesel - 1300C, Gas generated by natural gas – 1100C, Gases generated by high sulphur fuels - 1500C.
Protection against sulphur & corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
2) Hot Water
FLUE GAS IN
FLUE GAS BYPASS TO SILENCER
AUTOMATIC 3 WAY DIVERTOR VALVE
FINNED TUBE STEAM GENERATOR Vibrator F.W.PUMP
F.W. TO F.W.TANK F.W. FROM F.W.TANK
F.W.IN BLOW DOWN VALVE
FLUE GAS OUT
ECONOMIZER
Recostar FN ( Horizontal ) for 750 KVA engine
Recostar FN : Flow diagram ( Vertical )
Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 600KW X 1 No. HSD 2700 Kg./Hr. 5180C Main WHRB + Economizer 1850C Steam at 10 Bar(g) 320 Kg./Hr (F & A 1000C)
RECOSTAR FI Product Details Type
:
Finned, Water Tube, IBR
Installation
:
Horizontal & Vertical, Indoor as well as Outdoor
Tube Orientation
:
Horizontal & Vertical
Fin Type
:
1) ‘L’ Type steel fins with full contact of fin base of tube 2) Integral extruded / rolled aluminium fins on C.S. of tube.
Waste Gas Flow Direction
:
Horizontal/ Vertical (Upwards & Downwards)
Quality of Waste Gases
:
Normally clean dust free gases
Acceptable dust in waste gases
:
Moderate dust level acceptable for Boilers having vertical fin orientation with mechanized soot removal and collecting facility.
Type of output
:
Steam- D&S/ Superheated, Hot Water, Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot bulk powders, hot liquids, hot vapours.
Steam Pressure
:
Suitable for low as well as high pressure.
Steam Condition
:
Dry & saturated with external moisture separator. Superheated steam through provision of superheater.
Water side circulation
:
Natural Circulation, forced circulation.
Steam Water Separation
:
In steam drum or in external moisture separator.
Waste Heat Source suitability
:
Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Process heating, hot water generation, Thermic Fluid heating, Power generation, Cogeneration applications.
Duct firing possibilities
:
Possible for gas turbine exhaust applications.
Output capacity possibilities
:
No limits.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Travelling type soot blower. 3) Rotory soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater
Typical lowest exhaust gas temp. at outlet of system
:
Gases generated by diesel - 1300C, Gas generated by natural gas - – 1100C, Gases generated by sulphur fuels –1500C
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
STEAM OUT
PS LT LS ECONOMIZER
FLASH STEAM DRUM FLUE GAS FROM ENGINE ENTERS
FLUE GAS OUT
PS
AUTOMATIC 3 WAY DIVERTOR VALVE
FINNED TUBE HEAT RECOVERY UNIT FEED WATER IN
FEED WATER PUMPS
Recostar FI : Flow diagram Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 800KW X 1 No. HSD 4000 Kg./Hr. 5180C Main WHRB + Economizer 1510C Steam at 10 Bar(g) 700 Kg./Hr (F & A 1000C)
RECOSTAR WC Product Details Type
:
Bare Water Tube, IBR
Installation
:
Horizontal / Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Gases having low to high dust load special design for high dust load
Acceptable dust in waste gases
:
High dust level acceptable for Boilers having mechanized soot removing and collecting facility.
Type of heat recovery output
:
Steam (D&S/ Superheated), Hot Water, Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, hot bulk powders, hot liquids, hot vapors
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated and also superheated steam through provision of superheater.
Water side circulation
:
Once through, Natural Circulation & Forced / Assisted circulation
Steam Separation
:
In steam drum or in external moisture separator.
Waste heat source suitability
:
Fuel cell exhaust, Micro / miniturbine exhaust, Gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Exhaust of steel furnaces, cement kilns, metal smelters, Incinerators, Industrial furnaces, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust, Gas turbine exhaust.
Duct firing possibilities
:
Possible for applications on gas turbine exhaust. Heat addition into waste gas stream by addition of hot gases generated by separately fired hot gas generator.
Output capacity possibilities
:
No Limits.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Travelling type soot blower. 3) Rotory soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.
Typical lowest exhaust gas temperature at final outlet of system
:
Gases generated by diesel –130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
RECOSTAR S Product Details Type
:
Smoke Tube IBR PS PS
Installation
:
Horizontal & Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Low dust level acceptable.
Type of heat recovery output
:
1) D & S / superheated 2) Hot Water 3) Vapour phase Thermic Fluid Heating
Media of Waste Heat
:
Hot gases, hot liquids, hot vapors
Steam Pressure
:
Suitable for low as well as medium pressure
Steam Condition
:
Dry & saturated and also superheated steam through provision of superheater.
Water side circulation
:
Natural circulation internal to boiler.
Steam Separation
:
In Boiler drum.
Waste heat source suitability
:
Fuel cell exhaust, Micro / miniturbine exhaust small gas turbine exhaust, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Exhaust of steel furnaces, cement kilns, metal smelters, Incinerators, Industrial furnaces, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust, Gas turbine exhaust.
Output capacity possibilities
:
Typically 15 TPH
Soot removal
:
Sonic soot blowers can be used & also through self cleaning velocities.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.
Typical lowest exhaust gas temperature at final outlet of system
:
Gases generated by diesel – 130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
LS
LT
PS
Flue gas From Engine 1
PS
Steam out
Economizer
PS
Automatic 3 way Divertor valves
Flue gas Engine 2
LS
LT
PS
Flue gas out F.W. in
Recostar-S for 2 X 1 MW gas engines
F.W. pumps
Recostar-S : Typical arrangement
Recostar-S for 2 X 1 MW gas engines Recostar-S for 3 X 1 MW F.O. engines
Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 1 MW X 1 No. Furnace oil (Heavy oil) 24000 Kg./Hr. 3050C Main WHRB + 2 stage Eco. 1810C Steam at 10 Bar(g) 1500 Kg./Hr (F & A 1000C)
RECOSTAR WCOF Product Details Type
:
Water tube, coflow (Cocurrent gas flow) IBR
Installation
:
Horizontal / Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Vertical.
Waste gas flow direction
:
Vertical
Quality of Waste Gases
:
Specially suitable for dust laden gases. Provided with special mechanized soot removal and collection system.
Acceptable dust in waste gases
:
High dust level readily Accepted
Type of heat recovery output
:
1) Steam– D & S/Superheated 2) Hot Water 3) Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot vapours
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated. Superheated steam by provision of superheater.
Water side circulation
:
Natural Circulation / Forced (Assisted circulation)
Steam Separation
:
In steam drum or in external moisture separator
Waste heat source suitability
:
Exhaust of steel furnaces, cement kilns, metal smelters, incinerators, industrial furnaces, DG set exhaust process waste gases, Incinerator exhaust, Furnace exhaust, gas turbine exhaust.
Typical applications
:
Process heating, hot water generation, thermic fluid heating, power generation, cogeneration.
Duct firing possibilities
:
Possible for applications on gas turbine exhaust, Heat addition into waste gas stream by firing fuel.
Output capacity possibilities
:
No Limits.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Travelling type soot blower. 3) Rotory soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater
Typical lowest exhaust gas temp. at outlet of system
:
Glue gas from diesel – 1300C, Flue gas from Natural Gas – 1100C, Flue gas from high sulphur fuels –1500C
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
Steam drum
BYPASS
HOT GAS IN
AUTO. 3 WAY DIVERTOR VALVE STEAM FEED WATER AT 180 –1850 C
Steam drum TO CHIMNEY HOT GAS OUT
155 -1600C
EVAPORATOR
FEED WATER AT 900C
180 -1850C
ECONOMIZER -II 120 -1250C
ECONOMIZER -I
Recostar WCOF : Typical arrangement
Recostar-WCOF for 3.8 MW engine
Recostar WCOF : Flow diagram ( Vertical ) Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 3.8 MW X 1 No. Furnace oil ( Heavy oil ) 32180 Kg./Hr. 3270C Main WHRB + Economizer 1850C Steam at 10 Bar(g) 1950 Kg./Hr (F & A 1000C)
RECOSTAR WCRF Product Details Type
:
Water tube cross flow IBR
Installation
:
Vertical, Indoor and Outdoor.
