Waste Heat Recovery Boiler

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]

Transcript of Waste Heat Recovery Boiler

Page 1: Waste Heat Recovery Boiler

WASTE HEAT RECOVERY SYSTEMS

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

Page 2: Waste Heat Recovery Boiler

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.

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 energy into the most beneficial form of energy for any customer.

Various models of heat recovery systemsTransparent 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 : 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 EngineHot Waste Gases from

- Scrap melting steel furnaces - Cement kilns - Industrial furnaces- Incinerators- Process Waste Gases

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RECOSTAR FNProduct Details

Gases generated by diesel - 1300C, Gas generated by natural gas – 1100C, Gases generated by high sulphur fuels - 1500C.

:Typical lowest exhaust gas temp. 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 withmechanized soot removing and collecting facility.

:Acceptable dust in waste gases

1) Steam–D & 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 tube2) 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 exhaustCapacity of Engines : 600KW X 1 No.Fuel fired in Engines : HSDTotal flue gas quantity : 2700 Kg./Hr.Flue gas inlet temp. : 5180CSystem configuration : Main WHRB + EconomizerFlue gas outlet temp. : 1850COutput 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 TUBESTEAM GENERATOR

F.W. FROM F.W.TANK

F.W. TO F.W.TANK

Vibrator

BLOWDOWNVALVE

FLUE GASBYPASSTO SILENCER

Recostar FN ( Horizontal ) for 750 KVA engine

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3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater

:Number of heat recovery 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

1) Mechanized vibrating soot removal.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.

:Typical 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. Superheated steam 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.

:Acceptable dust in waste gases

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

Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

:Protection against sulphur 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

Horizontal & Vertical, Indoor as well as Outdoor

:Installation

Finned, Water Tube, IBR:Type

RECOSTAR FIProduct Details

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Case study

Waste heat source : Engine generator exhaustCapacity of Engines : 800KW X 1 No.Fuel fired in Engines : HSDTotal flue gas quantity : 4000 Kg./Hr.Flue gas inlet temp. : 5180CSystem configuration : Main WHRB + EconomizerFlue gas outlet temp. : 1510COutput type : Steam at 10 Bar(g) Output at 100% load : 700 Kg./Hr (F & A 1000C)

FLUE GASOUT

FEED WATER IN

FEED WATER PUMPS

STEAMOUT

ECONOMIZER

FLUE GASFROM ENGINEENTERS

AUTOMATIC3 WAYDIVERTORVALVE

FLASHSTEAMDRUM

FINNED TUBEHEAT 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.

:Number of heat recovery stages possible

Gases generated by diesel –130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.

:Typical lowest exhaust gas 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

1) Mechanized vibrating soot removal.2) Travelling type soot blower.3) Rotory soot blower.

: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 wastegases, Incinerator exhaust, furnace exhaust, Gas turbine exhaust.

:Typical applications

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.

:Acceptable dust in waste gases

Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

:Protection against sulphur corrosion on cold end side

Horizontal / Vertical.:Tube Orientation

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

Bare Water Tube, IBR:Type

RECOSTAR WCProduct Details

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Sonic soot blowers can be used & also through self cleaning velocities.

:Soot removal

3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.

:Number of heat recovery stages possible

Gases generated by diesel – 130oC, gas generated by Natural Gas – 110oC, Gases generated by high sulphur fuels – 150oC.

:Typical lowest exhaust gas temperature 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

Exhaust of steel furnaces, cement kilns, metal smelters, Incinerators, Industrial furnaces, DG set exhaust, process wastegases, Incinerator exhaust, furnace exhaust, Gas turbine exhaust.

:Typical applications

Typically 15 TPH:Output capacity possibilities

Natural circulation internal to boiler. :Water side circulation

Suitable for low as well as medium pressure:Steam Pressure

Dry & saturated and also superheated steam through provision 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 Water3) Vapour phase Thermic Fluid Heating

:Type of heat recovery output

Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

:Protection against sulphur corrosion on cold end side

Horizontal / Vertical.:Tube Orientation

Horizontal & Vertical, Indoor as well as Outdoor.

