118336089 Waste Heat Recovery Boiler

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WASTE HEATRECOVERY SYSTEMS

Transparent Energy Systems Pvt. Ltd.Pune- 37. (INDIA)Tel : 020 4211347, Fax : 020 4212533.E-mail : [email protected] &[email protected]


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Transparent has developed wide variety of superefficient Heat Recovery Systems forharnessing 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 thermaloutput and efficiency.

Transparent superefficient Waste Heat Recovery Systems find ideal applications in Cogeneration

Systems working on Reciprocating Engines and Gas Turbines.

Converting into useful formEnergy 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 energyinto 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 andconstructions of Waste Heat Recovery systems / HRSGs for above applications.

Various designs of Waste Heat Recovery Systems are :

Recostar FN : Finned, Water tube, Non IBR.

Recostar FI : Finned Water tube IBR.

Recostar S : Smoke tube IBR.

Recostar WC : Bare Water tube, IBR.

Recostar WCOF : Water tube, co-flow (concurrent flue-gas flows) IBR.

Recostar WCRF : Water tube cross tube IBR.

Recostar CC : Cylindrical coil type once through.

Recostar PC : Pancake coil type once through.

Recostar SCMP : Smoke tube, composite unfired plus fired type.

Recostar JW : Engine jacket water heat recovery system

INTRODUCTION

Various sources of waste heat.

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


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RECOSTAR FN

Product Details

Gases generated by diesel - 1300C, Gas generated by naturalgas 1100C, Gases generated by high sulphur fuels - 1500C.

: Typical lowest exhaust gastemp. at outlet of system

Provided by various means to ensure that metal temperature is

maintained above the actual incipient limit.

: Protection against sulphur

& corrosion on cold end

side

1) Mechanized vibrating soot removal.

2) Automatic pneumatic cylinder operated travelling type

steam jet or compressed air jet soot blower.

: Soot removal

3 to 4 stages of heat recovery possible e.g. super-heater

evaporator, economizer, water preheater

: Number of heat recovery

stages possible

Single unit output upto approx. 600 kg/hr. Multiple units can

generate proportionately higher outputs without mixing flue

gases.

: Output capacity Possibilities

Process heating, hot water generation, Thermic Fluid heating,

whenever IBR installation is desired to be avoided.

: Typical applications

Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust

process waste gases, Incinerator exhaust, furnace exhaust.

: Waste Heat source

suitability

Dry & saturated with external moisture separator. Superheated

steam through provision of super-heater.

: Steam Condition

In external moisture separator: Steam Water Separation

Once through, forced circulation: Water side circulation

Suitable for low as well as high pressure.: Steam Pressure

Moderate dust level acceptable for vertical fin orientation with

mechanized soot removing and collecting facility.

: Acceptable dust in waste

gases

1) SteamD & S / Superheated 2) Hot Water

3) Hot Thermic Fluid

: Type of heat recovery output

Hot gases, Hot bulk powders, hot liquids, hot vapours.: Media of Waste Heat

Normally clean dustfree gases: Quality of Waste Gases

Horizontal/ Vertical

(Upwards & Downwards)

: Waste Gas Flow Direction

1) L Type steel fins with

full contact of fin base to tube

2) Integral extruded / rolled

aluminium fins on C.S. tube.

: Fin Type

Horizontal & Vertical: Tube Orientation

Horizontal & Vertical,

Indoor as well as Outdoor

: Installation

Finned Water Tube, Non IBR: Type


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Case study

Waste heat source : Engine generator exhaust

Capacity of Engines : 600KW X 1 No.

Fuel fired in Engines : HSD Total flue gas quantity : 2700 Kg./Hr.

Flue gas inlet temp. : 5180C

System configuration : Main WHRB + Economizer

Flue gas outlet temp. : 1850C

Output type : Steam at 10 Bar(g)

Output at 100% load : 320 Kg./Hr (F & A 1000C)

Recostar FN : Flow diagram ( Vertical )

F.W.IN

FLUE GAS IN

AUTOMATIC 3 WAY

DIVERTOR VALVE

FLUE GAS OUT

F.W.PUMP

ECONOMIZER

FINNED TUBE

STEAM GENERATOR

F.W. FROM F.W.TANK

F.W. TO F.W.TANK

Vibrator

BLOW

DOWN

VALVE

FLUE GAS

BYPASS

TO SILENCER

Recostar FN ( Horizontal )

for 750 KVA engine


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stages possible

Gases generated by diesel - 1300C, Gas generated by natural gas

- 1100C, Gases generated by sulphur fuels 1500C

: Typical lowest exhaust gas

temp. at outlet of system


2) Travelling type soot blower.