Tube Orientation
:
Vertical.
Waste gas flow direction
:
Horizontal
Quality of Waste Gases
:
Moderately clean gas desired. Provided with mechanized Soot removal and collection System.
Acceptable dust in waste gases
:
Moderate dust level accepted
Type of heat recovery output
:
1) Steam– D & S / Super-heater 2) Hot Water 3) Vapour phase thermic fluid
Media of Waste Heat
:
Hot gases
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated and also superheated steam through provision of super-heater.
Water side circulation
:
Natural Circulation
Steam Separation
:
In steam drum or in external moisture separator.
Waste heat source suitability
:
Exhaust of steel furnaces, cement kilns, metal smelters, incinerators, industrial furnaces, DG set exhaust process waste gases, Incinerator exhaust, Furnace exhaust, gas turbine exhaust. (Gases with temperature less than 550oC)
Typical applications
:
Process heating, hot water generation, thermic fluid heating, power generation, cogeneration.
Duct firing possibilities
:
Possible for applications on gas turbine exhaust, Heat addition into waste gas steam by addition of hot gases generated by separately fired hot gas generator.
Output capacity possibilities
:
No Limits.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Travelling type steam soot blower.
3) Rotary soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.
Typical lowest exhaust gas temperature at final outlet of system
:
Gases generated by diesel – 130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above actual incipient limit.
STEAM OUT
STEAM DRUM FLUE GAS OUT
FLUE GAS IN
MUD DRUM
BLOW DOWN
Recostar WCRF : Flow diagram ( Vertical )
Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 3.8 MW X 1 No. Furnace oil ( Heavy oil ) 32180 Kg./Hr. 3270C Main WHRB 2050C Steam at 10 Bar(g) 1500 Kg./Hr (F & A 1000C)
RECOSTAR CC Product Details Type
:
Cylindrical coil type, water tube, once through
Installation
:
Horizontal / Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Normally clean dust free gases (special vertical design with self cleaning velocities available for dust laden gases with soot blowing arrangement)
Type of heat recovery output
:
1) Steam – D & S / Superheated 2) Hot Water 3) Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot vapours, Hot liquids
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated steam with external moisture separator. Superheated steam possible with provision of superheater and moisture separator installed between evaporator and superheater.
Degree of Superheat Possible
:
Superheat degree limited by lnlet gas temperature available.
Water side circulation
:
Once through Forced circulation
Steam Separation
:
With external moisture separator.
Waste heat source suitability
:
Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust. (High gases)
Typical applications
:
Thermic Fluid heating, process heating, hot water generation, superheated water generation, power generation, cogeneration.
Duct firing possibilities
:
Possible for gas turbine exhaust applications, heat addition into waste gas steam by addition of hot gases generated by separately fired hot gas generator.
Output capacity possibilities
:
No capacity limits as multiple units can generate higher outputs.
Soot removal
:
Through self cleaning velocities and pneumatic / steam soot blowers.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. evaporator, economizer, water preheater.
Super-heater,
Air bleed valve
Air bleed valve
Flue gas From Incinerator at 1000 0C
F. D. Fan
TIC Incinerator
Flue gas From Incinerator at 1000 0C
I. D. Fan
Waste heat recovery Thermic fluid heater
Flue gas Exit at 250 0C
F. D. Fan
TIC Incinerator
3 way Divertor Valve
3 way Divertor Valve
T.F. From Plant at 1900C
T.F. From Plant at 1900C Panel
Common Exp. Tank
I. D. Fan
Waste heat recovery Thermic fluid heater
Panel
Common Exp. Tank
DPS
T.F. From WHRTFH at 210 0C
DPS
T.F. From WHRTFH at 210 0C
T.F. to fired TFH at 2050C
T.F. to fired TFH at 2050C
Heat recovery ON
Heat recovery BYPASS
Recostar FN : Flow diagram for Incinerator based Heat recovery system
Case study
Waste heat source Material incinerated Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : :
Incinerator exhaust Waste from packaging industry 2450 Kg./Hr. 10000C Thermic fluid heater 2500C Thermic fluid at 2100C 4,86,202 Kcal/Hr.
RECOSTAR PC Product Details
Type
:
Pancake coil type, water tube, once through
Installation
:
Horizontal & Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Normally clean dust free gases.
Acceptable dust in waste gases
:
Low dust level needed in horizontal design high dust level acceptable only in vertical design with self cleaning velocities.
Type of heat recovery output
:
1) Steam – D & S / Superheated 2) Hot Water 3) Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot vapours, Hot liquids
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated steam with external moisture separator. Superheated steam possible with provision of superheater and moisture separator installed between evaporator and superheater.
Water side circulation
:
Once through Forced circulation.
Steam Separation
:
With external moisture separator.
Waste heat source suitability
:
Fuel cell exhaust, micro / min gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Thermic Fluid heating, process heating, hot water generation, superheated water generation, power generation, cogeneration.
Duct firing possibilities
:
Possible for gas turbine exhaust applications.
Output capacity possibilities
:
No capacity limits as multiple units can generate higher outputs.
Soot removal
:
Through self cleaning velocities and pneumatic steam soot blowers.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.
Hot Thermic fluid out
Pancake coils Cold Thermic fluid in
Hot flue gas in
Recostar PC : Flow diagram
Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 1 MW X 1 No. Natural Gas 5634 Kg./Hr. 4290C Main TFH 2500C Hot thermic fluid at 2200C 2,61,900 Kcal/Hr.
RECOSTAR SCMP Product Details Type
:
Smoke tube, composite (I.e. unfired plus fired zone)
Installation
:
Horizontal, Vertical, Indoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Low dust level desired.
Type of heat recovery output
:
1) Steam–D & S / Super-heat. 2) Hot water 3) Vapour phase Thermic Fluid Heating.
Media of Waste Heat
:
Hot gases, Hot vapors, Hot liquids
Steam Pressure
:
Suitable for low as well as medium pressure
Steam Condition
:
Dry & saturated and also superheated steam through provision of super-heater.
Water side circulation
:
Natural Circulation internal to boiler.
Steam Separation
:
In steam drum or in external moisture separator.
Waste heat source suitability
:
Fuel cell exhaust, micro / min gas turbine exhaust, Small gas turbine exhaust, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust, gas turbine exhaust.
Typical applications
:
Where heat recovery from waste heat needs to be supplemented with fuel firing and installation of two separate boilers unfired and fired has space limitation.
Supplemetory firing possibilities
:
Firing in internal furnace provided in boilers.
Output capacity possibilities
:
Typically upto 20T/hr capacity.
Soot removal
:
By sonic soot blowers and through self cleaning velocities.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. evaporator, economizer, water preheater.
Typical lowest exhaust gas temperature at final outlet of system
:
Gases generated by diesel – 130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
Super-heater
FLUE GAS FROM ENGINE ENTERS
ECONOMIZER
FLUE GAS FROM ENGINE LEAVES
PARTITION
BURNER
FLUE GAS FROM BURNER LEAVES
Recostar SCMP : Flow diagram ( Vertical ) Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration N.G. firing in fired zone Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : : :
Engine generator exhaust 1.1 MW X 1 No. Natural gas 4780 Kg./Hr. 5980C Main WHRB+Fired zone+ Eco. 60 SM3/Hr. 2050C Steam at 10 Bar(g) 2000 Kg./Hr (F & A 1000C)
PRODUCT FEATURES CONTROL PANEL The Control Panel is wired with solid conductor single strand wires for easy tracebility. Indications for all temperatures, safety trips provided on panel. Facilities for auto-manual switching of individual devices provided.
EASE OF FLUE GAS SIDE INSPECTION Front and rear doors are hinged type to provide simple & quick opening for full access to fireside tube surface. This job can be done by a single person
MAXIMUM HEAT RECOVERY Heat recovery in multiple stages ( 3 to 4) with help of single/double stage economizers plus water preheater ensures maximum possible heat recovery from the waste gases. Customer gets nearly 7 to 19 % of additional output compared to other makes.