:Installation

Smoke Tube IBR:Type

RECOSTAR SProduct Details

LT

PS

PS

LS

PS

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Flue gasout

Flue gasFromEngine 1

F.W. in

F.W. pumps

Automatic 3 wayDivertor valves

Steam out Economizer

LT

PS

PS

LS

PS

Flue gasEngine 2

Case study

Waste heat source : Engine generator exhaustCapacity of Engines : 1 MW X 1 No.Fuel fired in Engines : Furnace oil (Heavy oil)Total flue gas quantity : 24000 Kg./Hr.Flue gas inlet temp. : 3050CSystem configuration : Main WHRB + 2 stage Eco.Flue gas outlet temp. : 1810COutput type : Steam at 10 Bar(g) Output at 100% load : 1500 Kg./Hr (F & A 1000C)

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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3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater

:Number of heat recovery stages possible

Glue gas from diesel – 1300C, Flue gas from Natural Gas – 1100C, Flue gas from high sulphur fuels –1500C

:Typical lowest exhaust gas temp. at outlet of system

Process heating, hot water generation, thermic fluid heating, power generation, cogeneration.

:Typical applications

Possible for applications on gas turbine exhaust, Heat addition into waste gas stream by firing fuel.

:Duct firing possibilities

No Limits. :Output capacity possibilities

1) Mechanized vibrating soot removal. 2) Travelling type soot blower.3) Rotory soot blower.

:Soot removal

Hot gases, Hot vapours:Media of Waste Heat

Suitable for low as well as high pressure:Steam Pressure

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 Water3) Hot Thermic Fluid

:Type of heat recovery output

Exhaust of steel furnaces, cement kilns, metal smelters, incinerators, industrial furnaces, DG set exhaust process waste gases, Incinerator exhaust, Furnace exhaust, gas turbine exhaust.

:Waste heat source suitability

High dust level readily Accepted

:Acceptable dust in waste gases

Vertical :Waste gas flow direction

Specially suitable for dust laden gases. Provided with special mechanized soot removal and collection system.

:Quality of Waste Gases

Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

:Protection against sulphur corrosion on cold end side

Vertical.:Tube Orientation

Horizontal / Vertical, Indoor as well as Outdoor.

:Installation

Water tube, coflow (Cocurrent gas flow) IBR

:Type

RECOSTAR WCOF Product Details

Steam drum

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Case study

Waste heat source : Engine generator exhaustCapacity of Engines : 3.8 MW X 1 No.Fuel fired in Engines : Furnace oil ( Heavy oil )Total flue gas quantity : 32180 Kg./Hr.Flue gas inlet temp. : 3270CSystem configuration : Main WHRB + EconomizerFlue gas outlet temp. : 1850COutput type : Steam at 10 Bar(g) Output at 100% load : 1950 Kg./Hr (F & A 1000C)

Recostar WCOF : Typical arrangement

Recostar-WCOF for 3.8 MW engine

AUTO. 3 WAYDIVERTOR VALVE

Steam drum

FEED WATERAT 900C

ECONOMIZER -I

EVAPORATOR

TO CHIMNEY

FEED WATERAT 180 –1850 C

STEAM

BYPASS

HOT GAS OUT

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

:Typical lowest exhaust gas temperature at final outlet of system

Exhaust of steel furnaces, cement kilns, metal smelters, incinerators, industrial furnaces, DG set exhaust process wastegases, 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.

:Typical applications

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.

:Duct firing possibilities

No Limits. :Output capacity possibilities

1) Mechanized vibrating soot removal. 2) Travelling type steam soot blower. 3) Rotary 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

1) Steam– D & S / Super-heater 2) Hot Water 3) Vapour phase thermic fluid

:Type of heat recovery output

Hot gases:Media of Waste Heat

Moderate dust level accepted:Acceptable dust in waste gases

Suitable for low as well as high pressure:Steam Pressure

Moderately clean gas desired. Provided with mechanized Soot removal and collection System.