3) Rotory soot blower.

: Soot removal

No limits.: Output capacity possibilities

Possible for gas turbine exhaust applications.: Duct firing possibilities

Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust

process waste gases, Incinerator exhaust, furnace exhaust.

: Waste Heat Source

suitability

Process heating, hot water generation, Thermic Fluid heating,

Power generation, Cogeneration applications.


Natural Circulation, forced circulation.: Water side circulation

In steam drum or in external moisture separator.: Steam Water Separation

Dry & saturated with external moisture separator. Superheatedsteam through provision of superheater.

: Steam Condition

Suitable for low as well as high pressure.: Steam Pressure

Hot gases, Hot bulk powders, hot liquids, hot vapours.: Media of Waste Heat

Moderate dust level acceptable for Boilers having vertical fin

orientation with mechanized soot removal and collecting facility.


gases

Steam- D&S/ Superheated, Hot Water, Hot Thermic Fluid: Type of output




corrosion on cold end side

Normally clean dust free gases: Quality of Waste Gases

Horizontal/ Vertical

(Upwards & Downwards)

: Waste Gas Flow Direction

1) L Type steel fins with

full contact of fin base of tube

2) Integral extruded / rolled

aluminium fins on C.S. of tube.

: Fin Type

Horizontal & Vertical: Tube Orientation


Indoor as well as Outdoor

: Installation

Finned, Water Tube, IBR: Type

RECOSTAR FI

Product Details


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Case study

Waste heat source : Engine generator exhaust Capacity of Engines : 800KW X 1 No.

Fuel fired in Engines : HSD

Total flue gas quantity : 4000 Kg./Hr.




Output type : Steam at 10 Bar(g) Output at 100% load : 700 Kg./Hr (F & A 1000C)

FLUE GAS

OUT

FEED

WATER IN

FEED WATER PUMPS

STEAM

OUT

ECONOMIZER

FLUE GAS

FROM

ENGINE

ENTERS

AUTOMATIC

3 WAY

DIVERTOR

VALVE

FLASH

STEAM

DRUM

FINNED TUBE

HEAT RECOVERY UNIT

LT

PS

PS

LS

Recostar FI : Flow diagram


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3 to 4 stages of heat recovery possible e.g. super-heater,

evaporator, economizer, water preheater.


stages possible

Gases generated by diesel 130oC, gas generated by Natural

Gas 110oC, Gases generated by high sulphur fuels 150oC.


temperature at final outlet of

system

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.

: Duct firing possibilities

No Limits.: Output capacity possibilities




: Soot removal

In steam drum or in external moisture separator.: Steam Separation

Fuel cell exhaust, Micro / miniturbine exhaust, Gas turbine

exhaust, DG set exhaust process waste gases, Incinerator

exhaust, furnace exhaust.

: 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.


Once through, Natural Circulation & Forced / Assisted

circulation

: Water side circulation

Suitable for low as well as high pressure: Steam Pressure

Dry & saturated and also superheated steam through provision

of superheater.

: Steam Condition

Steam (D&S/ Superheated), Hot Water, Hot Thermic Fluid: Type of heat recovery output

Hot gases, hot bulk powders, hot liquids, hot vapors: Media of Waste Heat

Horizontal / Vertical (upwards & downwards): Waste gas flow direction

Gases having low to high dust load special design for high dust

load

: Quality of Waste Gases

High dust level acceptable for Boilers having mechanized soot

removing and collecting facility.


gases





Horizontal / Vertical.: Tube Orientation

Horizontal / Vertical, Indoor as well as Outdoor.: Installation

Bare Water Tube, IBR: Type

RECOSTAR WC

Product Details


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Sonic soot blowers can be used & also through self cleaning

velocities.

: Soot removal




stages possible

Gases generated by diesel 130o

C, gas generated by NaturalGas 110oC, Gases generated by high sulphur fuels 150oC.:

Typical lowest exhaust gastemperature at final outlet of

system

In Boiler drum.: Steam Separation

Fuel cell exhaust, Micro / miniturbine exhaust small gas turbine

exhaust, DG set exhaust, process waste gases, Incinerator

exhaust, furnace exhaust.