CUSTOM ENGINEERED / CUSTOM BUILT
DIVERTOR VALVE
INSULATION Insulation thickness is selected scientifically to minimize heat loss even at a high flue gas temp. (Typical thickness used is 300 mm for 5000C)
Automatic pneumatically operated, Linear movement of valve, Stainless steel can work continuously. 850oC Pneumatic pressure eliminating possibility of any leakage.
Every TRANSPARENT Boiler is specifically engineered and built to every customer’s needs and specifications. Special sizes, sources of heat and auxiliary equipment are no problem with TRANSPARENT.
APPLICATION SUITABILITY PRODUCT MATRIX Matrix for of converting waste heat in useful form Source of Waste Heat
Useful Form Of Output
H O E E
L O E E
Low Pressure Steam Medium Pressure Steam High Pressure Steam Hot Thermic Fluid Hot Water (Pressurized) Hot Water (Non Pressurized) Hot Air for Process (Dryer etc) Chilled Water Chilled Brine Ice Making Cold Storage Waste Water Recycling Power Combustion Air Preheating Inlet Air Cooling
Source of Waste Heat
HOEE LOEE GEE EJH GTE IEG CPKG SPF HGP GFG FGFH AC HPC
: : : : : : : : : : : : :
Heavy Oil Engine Exhaust Light Oil Engine Exhaust Gas Engine Exhaust Engine Jacket Heat Gas Turbine Exhaust Incinerator Exit Gases Cement Plant Kiln Gases Steel Plant Furnaces Hot Gases From Process Glass Furnace Gases Flue Gases From Fired Heaters Air Compressors High Pressure Condensate
G E E
E J H
G T E
I E G
C P K G
S P F
H G P
G F G
F G F H
A C
H P C
WHRB INSTALLATION
WHRB Installed at Square Spinnings Ltd., Bangladesh, Natural Gas Fired Engine, Steam Pressure – 10.54 kg/cm2 (g).
WHRB Installed at Reid & Taylor (S. Kumar)
WHRB Installed at Heubach Colour Ltd., Natural Gas Steam Pressure – 10.54 kg/cm2 (g) WHRB Installed at Tesitura Monti (I) Pvt. Ltd. Heavy Fuel Oil Steam Pressure – 14 Kg/cm2 (g)
WHRB Installed at Hindustan Mills Ltd
WHRB Installed at Janta Jute - Dhaka
COMPARISION Safety of Source Equipment Flue gas from Engine
Flue gas bypass
Back pr. limit
pressure sensor
FPS
FPS
Automatic 3 way Divertor Valve
Back pressure control on flue gas side Transparent provides automatic flue gas monitoring & control system. If the steam pressure exceeds the predetermined value, the flue gases automatically diverted to stack. This saves the source (Engine or turbine) from getting subjected to excessive back pressure. No such system exists in other make whrb (standard model). This is quite unsafe for the engine or turbine on which the WHRB is installed. Note : In case of gas fired engines or turbines, eventhough there is very little possibility of carbon accumulation but other possibilities do exist for excessive back pressure on flue gas side. It can happen either due to leakage of boiler tube or lube oil vapour condensation in abnormal conditions. Hence even in case of gas engines/turbines, above safety feature is of paramount importance.
Safety of Waste Heat Recovery Boiler Steam pr. limit Pressure sensor
Flue gas bypass
Steam pr. limit
SPS SPS
Automatic 3 way Divertor valve
High steam pressure control Transparent provides automatic steam pressure monitoring & control system. If the steam pressure exceeds the predetermined value, the flue gases are automatically diverted to stack. This eliminates frequent operation of safety relief valve. No such system exists in other make whrb (standard model). This is quite unsafe for the WHRB. In such case one has to solely depend on safety valve. Note : Frequent operation of safety valve is an undesirable situation since it is meant for ultimate safety of boiler & supposed to operate once in a while.
COMPARISION Safety of Waste Heat Recovery Boiler Flue gas bypass Flue gas from Engine
Level sensor
LSL
LSL
Automatic 3 way Divertor Valve
Low water level safety trip Transparent provides automatic boiler water level monitoring & control system.In case the level falls below safe level, the flue gases automatically bypass the WHRB & go to stack. This eliminates boiler tubes overheating. No such system exists in other make WHRB (standard model). This is quite unsafe for the WHRB. Overheating of tubes can result into cracking & leakage. Note : Generally the feed pump & drum level controller system maintains desired level. Anyhow in case of abnormal situation the level can drop in spite of above system due to various reasons such as unavailability of water in F.W. tank, malfunctioning of drum level controller etc.
Efficiency and Outputs Heat From the Gases Flue gas from Engine at 5860C Flue gas out from WHRB at 1340C
Automatic 3 way Divertor Valve
Transparent WHRB recovers maximum possible heat from the gases. It gives atleast 7 to 10% extra output compared to other make. This needs a much bigger economizer & high manufacturing cost for Transparent but gives benefit to user in terms of more savings.
In other makes, eventhough economizer is provided, heat is recovered upto a temperature level where the manufacturing cost is less. This results in cost savings for WHRB supplier but recurring loss to the user.
COMPARISION Divertor Valve Transparent Make From Engine
Other Make Linear movement
Possible leakage Swing type movement Flap To WHRB
• Automatic pneumatically operated. • Linear movement of valve(poppet). No possibility of jamming. • Positive pneumatic pressure acts as good sealing force continuously when the valve reaches the respective positions. The poppet is pressed against the valve seat by pneumatic pressure eliminating possibility of any leakage. • Force is applied at center of poppet ensuring equal distribution throughout the sealing edges. • Made of Stainless steel which can work upto 8500C continuously.
• • •
•
•
From Engine
Manually operated. Swing type movement of valve(flap). Possibility of jamming. No positive force is applied after the flap reaches its respective positions.The mechanical play in the gearbox results in small opening due to self weight of flap & flue gas back pressure. This can result in leakage in the long run. Force is applied at one end of flap. This results in unequal force distribution.The distant edge gets less force. Made of carbon steel alloy which is not suitable for more than 5000C.
Vertical Co-flow WHRB vs. other make WHRB
Tubes are placed vertically with axis parallel to gas flow. It does not obstruct the flow of gas. Possibilities of soot accumulation are less since vertical downward flow of flue gas will help in dislodging the soot particles.
Tubes are placed horizontally with their axis perpendicular to flow of gas. This results into obstruction to gas flow & soot particles are arrested on tube surface.
COMPARISION Vertical Co-flow WHRB vs. other make WHRB DRUM
DRUM
DISCHARGE
RISER
PUMP SUCTION PUMP
Natural circulation design. No dependence on any external equipment for circulation. Uninterrupted circulation eliminates possibilities of higher TDS level in evaporator and subsequent scale deposition. Bare tubes reduces possibility of soot accumulation. Particularly for gases with high SPM like flue gases of F.O. engine, it is highly recommended to use only bare tubes without manufacturing cost goes up, user gets benefited. Bare tubes used in manufacturing are standard tubes available in market. In case of replacement user is not dependent on manufacturer for supply of tubes. Main boiler
Economizer 1st stage
Forced circulation design. Circulation is dependent on pump. Failure of pump suddenly stops circulation and results into higher TDS level in evaporator and subsequent scale deposition. Pump has to operate at very high suction pressure making the operation critical. Finned tube construction invites accumulation of soot between fins. This type of tube is not recommended particularly for flue gases with high SPM. Their use should be restricted for cleaner flue gases like gas engine / turbine.
Finned tubes used have specific fin size, shape and configuration. These tubes have to be purchased only from manufacturer and hence user is completely dependent on manufacturer for lifetime of boiler. Main boiler
Economizer 2nd stage
Two stage economizer improves Heat recovery. Feed water is heated completely upto saturation temperature with waste heat after main boiler. This is done while maintaining feed water temperature at economizer inlet above 122 Deg.C even if temperature in tank is 85 – 90 Deg.C
Economizer
Single stage economizer. Hence limited heat recovery.