: Waste heat source

suitability


Incinerators, Industrial furnaces, DG set exhaust, process waste

gases, Incinerator exhaust, furnace exhaust, Gas turbineexhaust.


Typically 15 TPH: Output capacity possibilities

Natural circulation internal to boiler.: Water side circulation

Suitable for low as well as medium pressure: Steam Pressure


of superheater.

: Steam Condition

Low dust level acceptable.: Quality of Waste Gases

Hot gases, hot liquids, hot vapors: Media of Waste Heat

Horizontal / Vertical

(upwards & downwards)

: Waste gas flow direction

1) D & S / superheated2) Hot Water

3) Vapour phase Thermic Fluid Heating








Indoor as well as Outdoor.

: Installation

Smoke Tube IBR: Type

RECOSTAR S

Product Details

LT

PS

PS

LS

PS


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Flue

gas

out

Flue gas

From

Engine 1

F.W. in

F.W. pumps

Automatic3 way

Divertor valves

Steam out Economizer

LT

PS

PS

LS

PS

Flue gas

Engine 2

Case study


Capacity of Engines : 1 MW X 1 No.

Fuel fired in Engines : Furnace oil (Heavy oil)



System configuration : Main WHRB + 2 stage Eco.


Output type : Steam at 10 Bar(g)


Recostar-S for 3 X 1 MW F.O. engines

Recostar-S for 2 X 1 MW gas engines

Recostar-S for 2 X 1 MW gas engines

Recostar-S : Typical arrangement


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stages possible

Glue gas from diesel 1300C, Flue gas from Natural Gas 1100C,

Flue gas from high sulphur fuels 1500C


temp. at outlet of system

Process heating, hot water generation, thermic fluid heating,

power generation, cogeneration.


Possible for applications on gas turbine exhaust, Heat addition

into waste gas stream by firing fuel.






: Soot removal

Hot gases, Hot vapours: Media of Waste Heat


Dry & saturated. Superheated steam by provision of superheater.: Steam Condition

Natural Circulation / Forced (Assisted circulation): Water side circulation

In steam drum or in external moisture separator: Steam Separation

1) Steam D & S/Superheated

2) Hot Water


: Type of heat recovery

output


incinerators, industrial furnaces, DG set exhaust process waste

gases, Incinerator exhaust, Furnace exhaust, gas turbine

exhaust.

: Waste heat source

suitability

High dust level readilyAccepted

: Acceptable dust in wastegases

Vertical: Waste gas flow direction

Specially suitable for dust

laden gases. Provided with

special mechanized soot

removal and collection system.






Vertical.: Tube Orientation

Horizontal / Vertical,


: Installation

Water tube, coflow

(Cocurrent gas flow) IBR

: Type

RECOSTAR WCOF

Product Details

Steam

drum


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Case study


Capacity of Engines : 3.8 MW X 1 No.

Fuel fired in Engines : Furnace oil ( Heavy oil )




Flue gas outlet temp. : 1850

C Output type : Steam at 10 Bar(g)


Recostar WCOF : Typical arrangement

Recostar-WCOF for 3.8 MW engine

AUTO. 3 WAY

DIVERTOR VALVE

Steam

drum

FEED

WATER

AT 900C

ECONOMIZER -I

EVAPORATOR

TO CHIMNEY

FEED WATER

AT 180 1850 C

STEAM

BYPASS

HOTGAS

OUT

HOT

GAS IN

ECONOMIZER -II

155 -1600C

120 -1250C

180 -1850C

Recostar WCOF : Flow diagram ( Vertical )


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Gases generated by diesel 130oC, gas generated by NaturalGas 110oC, Gases generated by high sulphur fuels 150oC.

: Typical lowest exhaust gastemperature at final outlet of

system


incinerators, industrial furnaces, DG set exhaust process waste

gases, Incinerator exhaust, Furnace exhaust, gas turbine

exhaust. (Gases with temperature less than 550oC)

: Waste heat source

suitability

Process heating, hot water generation, thermic fluid heating,

power generation, cogeneration.


Possible for applications on gas turbine exhaust, Heat additioninto waste gas steam by addition of hot gases generated by





2) Travelling type steam soot blower. 3) Rotary soot blower.