COMPARISION Vertical Co-flow WHRB vs. other make WHRB F.W. at 1850 C To boiler Economizer 1st stage Feed water At 90 Deg.C
Economizer 2nd stage 1220 C
F.W. to boiler
Economizer
1550 C
Water Pre-heater
Feed water At 90 Deg.C
For flue gases of furnace oil with 4% sulphur, it is necessary to maintain metal temperature above 121 Deg.C. We provide auto temperature correction system which ensures that them feed water entering each stage of economizer is at-least at 122 Deg.C. This will ensure that all contact area is above the safe temperature level and will eliminate any possibility of corrosion.
Water in the tank directly enters Economizer without any temperature correction. Hence the tube wall temperature at economizer inlet drops below safe level and results into Cold end Corrosion. User has to buy the tubes frequently from manufacturer since these tube are not available in market.
Two alternatives are available. Steam soot blowers are provided as one of the alternatives. As a second alternative, soot removal is done on-line with mechanical knockers. This has negligible operating costs. These soot blowers can operate automatically based on ‘flue gas back pressure feedback signal’ or ‘flue gas outlet temperature feedback signal’.
Steam soot blower consume almost 3-4% of the steam output per day. This reduces net steam available to plant. Operation is manual and if not done properly, can create problems.
Transparent Group of Companies Transparent group companies, are technology leaders working in the field of Co-generation Systems, Ammonia Absorption Refrigeration Plants (AARP), Energy Conservation Contracts, Water Recycling Plants. Superefficient Boilers, Heat Recovery Systems, Pollution control, Drying Plants etc.
Business groups, Products & Systems Transparent Energy Systems Private Limited Our company was incorporated on 16th April, 1986 with the name of Vapor Energy Machines Private Limited. The first commercial production was started in January, 1988. The name of the company was changed from Vapor Energy Machines Private Limited to Transparent Energy Systems Private Limited on 18th December, 1995. 1. Co-generation Systems - www.tesplcogen.com Cogeneration Systems involving combined generation of - Power - Heat - Refrigeration / Chilling - Water Recycling / Desalination by multistage evaporation. Fuels and energy sources for Cogeneration. - Natural Gas - Heavy Fuel Oil (HFO) - Coal - Process Waste Heat - Biogas - HSD / Kerosene / LDO - Biomass Types of Cogeneration Systems - Steam Engine / Turbine Based Co-generation - Reciprocating Engine Generator Based Co-generation - Gas Turbine Based Cogeneration Type of Industries - Dairies - Paper Mills - Textile Industries - Software Parks - Chemicals & Process Industries - Hotels - Ceramic Industries - Commercial Complexes - Sugar Industries - Residential Complexes - Food Industries - Cement - Steel - Five Star Industrial Estate 2. Ammonia Absorption Refrigeration Plants- www.tesplaarp.com - Refrigerant Evaporators - Refrigerant Circulation Systems - Air Handling Units - Accessories - Flash Vessels - Ammonia Vaporizers - Turnkey Refrigeration Contracts. 3. Heat Recovery Systems – www.heatrecovery-system.com Waste Heat Recovery Boilers - Finned Tube - Water Tube - Smoke Tube Waste Heat Recovery Thermic Fluid Heaters Heat Recovery & Efficiency improvement Retrofits - Combustion Air Preheater - Economisers ( Smoke tube / water tube / finned tube type) - Condensate Recovery Systems - Blow Down Heat Recovery Systems - Flash Steam Recovery Systems 4. Boilers & Heaters – www.tespl.com - 96% Superefficient Oil / Gas Fuelled Boilers - 89% Superefficient Agrofuelled / Coal Fired Boilers. Biomass Fired) for Cogeneration application
- 93% Superefficient Thermic Fluid Heaters / Hot Air Generators - Superefficient High Pressure steam Boilers, (Oil / Gas / Coal /
5. Energy Conservation Projects – www.tespl.com Conservation of Electrical heating to Steam / Thermic Fluid / Hot Water Heating 6.
Water Treatment Plants & Other Accessories – www.tespl.com - Feed Water Deaerators - Pressure Reducing Station - Water Softners - High / Low pressure chemical dosing systems - Demineralising Plants - Structural / Self supported / Guyrope supported Steel Chimney / Stacks - Sand Filters - Fuel Storage & Handling Systems. - Activated Carbon Filters - Moisture Seperators
Transparent Technologies Private Limited 7. Evaporation, Water Recycling & zero effluent discharge plants – www.waterrecyclingplant.com Hot Water / Steam Driven Multistage Evaporators for continuous water distillation, desalination, product concentration & crystallization. - Falling Film Evaporators - Rising Film Evaporators - Plate Evaporators - Fluidized Bed evaporators - Natural Circulation Evaporators - Forced Circulation Evaporators - Counterflow Evaporators - Assisted Circulation Evaporators - Agitated Evaporators - Spiral Tube Evaporators 8. Dryers – www.ttplpune.com - Spray Dryers - Flash Dryers - Spray Coolers - Fluidized Bed / Spray Dryers
- Fluid Bed Dryers / Coolers / Agglomerators - Paddle Dryers / Vacuum Paddle Dryers - Spray Reactors cum Dryers - Homogenizers and Dispersion Mills
- Fluidized Bed Incinerators / Calciners - Dry Powder Mixing Systems and Granulators - Disintegrators & Pulvarisers
9. Pollution Control Group – www.air-pollutioncontrol.com Incinerators - Spray Dryer cum Combustion Chamber Incinerators - Fluidized Bed Incinerators for Liquids and Solids & Gases - Packaged Fixed Grate Incinerators for Solids - Liquid / Gas Incinerators - Fluidized Bed Paint Stripping Systems for Paint Coating Air Pollution Control - Cyclone / Multicones - Bag Filters - Wet / Venturi Scrubbers - Mechanical Dust Collectors - Flue Gas Desulphurisation Plants
Transparent Energy Systems Pvt. Ltd. Pune- 37. (INDIA) Tel : 020 – 4211347, Fax : 020 – 4212533. E-mail : [email protected] & [email protected]
INTRODUCTION Transparent has developed wide variety of superefficient Heat Recovery Systems for harnessing all types of waste heat, originating from various fuels and from different industrial sources. The Waste Heat Recovery Boilers are provided with Economizers which improve their thermal output and efficiency. Transparent superefficient Waste Heat Recovery Systems find ideal applications in Cogeneration Systems working on Reciprocating Engines and Gas Turbines.
Various sources of waste heat. ¾
¾ ¾ ¾
Exhaust heat recovery from Reciprocating Engine driven Gen-sets used for Captive Power Cogeneration and Independent Power Production. - Heavy fuel fired - Gas fired - Diesel fired Exhaust heat recovery from Gas Turbine exhaust. Jacket heat recovery from Engine Hot Waste Gases from - Scrap melting steel furnaces - Cement kilns - Industrial furnaces - Incinerators - Process Waste Gases
Converting into useful form Energy is consumed in various forms like steam, hot water, Chilling, refrigeration etc. at different places. Please refer next page for separate matrix to check different useful forms of energy to which this waste heat can be converted. Transparent has expertise in converting this waste energy into the most beneficial form of energy for any customer.
Various models of heat recovery systems
Transparent
has developed following wide range of ‘application specific designs and constructions’ of Waste Heat Recovery systems / HRSGs for above applications. Various designs of Waste Heat Recovery Systems are :
Recostar – FN Recostar – FI Recostar – S Recostar – WC Recostar – WCOF Recostar – WCRF Recostar – CC Recostar – PC Recostar – SCMP Recostar – JW
: Finned, Water tube, Non IBR. : Finned Water tube IBR. : Smoke tube IBR. : Bare Water tube, IBR. : Water tube, co-flow (concurrent flue-gas flows) IBR. : Water tube cross tube IBR. : Cylindrical coil type once through. : Pancake coil type once through. : Smoke tube, composite unfired plus fired type. : Engine jacket water heat recovery system
RECOSTAR FN Product Details Type
:
Finned Water Tube, Non IBR
Installation
:
Horizontal & Vertical, Indoor as well as Outdoor
Tube Orientation
:
Horizontal & Vertical
Fin Type
:
1) ‘L’ Type steel fins with full contact of fin base to tube 2) Integral extruded / rolled aluminium fins on C.S. tube.