: Soot removal




stages possible

1) Steam D & S / Super-heater

2) Hot Water

3) Vapour phase thermic fluid


Hot gases: Media of Waste Heat

Moderate dust level accepted: Acceptable dust in waste

gases


Moderately clean gas desired.

Provided with mechanized

Soot removal and collection

System.



of super-heater.

: Steam Condition

Natural Circulation: Water side circulation

Horizontal: Waste gas flow direction



maintained above actual incipient limit.



Vertical.: Tube Orientation

Vertical, Indoor and Outdoor.: Installation

Water tube cross flow IBR: Type

RECOSTAR WCRF

Product Details


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Case study

Waste heat source : Engine generator exhaust Capacity of Engines : 3.8 MW X 1 No.

Fuel fired in Engines : Furnace oil ( Heavy oil )



System configuration : Main WHRB


Output type : Steam at 10 Bar(g) Output at 100% load : 1500 Kg./Hr (F & A 1000C)

STEAM

DRUM

MUD

DRUM

STEAM OUT

FLUE

GAS IN

FLUE

GAS OUT

BLOW DOWN

Recostar WCRF : Flow diagram ( Vertical )


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Through self cleaning velocities and pneumatic / steam soot

blowers.

: Soot removal

Thermic Fluid heating, process heating, hot water generation,

superheated water generation, power generation, cogeneration.


Possible for gas turbine exhaust applications, heat addition into

waste gas steam by addition of hot gases generated by



Superheat degree limited by lnlet gas temperature available.: Degree of Superheat

Possible

Once through Forced circulation: Water side circulation

With external moisture separator.: Steam Separation

Fuel cell exhaust, micro gas turbine exhaust, DG set exhaustprocess waste gases, Incinerator exhaust, furnace exhaust.

(High gases)

:

Waste heat sourcesuitability

No capacity limits as multiple units can generate higher outputs.: Output capacity possibilities




Normally clean dust free

gases (special vertical design

with self cleaning velocitiesavailable for dust laden gases

with soot blowing arrangement)


1) Steam D & S / Superheated 2) Hot Water 3) Hot Thermic

Fluid

: Type of heat recovery

output

Hot gases, Hot vapours, Hot liquids: Media of Waste Heat


Dry & saturated steam with external moisture separator.Superheated steam possible with provision of superheater and

moisture separator installed between evaporator and super-

heater.

:

Steam Condition

3 to 4 stages of heat recovery possible e.g. Super-heater,



stages possible


Horizontal / Vertical,


: Installation

Cylindrical coil type,

water tube, once through

: Type

RECOSTAR CC

Product Details


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Case study

Waste heat source : Incinerator exhaust

Material incinerated : Waste from packaging industry



System configuration : Thermic fluid heater


Output type : Thermic fluid at 210

0

C Output at 100% load : 4,86,202 Kcal/Hr.

Flue gas

Exit

at 250 0C

Incinerator

Waste heat

recovery

Thermic

fluid heater

Common Exp.

Tank

T.F. From

Plant at 1900C

T.F. From

WHRTFH

at 210 0C

T.F. to firedTFH at 2050C

3 way Divertor

Valve

Air bleed valve

I. D. Fan

F. D. Fan

DPS

Panel

TIC

Flue gas From

Incinerator at1000 0C

Incinerator

Waste heat

recovery

Thermic

fluid heater

Common Exp.

Tank

T.F. From

Plant at 1900C

T.F. From

WHRTFH

at 210 0C

T.F. to firedTFH at 2050C

3 way Divertor

Valve

Air bleed valve

I. D. Fan

F. D. Fan

DPS

Panel

TIC

Flue gas From

Incinerator at

1000 0C

Heat recovery ON Heat recovery BYPASS

Recostar FN : Flow diagram for Incinerator based

Heat recovery system


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No capacity limits as multiple units can generate higher outputs.: Output capacity possibilities

Thermic Fluid heating, process heating, hot water generation,

superheated water generation, power generation, cogeneration.


Possible for gas turbine exhaust applications.: Duct firing possibilities

Through self cleaning velocities and pneumatic steam soot

blowers.

: Soot removal

Once through Forced circulation.: Water side circulation

With external moisture separator.: Steam Separation

Fuel cell exhaust, micro / min gas turbine exhaust, DG set

exhaust process waste gases, Incinerator exhaust, furnace

exhaust.