Waste Gas Flow Direction
:
Horizontal/ Vertical (Upwards & Downwards)
Quality of Waste Gases
:
Normally clean dustfree gases
Acceptable dust in waste gases
:
Moderate dust level acceptable for vertical fin orientation with mechanized soot removing and collecting facility.
Type of heat recovery output
:
1) Steam–D & S / Superheated 3) Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot bulk powders, hot liquids, hot vapours.
Steam Pressure
:
Suitable for low as well as high pressure.
Steam Condition
:
Dry & saturated with external moisture separator. Superheated steam through provision of super-heater.
Water side circulation
:
Once through, forced circulation
Steam Water Separation
:
In external moisture separator
Waste Heat source suitability
:
Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Process heating, hot water generation, Thermic Fluid heating, whenever IBR installation is desired to be avoided.
Output capacity Possibilities
:
Single unit output upto approx. 600 kg/hr. Multiple units can generate proportionately higher outputs without mixing flue gases.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Automatic pneumatic cylinder operated travelling type steam jet or compressed air jet soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater
Typical lowest exhaust gas temp. at outlet of system
:
Gases generated by diesel - 1300C, Gas generated by natural gas – 1100C, Gases generated by high sulphur fuels - 1500C.
Protection against sulphur & corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
2) Hot Water
FLUE GAS IN
FLUE GAS BYPASS TO SILENCER
AUTOMATIC 3 WAY DIVERTOR VALVE
FINNED TUBE STEAM GENERATOR Vibrator F.W.PUMP
F.W. TO F.W.TANK F.W. FROM F.W.TANK
F.W.IN BLOW DOWN VALVE
FLUE GAS OUT
ECONOMIZER
Recostar FN ( Horizontal ) for 750 KVA engine
Recostar FN : Flow diagram ( Vertical )
Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 600KW X 1 No. HSD 2700 Kg./Hr. 5180C Main WHRB + Economizer 1850C Steam at 10 Bar(g) 320 Kg./Hr (F & A 1000C)
RECOSTAR FI Product Details Type
:
Finned, Water Tube, IBR
Installation
:
Horizontal & Vertical, Indoor as well as Outdoor
Tube Orientation
:
Horizontal & Vertical
Fin Type
:
1) ‘L’ Type steel fins with full contact of fin base of tube 2) Integral extruded / rolled aluminium fins on C.S. of tube.
Waste Gas Flow Direction
:
Horizontal/ Vertical (Upwards & Downwards)
Quality of Waste Gases
:
Normally clean dust free gases
Acceptable dust in waste gases
:
Moderate dust level acceptable for Boilers having vertical fin orientation with mechanized soot removal and collecting facility.
Type of output
:
Steam- D&S/ Superheated, Hot Water, Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot bulk powders, hot liquids, hot vapours.
Steam Pressure
:
Suitable for low as well as high pressure.
Steam Condition
:
Dry & saturated with external moisture separator. Superheated steam through provision of superheater.
Water side circulation
:
Natural Circulation, forced circulation.
Steam Water Separation
:
In steam drum or in external moisture separator.
Waste Heat Source suitability
:
Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Process heating, hot water generation, Thermic Fluid heating, Power generation, Cogeneration applications.
Duct firing possibilities
:
Possible for gas turbine exhaust applications.
Output capacity possibilities
:
No limits.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Travelling type soot blower. 3) Rotory soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater
Typical lowest exhaust gas temp. at outlet of system
:
Gases generated by diesel - 1300C, Gas generated by natural gas - – 1100C, Gases generated by sulphur fuels –1500C
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
STEAM OUT
PS LT LS ECONOMIZER
FLASH STEAM DRUM FLUE GAS FROM ENGINE ENTERS
FLUE GAS OUT
PS
AUTOMATIC 3 WAY DIVERTOR VALVE
FINNED TUBE HEAT RECOVERY UNIT FEED WATER IN
FEED WATER PUMPS
Recostar FI : Flow diagram Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 800KW X 1 No. HSD 4000 Kg./Hr. 5180C Main WHRB + Economizer 1510C Steam at 10 Bar(g) 700 Kg./Hr (F & A 1000C)
RECOSTAR WC Product Details Type
:
Bare Water Tube, IBR
Installation
:
Horizontal / Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Gases having low to high dust load special design for high dust load
Acceptable dust in waste gases
:
High dust level acceptable for Boilers having mechanized soot removing and collecting facility.
Type of heat recovery output
:
Steam (D&S/ Superheated), Hot Water, Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, hot bulk powders, hot liquids, hot vapors
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated and also superheated steam through provision of superheater.
Water side circulation
:
Once through, Natural Circulation & Forced / Assisted circulation
Steam Separation
:
In steam drum or in external moisture separator.
Waste heat source suitability
:
Fuel cell exhaust, Micro / miniturbine exhaust, Gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Exhaust of steel furnaces, cement kilns, metal smelters, Incinerators, Industrial furnaces, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust, Gas turbine exhaust.
Duct firing possibilities
:
Possible for applications on gas turbine exhaust. Heat addition into waste gas stream by addition of hot gases generated by separately fired hot gas generator.
Output capacity possibilities
:
No Limits.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Travelling type soot blower. 3) Rotory soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.
Typical lowest exhaust gas temperature at final outlet of system
:
Gases generated by diesel –130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
RECOSTAR S Product Details Type
:
Smoke Tube IBR PS PS
Installation
:
Horizontal & Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Low dust level acceptable.
Type of heat recovery output
:
1) D & S / superheated 2) Hot Water 3) Vapour phase Thermic Fluid Heating
Media of Waste Heat
:
Hot gases, hot liquids, hot vapors
Steam Pressure
:
Suitable for low as well as medium pressure
Steam Condition
:
Dry & saturated and also superheated steam through provision of superheater.
Water side circulation
:
Natural circulation internal to boiler.
Steam Separation
:
In Boiler drum.
Waste heat source suitability
:
Fuel cell exhaust, Micro / miniturbine exhaust small gas turbine exhaust, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Exhaust of steel furnaces, cement kilns, metal smelters, Incinerators, Industrial furnaces, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust, Gas turbine exhaust.
Output capacity possibilities
:
Typically 15 TPH
Soot removal
:
Sonic soot blowers can be used & also through self cleaning velocities.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.
Typical lowest exhaust gas temperature at final outlet of system
:
Gases generated by diesel – 130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
LS
LT
PS
Flue gas From Engine 1
PS
Steam out
Economizer
PS
Automatic 3 way Divertor valves
Flue gas Engine 2
LS
LT
PS
Flue gas out F.W. in
Recostar-S for 2 X 1 MW gas engines
F.W. pumps
Recostar-S : Typical arrangement
Recostar-S for 2 X 1 MW gas engines Recostar-S for 3 X 1 MW F.O. engines
Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 1 MW X 1 No. Furnace oil (Heavy oil) 24000 Kg./Hr. 3050C Main WHRB + 2 stage Eco. 1810C Steam at 10 Bar(g) 1500 Kg./Hr (F & A 1000C)
RECOSTAR WCOF Product Details Type
:
Water tube, coflow (Cocurrent gas flow) IBR
Installation
:
Horizontal / Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Vertical.
Waste gas flow direction
:
Vertical
Quality of Waste Gases
:
Specially suitable for dust laden gases. Provided with special mechanized soot removal and collection system.
Acceptable dust in waste gases
:
High dust level readily Accepted
Type of heat recovery output
:
1) Steam– D & S/Superheated 2) Hot Water 3) Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot vapours
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated. Superheated steam by provision of superheater.
Water side circulation
:
Natural Circulation / Forced (Assisted circulation)
Steam Separation
:
In steam drum or in external moisture separator
Waste heat source suitability
:
Exhaust of steel furnaces, cement kilns, metal smelters, incinerators, industrial furnaces, DG set exhaust process waste gases, Incinerator exhaust, Furnace exhaust, gas turbine exhaust.
Typical applications
:
Process heating, hot water generation, thermic fluid heating, power generation, cogeneration.
Duct firing possibilities
:
Possible for applications on gas turbine exhaust, Heat addition into waste gas stream by firing fuel.
Output capacity possibilities
:
No Limits.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Travelling type soot blower. 3) Rotory soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater
Typical lowest exhaust gas temp. at outlet of system
:
Glue gas from diesel – 1300C, Flue gas from Natural Gas – 1100C, Flue gas from high sulphur fuels –1500C
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
Steam drum
BYPASS
HOT GAS IN
AUTO. 3 WAY DIVERTOR VALVE STEAM FEED WATER AT 180 –1850 C
Steam drum TO CHIMNEY HOT GAS OUT
155 -1600C
EVAPORATOR
FEED WATER AT 900C
180 -1850C
ECONOMIZER -II 120 -1250C
ECONOMIZER -I
Recostar WCOF : Typical arrangement
Recostar-WCOF for 3.8 MW engine
Recostar WCOF : Flow diagram ( Vertical ) Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 3.8 MW X 1 No. Furnace oil ( Heavy oil ) 32180 Kg./Hr. 3270C Main WHRB + Economizer 1850C Steam at 10 Bar(g) 1950 Kg./Hr (F & A 1000C)
RECOSTAR WCRF Product Details Type
:
Water tube cross flow IBR
Installation
:
Vertical, Indoor and Outdoor.
Tube Orientation
:
Vertical.
Waste gas flow direction
:
Horizontal
Quality of Waste Gases
:
Moderately clean gas desired. Provided with mechanized Soot removal and collection System.
Acceptable dust in waste gases
:
Moderate dust level accepted
Type of heat recovery output
:
1) Steam– D & S / Super-heater 2) Hot Water 3) Vapour phase thermic fluid
Media of Waste Heat
:
Hot gases
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated and also superheated steam through provision of super-heater.
Water side circulation
:
Natural Circulation
Steam Separation
:
In steam drum or in external moisture separator.
Waste heat source suitability
:
Exhaust of steel furnaces, cement kilns, metal smelters, incinerators, industrial furnaces, DG set exhaust process waste gases, Incinerator exhaust, Furnace exhaust, gas turbine exhaust. (Gases with temperature less than 550oC)
Typical applications
:
Process heating, hot water generation, thermic fluid heating, power generation, cogeneration.
Duct firing possibilities
:
Possible for applications on gas turbine exhaust, Heat addition into waste gas steam by addition of hot gases generated by separately fired hot gas generator.
Output capacity possibilities
:
No Limits.
Soot removal
:
1) Mechanized vibrating soot removal. 2) Travelling type steam soot blower.
3) Rotary soot blower.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.
Typical lowest exhaust gas temperature at final outlet of system
:
Gases generated by diesel – 130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above actual incipient limit.
STEAM OUT
STEAM DRUM FLUE GAS OUT
FLUE GAS IN
MUD DRUM
BLOW DOWN
Recostar WCRF : Flow diagram ( Vertical )
Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 3.8 MW X 1 No. Furnace oil ( Heavy oil ) 32180 Kg./Hr. 3270C Main WHRB 2050C Steam at 10 Bar(g) 1500 Kg./Hr (F & A 1000C)
RECOSTAR CC Product Details Type
:
Cylindrical coil type, water tube, once through
Installation
:
Horizontal / Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Normally clean dust free gases (special vertical design with self cleaning velocities available for dust laden gases with soot blowing arrangement)
Type of heat recovery output
:
1) Steam – D & S / Superheated 2) Hot Water 3) Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot vapours, Hot liquids
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated steam with external moisture separator. Superheated steam possible with provision of superheater and moisture separator installed between evaporator and superheater.
Degree of Superheat Possible
:
Superheat degree limited by lnlet gas temperature available.
Water side circulation
:
Once through Forced circulation
Steam Separation
:
With external moisture separator.
Waste heat source suitability
:
Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust. (High gases)
Typical applications
:
Thermic Fluid heating, process heating, hot water generation, superheated water generation, power generation, cogeneration.
Duct firing possibilities
:
Possible for gas turbine exhaust applications, heat addition into waste gas steam by addition of hot gases generated by separately fired hot gas generator.
Output capacity possibilities
:
No capacity limits as multiple units can generate higher outputs.
Soot removal
:
Through self cleaning velocities and pneumatic / steam soot blowers.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. evaporator, economizer, water preheater.
Super-heater,
Air bleed valve
Air bleed valve
Flue gas From Incinerator at 1000 0C
F. D. Fan
TIC Incinerator
Flue gas From Incinerator at 1000 0C
I. D. Fan
Waste heat recovery Thermic fluid heater
Flue gas Exit at 250 0C
F. D. Fan
TIC Incinerator
3 way Divertor Valve
3 way Divertor Valve
T.F. From Plant at 1900C
T.F. From Plant at 1900C Panel
Common Exp. Tank
I. D. Fan
Waste heat recovery Thermic fluid heater
Panel
Common Exp. Tank
DPS
T.F. From WHRTFH at 210 0C
DPS
T.F. From WHRTFH at 210 0C
T.F. to fired TFH at 2050C
T.F. to fired TFH at 2050C
Heat recovery ON
Heat recovery BYPASS
Recostar FN : Flow diagram for Incinerator based Heat recovery system
Case study
Waste heat source Material incinerated Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : :
Incinerator exhaust Waste from packaging industry 2450 Kg./Hr. 10000C Thermic fluid heater 2500C Thermic fluid at 2100C 4,86,202 Kcal/Hr.
RECOSTAR PC Product Details
Type
:
Pancake coil type, water tube, once through
Installation
:
Horizontal & Vertical, Indoor as well as Outdoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Normally clean dust free gases.
Acceptable dust in waste gases
:
Low dust level needed in horizontal design high dust level acceptable only in vertical design with self cleaning velocities.
Type of heat recovery output
:
1) Steam – D & S / Superheated 2) Hot Water 3) Hot Thermic Fluid
Media of Waste Heat
:
Hot gases, Hot vapours, Hot liquids
Steam Pressure
:
Suitable for low as well as high pressure
Steam Condition
:
Dry & saturated steam with external moisture separator. Superheated steam possible with provision of superheater and moisture separator installed between evaporator and superheater.
Water side circulation
:
Once through Forced circulation.
Steam Separation
:
With external moisture separator.
Waste heat source suitability
:
Fuel cell exhaust, micro / min gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications
:
Thermic Fluid heating, process heating, hot water generation, superheated water generation, power generation, cogeneration.
Duct firing possibilities
:
Possible for gas turbine exhaust applications.
Output capacity possibilities
:
No capacity limits as multiple units can generate higher outputs.
Soot removal
:
Through self cleaning velocities and pneumatic steam soot blowers.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.
Hot Thermic fluid out
Pancake coils Cold Thermic fluid in
Hot flue gas in
Recostar PC : Flow diagram
Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : :
Engine generator exhaust 1 MW X 1 No. Natural Gas 5634 Kg./Hr. 4290C Main TFH 2500C Hot thermic fluid at 2200C 2,61,900 Kcal/Hr.
RECOSTAR SCMP Product Details Type
:
Smoke tube, composite (I.e. unfired plus fired zone)
Installation
:
Horizontal, Vertical, Indoor.
Tube Orientation
:
Horizontal / Vertical.
Waste gas flow direction
:
Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases
:
Low dust level desired.
Type of heat recovery output
:
1) Steam–D & S / Super-heat. 2) Hot water 3) Vapour phase Thermic Fluid Heating.
Media of Waste Heat
:
Hot gases, Hot vapors, Hot liquids
Steam Pressure
:
Suitable for low as well as medium pressure
Steam Condition
:
Dry & saturated and also superheated steam through provision of super-heater.
Water side circulation
:
Natural Circulation internal to boiler.
Steam Separation
:
In steam drum or in external moisture separator.
Waste heat source suitability
:
Fuel cell exhaust, micro / min gas turbine exhaust, Small gas turbine exhaust, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust, gas turbine exhaust.