: Waste heat source

suitability

1) Steam D & S / Superheated

2) Hot Water



Hot gases, Hot vapours, Hot liquids: Media of Waste Heat

Normally clean dust free gases.:

Quality of Waste Gases

Low dust level needed in

horizontal design high dust

level acceptable only in vertical

design with self cleaning velocities.


gases





Dry & saturated steam with external moisture separator.

Superheated steam possible with provision of superheater and

moisture separator installed between evaporator and

superheater.

: Steam Condition




stages possible




: Installation

Pancake coil type,water tube, once through

: Type

RECOSTAR PC

Product Details


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Case study

Waste heat source : Engine generator exhaust Capacity of Engines : 1 MW X 1 No.

Fuel fired in Engines : Natural Gas



System configuration : Main TFH


Output type : Hot thermic fluid at 2200C Output at 100% load : 2,61,900 Kcal/Hr.

Cold Thermic fluid in

Hot Thermic fluid out

Hot flue gas in

Pancake coils

Recostar PC : Flow diagram


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Gases generated by diesel 130oC, gas generated by Natural

Gas 110oC, Gases generated by high sulphur fuels 150oC.


temperature at final outlet ofsystem

3 to 4 stages of heat recovery possible e.g. Super-heater



stages possible

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.


Firing in internal furnace provided in boilers.: Supplemetory firing

possibilities

Typically upto 20T/hr capacity.: Output capacity possibilities

By sonic soot blowers and through self cleaning velocities.: Soot removal

Hot gases, Hot vapors, Hot liquids: Media of Waste Heat

Suitable for low as well as medium pressure: Steam Pressure


of super-heater.

: Steam Condition

Natural Circulation internal to boiler.: Water side circulation





Low dust level desired.: Quality of Waste Gases

1) SteamD & S / Super-heat.2) Hot water

3) Vapour phase Thermic Fluid Heating.

:

Type of heat recovery output

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.

: Waste heat source

suitability






Horizontal, Vertical, Indoor.: Installation

Smoke tube, composite

(I.e. unfired plus fired zone)

: Type

RECOSTAR SCMP

Product Details


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Case study

Waste heat source : Engine generator exhaust Capacity of Engines : 1.1 MW X 1 No.

Fuel fired in Engines : Natural gas



System configuration : Main WHRB+Fired zone+ Eco.

N.G. firing in fired zone : 60 SM3/Hr.

Flue gas outlet temp. : 2050

C Output type : Steam at 10 Bar(g)


FLUE GAS

FROM ENGINE ENTERS

FLUE GAS

FROM

BURNER

LEAVES

FLUE GAS

FROM ENGINE

LEAVES

BURNER

PARTITION

ECONOMIZER

Recostar SCMP : Flow diagram ( Vertical )


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PRODUCT FEATURES

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)

DIVERTOR VALVE

Automatic pneumatically

operated, Linear

movement of valve,

Stainless steel can work

850oC continuously.

Pneumatic pressureeliminating possibility of

any leakage.

CUSTOM

ENGINEERED /

CUSTOM BUILT

Every TRANSPARENT

Boiler is specifically

engineered and built toevery customers needs

and specifications.

Special sizes, sources

of heat and auxiliary

equipment are no

problem with

TRANSPARENT.

MAXIMUM HEAT

RECOVERY

Heat recovery in multiple

stages ( 3 to 4) with help

of single/double stage

economizers plus water

preheater ensuresmaximum possible heat

recovery from the waste

gases. Customer gets

nearly 7 to 19 % of

additional output

compared to other

makes.

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

CONTROL PANEL

The Control Panel iswired 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.


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Matrix for of converting waste heat in useful form

APPLICATION SUITABILITYPRODUCT MATRIX

Power

Combustion Air Preheating

Inlet Air Cooling

Waste Water Recycling

Cold Storage

Ice Making

Chilled Brine

Chilled Water

Hot Air for Process (Dryer etc)

Hot Water (Non Pressurized)