Typical applications
:
Where heat recovery from waste heat needs to be supplemented with fuel firing and installation of two separate boilers unfired and fired has space limitation.
Supplemetory firing possibilities
:
Firing in internal furnace provided in boilers.
Output capacity possibilities
:
Typically upto 20T/hr capacity.
Soot removal
:
By sonic soot blowers and through self cleaning velocities.
Number of heat recovery stages possible
:
3 to 4 stages of heat recovery possible e.g. evaporator, economizer, water preheater.
Typical lowest exhaust gas temperature at final outlet of system
:
Gases generated by diesel – 130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
Protection against sulphur corrosion on cold end side
:
Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
Super-heater
FLUE GAS FROM ENGINE ENTERS
ECONOMIZER
FLUE GAS FROM ENGINE LEAVES
PARTITION
BURNER
FLUE GAS FROM BURNER LEAVES
Recostar SCMP : Flow diagram ( Vertical ) Case study
Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration N.G. firing in fired zone Flue gas outlet temp. Output type Output at 100% load
: : : : : : : : : :
Engine generator exhaust 1.1 MW X 1 No. Natural gas 4780 Kg./Hr. 5980C Main WHRB+Fired zone+ Eco. 60 SM3/Hr. 2050C Steam at 10 Bar(g) 2000 Kg./Hr (F & A 1000C)
PRODUCT FEATURES CONTROL PANEL The Control Panel is wired with solid conductor single strand wires for easy tracebility. Indications for all temperatures, safety trips provided on panel. Facilities for auto-manual switching of individual devices provided.
EASE OF FLUE GAS SIDE INSPECTION Front and rear doors are hinged type to provide simple & quick opening for full access to fireside tube surface. This job can be done by a single person
MAXIMUM HEAT RECOVERY Heat recovery in multiple stages ( 3 to 4) with help of single/double stage economizers plus water preheater ensures maximum possible heat recovery from the waste gases. Customer gets nearly 7 to 19 % of additional output compared to other makes.
CUSTOM ENGINEERED / CUSTOM BUILT
DIVERTOR VALVE
INSULATION Insulation thickness is selected scientifically to minimize heat loss even at a high flue gas temp. (Typical thickness used is 300 mm for 5000C)
Automatic pneumatically operated, Linear movement of valve, Stainless steel can work continuously. 850oC Pneumatic pressure eliminating possibility of any leakage.
Every TRANSPARENT Boiler is specifically engineered and built to every customer’s needs and specifications. Special sizes, sources of heat and auxiliary equipment are no problem with TRANSPARENT.
APPLICATION SUITABILITY PRODUCT MATRIX Matrix for of converting waste heat in useful form Source of Waste Heat
Useful Form Of Output
H O E E
L O E E
Low Pressure Steam Medium Pressure Steam High Pressure Steam Hot Thermic Fluid Hot Water (Pressurized) Hot Water (Non Pressurized) Hot Air for Process (Dryer etc) Chilled Water Chilled Brine Ice Making Cold Storage Waste Water Recycling Power Combustion Air Preheating Inlet Air Cooling
Source of Waste Heat
HOEE LOEE GEE EJH GTE IEG CPKG SPF HGP GFG FGFH AC HPC
: : : : : : : : : : : : :
Heavy Oil Engine Exhaust Light Oil Engine Exhaust Gas Engine Exhaust Engine Jacket Heat Gas Turbine Exhaust Incinerator Exit Gases Cement Plant Kiln Gases Steel Plant Furnaces Hot Gases From Process Glass Furnace Gases Flue Gases From Fired Heaters Air Compressors High Pressure Condensate
G E E
E J H
G T E
I E G
C P K G
S P F
H G P
G F G
F G F H
A C
H P C
WHRB INSTALLATION
WHRB Installed at Square Spinnings Ltd., Bangladesh, Natural Gas Fired Engine, Steam Pressure – 10.54 kg/cm2 (g).
WHRB Installed at Reid & Taylor (S. Kumar)
WHRB Installed at Heubach Colour Ltd., Natural Gas Steam Pressure – 10.54 kg/cm2 (g) WHRB Installed at Tesitura Monti (I) Pvt. Ltd. Heavy Fuel Oil Steam Pressure – 14 Kg/cm2 (g)
WHRB Installed at Hindustan Mills Ltd
WHRB Installed at Janta Jute - Dhaka
COMPARISION Safety of Source Equipment Flue gas from Engine
Flue gas bypass
Back pr. limit
pressure sensor
FPS
FPS
Automatic 3 way Divertor Valve
Back pressure control on flue gas side Transparent provides automatic flue gas monitoring & control system. If the steam pressure exceeds the predetermined value, the flue gases automatically diverted to stack. This saves the source (Engine or turbine) from getting subjected to excessive back pressure. No such system exists in other make whrb (standard model). This is quite unsafe for the engine or turbine on which the WHRB is installed. Note : In case of gas fired engines or turbines, eventhough there is very little possibility of carbon accumulation but other possibilities do exist for excessive back pressure on flue gas side. It can happen either due to leakage of boiler tube or lube oil vapour condensation in abnormal conditions. Hence even in case of gas engines/turbines, above safety feature is of paramount importance.
Safety of Waste Heat Recovery Boiler Steam pr. limit Pressure sensor
Flue gas bypass
Steam pr. limit
SPS SPS
Automatic 3 way Divertor valve
High steam pressure control Transparent provides automatic steam pressure monitoring & control system. If the steam pressure exceeds the predetermined value, the flue gases are automatically diverted to stack. This eliminates frequent operation of safety relief valve. No such system exists in other make whrb (standard model). This is quite unsafe for the WHRB. In such case one has to solely depend on safety valve. Note : Frequent operation of safety valve is an undesirable situation since it is meant for ultimate safety of boiler & supposed to operate once in a while.
COMPARISION Safety of Waste Heat Recovery Boiler Flue gas bypass Flue gas from Engine
Level sensor
LSL
LSL
Automatic 3 way Divertor Valve
Low water level safety trip Transparent provides automatic boiler water level monitoring & control system.In case the level falls below safe level, the flue gases automatically bypass the WHRB & go to stack. This eliminates boiler tubes overheating. No such system exists in other make WHRB (standard model). This is quite unsafe for the WHRB. Overheating of tubes can result into cracking & leakage. Note : Generally the feed pump & drum level controller system maintains desired level. Anyhow in case of abnormal situation the level can drop in spite of above system due to various reasons such as unavailability of water in F.W. tank, malfunctioning of drum level controller etc.
Efficiency and Outputs Heat From the Gases Flue gas from Engine at 5860C Flue gas out from WHRB at 1340C
Automatic 3 way Divertor Valve
Transparent WHRB recovers maximum possible heat from the gases. It gives atleast 7 to 10% extra output compared to other make. This needs a much bigger economizer & high manufacturing cost for Transparent but gives benefit to user in terms of more savings.
In other makes, eventhough economizer is provided, heat is recovered upto a temperature level where the manufacturing cost is less. This results in cost savings for WHRB supplier but recurring loss to the user.
COMPARISION Divertor Valve Transparent Make From Engine
Other Make Linear movement
Possible leakage Swing type movement Flap To WHRB
• Automatic pneumatically operated. • Linear movement of valve(poppet). No possibility of jamming. • Positive pneumatic pressure acts as good sealing force continuously when the valve reaches the respective positions. The poppet is pressed against the valve seat by pneumatic pressure eliminating possibility of any leakage. • Force is applied at center of poppet ensuring equal distribution throughout the sealing edges. • Made of Stainless steel which can work upto 8500C continuously.
• • •
•
•
From Engine
Manually operated. Swing type movement of valve(flap). Possibility of jamming. No positive force is applied after the flap reaches its respective positions.The mechanical play in the gearbox results in small opening due to self weight of flap & flue gas back pressure. This can result in leakage in the long run. Force is applied at one end of flap. This results in unequal force distribution.The distant edge gets less force. Made of carbon steel alloy which is not suitable for more than 5000C.