Hot Water (Pressurized)Hot Thermic Fluid

High Pressure Steam

Medium Pressure Steam

Low Pressure Steam

HP

C

AC

FG

F

H

GF

G

HG

P

SP

F

CP

K

G

IE

G

GT

E

EJ

H

GE

E

LO

E

E

HO

E

E

Source ofWaste HeatUseful Form

Of Output

HOEE : Heavy Oil Engine Exhaust

LOEE : Light Oil Engine Exhaust

GEE : Gas Engine Exhaust

EJH : Engine Jacket Heat

GTE : Gas Turbine Exhaust

IEG : Incinerator Exit Gases

CPKG : Cement Plant Kiln Gases

SPF : Steel Plant Furnaces

HGP : Hot Gases From Process

GFG : Glass Furnace Gases

FGFH : Flue Gases From Fired Heaters

AC : Air Compressors

HPC : High Pressure Condensate

Source of Waste Heat


22/28

WHRB INSTALLATION

WHRB Installed at Square Spinnings Ltd., Bangladesh,

Natural Gas Fired Engine,

Steam Pressure 10.54 kg/cm2 (g).

WHRB Installed at Hindustan Mills Ltd

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 OilSteam Pressure 14 Kg/cm2 (g)

WHRB Installed at Reid & Taylor (S. Kumar)

WHRB Installed at Janta Jute - Dhaka


23/28


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COMPARISION

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.

Safety of Waste Heat Recovery Boiler

Low water level safety trip

Transparent provides automatic boiler water level monitoring & control system.In case the level fallsbelow safe level, the flue gases automatically bypass the WHRB & go to stack. This eliminates boilertubes overheating.

Flue gas bypass

LSL

Flue gas

from Engine

Automatic 3 way

Divertor Valve

Level sensor

LSL

In other makes, eventhough economizer is provided, heat is recovered upto a temperature levelwhere the manufacturing cost is less. This results in cost savings for WHRB supplier but recurring

loss to the user.

Heat From the Gases

Transparent WHRB recovers

maximum possible heat from

the gases. It gives atleast 7 to10% 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.

Efficiency and Outputs

Automatic

3 way Divertor

Valve

Flue gas from Engine

at 5860C

Flue gas out from

WHRB at 1340C


25/28

COMPARISION

Divertor Valve

From Engine Linear

movement

Automatic pneumatically operated.

Linear movement of valve(poppet). Nopossibility of jamming.

Positive pneumatic pressure acts as goodsealing force continuously when the valvereaches the respective positions. Thepoppet is pressed against the valve seatby pneumatic pressure eliminating

possibility of any leakage. Force is applied at center of poppet

ensuring equal distribution throughout thesealing edges.

Made of Stainless steel which canwork upto 8500C continuously.

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 formore than 5000C.

To WHRB

Possible leakage

From Engine

Flap

Swing type

movement

Transparent Make Other Make

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.


26/28

COMPARISION

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 ishighly 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.

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 highSPM. 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.

DRUM

RISER

DRUM

PUMP SUCTION

DISCHARGE

PUMP


Main boiler

Economizer1st stage

Economizer2nd stage

Main boiler

Economizer

Two stage economizer improves Heat

recovery. Feed water is heated completely up-

to 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

Single stage economizer. Hence limited heat

recovery.


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COMPARISION

Economizer

1st stage

Economizer

2nd stage

Water

Pre-heater

Feed water

At 90 Deg.C

1550 C1220 C

F.W. at 1850 C

To boiler

Economizer

Feed water

At 90 Deg.C

F.W. to boiler

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.

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.

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.

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.



28/28

Business groups, Products & Systems

Transparent Group of CompaniesTransparent 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.

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 Co-

generation

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 - 93% Superefficient Thermic Fluid Heaters / Hot Air Generators

- 89% Superefficient Agrofuelled / Coal Fired Boilers. - Superefficient High Pressure steam Boilers, (Oil / Gas / Coal /

Biomass Fired) for Cogeneration application

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 - Fluid Bed Dryers / Coolers / Agglomerators - Fluidized Bed Incinerators / Calciners

- Flash Dryers - Paddle Dryers / Vacuum Paddle Dryers - Dry Powder Mixing Systems and Granulators

- Spray Coolers - Spray Reactors cum Dryers - Disintegrators & Pulvarisers

- Fluidized Bed / Spray Dryers - Homogenizers and Dispersion Mills

9. Pollution Control Group www.air-pollutioncontrol.com

I i

Transparent Energy Systems Private Limited

Our company was incorporated on 16 thApril, 1986 with the name of Vapor Energy Machines Private Limited. The first commercial production wasstarted 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.

118336089 Waste Heat Recovery Boiler

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Transcript of 118336089 Waste Heat Recovery Boiler