Vertical Co-flow WHRB vs. other make WHRB
Tubes are placed vertically with axis parallel to gas flow. It does not obstruct the flow of gas. Possibilities of soot accumulation are less since vertical downward flow of flue gas will help in dislodging the soot particles.
Tubes are placed horizontally with their axis perpendicular to flow of gas. This results into obstruction to gas flow & soot particles are arrested on tube surface.
COMPARISION Vertical Co-flow WHRB vs. other make WHRB DRUM
DRUM
DISCHARGE
RISER
PUMP SUCTION PUMP
Natural circulation design. No dependence on any external equipment for circulation. Uninterrupted circulation eliminates possibilities of higher TDS level in evaporator and subsequent scale deposition. Bare tubes reduces possibility of soot accumulation. Particularly for gases with high SPM like flue gases of F.O. engine, it is highly recommended to use only bare tubes without manufacturing cost goes up, user gets benefited. Bare tubes used in manufacturing are standard tubes available in market. In case of replacement user is not dependent on manufacturer for supply of tubes. Main boiler
Economizer 1st stage
Forced circulation design. Circulation is dependent on pump. Failure of pump suddenly stops circulation and results into higher TDS level in evaporator and subsequent scale deposition. Pump has to operate at very high suction pressure making the operation critical. Finned tube construction invites accumulation of soot between fins. This type of tube is not recommended particularly for flue gases with high SPM. Their use should be restricted for cleaner flue gases like gas engine / turbine.
Finned tubes used have specific fin size, shape and configuration. These tubes have to be purchased only from manufacturer and hence user is completely dependent on manufacturer for lifetime of boiler. Main boiler
Economizer 2nd stage
Two stage economizer improves Heat recovery. Feed water is heated completely upto saturation temperature with waste heat after main boiler. This is done while maintaining feed water temperature at economizer inlet above 122 Deg.C even if temperature in tank is 85 – 90 Deg.C
Economizer
Single stage economizer. Hence limited heat recovery.
COMPARISION Vertical Co-flow WHRB vs. other make WHRB F.W. at 1850 C To boiler Economizer 1st stage Feed water At 90 Deg.C
Economizer 2nd stage 1220 C
F.W. to boiler
Economizer
1550 C
Water Pre-heater
Feed water At 90 Deg.C
For flue gases of furnace oil with 4% sulphur, it is necessary to maintain metal temperature above 121 Deg.C. We provide auto temperature correction system which ensures that them feed water entering each stage of economizer is at-least at 122 Deg.C. This will ensure that all contact area is above the safe temperature level and will eliminate any possibility of corrosion.
Water in the tank directly enters Economizer without any temperature correction. Hence the tube wall temperature at economizer inlet drops below safe level and results into Cold end Corrosion. User has to buy the tubes frequently from manufacturer since these tube are not available in market.
Two alternatives are available. Steam soot blowers are provided as one of the alternatives. As a second alternative, soot removal is done on-line with mechanical knockers. This has negligible operating costs. These soot blowers can operate automatically based on ‘flue gas back pressure feedback signal’ or ‘flue gas outlet temperature feedback signal’.
Steam soot blower consume almost 3-4% of the steam output per day. This reduces net steam available to plant. Operation is manual and if not done properly, can create problems.
Transparent Group of Companies Transparent group companies, are technology leaders working in the field of Co-generation Systems, Ammonia Absorption Refrigeration Plants (AARP), Energy Conservation Contracts, Water Recycling Plants. Superefficient Boilers, Heat Recovery Systems, Pollution control, Drying Plants etc.
Business groups, Products & Systems Transparent Energy Systems Private Limited Our company was incorporated on 16th April, 1986 with the name of Vapor Energy Machines Private Limited. The first commercial production was started in January, 1988. The name of the company was changed from Vapor Energy Machines Private Limited to Transparent Energy Systems Private Limited on 18th December, 1995. 1. Co-generation Systems - www.tesplcogen.com Cogeneration Systems involving combined generation of - Power - Heat - Refrigeration / Chilling - Water Recycling / Desalination by multistage evaporation. Fuels and energy sources for Cogeneration. - Natural Gas - Heavy Fuel Oil (HFO) - Coal - Process Waste Heat - Biogas - HSD / Kerosene / LDO - Biomass Types of Cogeneration Systems - Steam Engine / Turbine Based Co-generation - Reciprocating Engine Generator Based Co-generation - Gas Turbine Based Cogeneration Type of Industries - Dairies - Paper Mills - Textile Industries - Software Parks - Chemicals & Process Industries - Hotels - Ceramic Industries - Commercial Complexes - Sugar Industries - Residential Complexes - Food Industries - Cement - Steel - Five Star Industrial Estate 2. Ammonia Absorption Refrigeration Plants- www.tesplaarp.com - Refrigerant Evaporators - Refrigerant Circulation Systems - Air Handling Units - Accessories - Flash Vessels - Ammonia Vaporizers - Turnkey Refrigeration Contracts. 3. Heat Recovery Systems – www.heatrecovery-system.com Waste Heat Recovery Boilers - Finned Tube - Water Tube - Smoke Tube Waste Heat Recovery Thermic Fluid Heaters Heat Recovery & Efficiency improvement Retrofits - Combustion Air Preheater - Economisers ( Smoke tube / water tube / finned tube type) - Condensate Recovery Systems - Blow Down Heat Recovery Systems - Flash Steam Recovery Systems 4. Boilers & Heaters – www.tespl.com - 96% Superefficient Oil / Gas Fuelled Boilers - 89% Superefficient Agrofuelled / Coal Fired Boilers. Biomass Fired) for Cogeneration application
- 93% Superefficient Thermic Fluid Heaters / Hot Air Generators - Superefficient High Pressure steam Boilers, (Oil / Gas / Coal /
5. Energy Conservation Projects – www.tespl.com Conservation of Electrical heating to Steam / Thermic Fluid / Hot Water Heating 6.
Water Treatment Plants & Other Accessories – www.tespl.com - Feed Water Deaerators - Pressure Reducing Station - Water Softners - High / Low pressure chemical dosing systems - Demineralising Plants - Structural / Self supported / Guyrope supported Steel Chimney / Stacks - Sand Filters - Fuel Storage & Handling Systems. - Activated Carbon Filters - Moisture Seperators
Transparent Technologies Private Limited 7. Evaporation, Water Recycling & zero effluent discharge plants – www.waterrecyclingplant.com Hot Water / Steam Driven Multistage Evaporators for continuous water distillation, desalination, product concentration & crystallization. - Falling Film Evaporators - Rising Film Evaporators - Plate Evaporators - Fluidized Bed evaporators - Natural Circulation Evaporators - Forced Circulation Evaporators - Counterflow Evaporators - Assisted Circulation Evaporators - Agitated Evaporators - Spiral Tube Evaporators 8. Dryers – www.ttplpune.com - Spray Dryers - Flash Dryers - Spray Coolers - Fluidized Bed / Spray Dryers
- Fluid Bed Dryers / Coolers / Agglomerators - Paddle Dryers / Vacuum Paddle Dryers - Spray Reactors cum Dryers - Homogenizers and Dispersion Mills
- Fluidized Bed Incinerators / Calciners - Dry Powder Mixing Systems and Granulators - Disintegrators & Pulvarisers
9. Pollution Control Group – www.air-pollutioncontrol.com Incinerators - Spray Dryer cum Combustion Chamber Incinerators - Fluidized Bed Incinerators for Liquids and Solids & Gases - Packaged Fixed Grate Incinerators for Solids - Liquid / Gas Incinerators - Fluidized Bed Paint Stripping Systems for Paint Coating Air Pollution Control - Cyclone / Multicones - Bag Filters - Wet / Venturi Scrubbers - Mechanical Dust Collectors - Flue Gas Desulphurisation Plants
Related Documents
Waste Heat Recovery Boiler
June 2020 4
Chapter-waste Heat Recovery
June 2020 8
Waste Heat Recovery
May 2020 4
Waste Heat Recovery Power Plant
May 2020 3
Diy-airconditioning Waste Water Recovery
May 2020 3