:Quality of Waste Gases

Dry & saturated and also superheated steam through provision of super-heater.

:Steam Condition

Natural Circulation:Water side circulation

Horizontal :Waste gas flow direction

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

Provided by various means to ensure that metal temperature is maintained above actual incipient limit.

:Protection against sulphur corrosion on cold end side

Vertical.:Tube Orientation

Vertical, Indoor and Outdoor.:Installation

Water tube cross flow IBR:Type

RECOSTAR WCRFProduct Details

Page 13: Waste Heat Recovery Boiler

Case study

Waste heat source : Engine generator exhaustCapacity of Engines : 3.8 MW X 1 No.Fuel fired in Engines : Furnace oil ( Heavy oil )Total flue gas quantity : 32180 Kg./Hr.Flue gas inlet temp. : 3270CSystem configuration : Main WHRBFlue gas outlet temp. : 2050COutput type : Steam at 10 Bar(g) Output at 100% load : 1500 Kg./Hr (F & A 1000C)

STEAMDRUM

MUDDRUM

STEAM OUT

FLUEGAS IN

FLUEGAS 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.

:Typical applications

Possible for gas turbine exhaust applications, heat addition into waste gas steam by addition of hot gases generated by separately fired hot gas generator.

:Duct firing possibilities

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 exhaust process waste gases, Incinerator exhaust, furnace exhaust. (High gases)

:Waste heat source suitability

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

Horizontal / Vertical (upwards & downwards)

:Waste gas flow direction

Normally clean dust free gases (special vertical design with self cleaning velocities available for dust laden gaseswith soot blowing arrangement)

:Quality of Waste Gases

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

Suitable for low as well as high pressure:Steam Pressure

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, evaporator, economizer, water preheater.

:Number of heat recovery stages possible

Horizontal / Vertical.:Tube Orientation

Horizontal / Vertical, Indoor as well as Outdoor.

:Installation

Cylindrical coil type,water tube, once through

:Type

RECOSTAR CCProduct Details

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Case study

Waste heat source : Incinerator exhaustMaterial incinerated : Waste from packaging industryTotal flue gas quantity : 2450 Kg./Hr.Flue gas inlet temp. : 10000CSystem configuration : Thermic fluid heaterFlue gas outlet temp. : 2500COutput type : Thermic fluid at 2100C Output at 100% load : 4,86,202 Kcal/Hr.

Flue gas Exit at 250 0C

Incinerator

Waste heatrecoveryThermic

fluid heater

Common Exp. Tank

T.F. FromPlant at 1900C

T.F. FromWHRTFHat 210 0C

T.F. to fired TFH at 2050C

3 way Divertor Valve

Air bleed valve

I. D. Fan

F. D. Fan

DPS

Panel

TIC

Flue gas FromIncinerator at 1000 0C

Incinerator

Waste heatrecoveryThermic

fluid heater

Common Exp. Tank

T.F. FromPlant at 1900C

T.F. FromWHRTFHat 210 0C

T.F. to fired TFH at 2050C

3 way Divertor Valve

Air bleed valve

I. D. Fan

F. D. Fan

DPS

Panel

TIC

Flue gas FromIncinerator at 1000 0C

Heat recovery ON Heat recovery BYPASS

Recostar FN : Flow diagram for Incinerator basedHeat 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.

:Typical applications

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 Water3) Hot Thermic Fluid

:Type of heat recovery output

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

Normally clean dust free gases.:Quality of Waste Gases

Low dust level needed inhorizontal design high dust level acceptable only in vertical design with self cleaning velocities.

:Acceptable dust in waste gases

Horizontal / Vertical (upwards & downwards)

:Waste gas flow direction

Suitable for low as well as high pressure:Steam Pressure

Dry & saturated steam with external moisture separator. Superheated steam possible with provision of superheater and moisture separator installed between evaporator andsuperheater.

:Steam Condition

3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.

:Number of heat recovery stages possible

Horizontal / Vertical.:Tube Orientation

Horizontal & Vertical, Indoor as well as Outdoor.

:Installation

Pancake coil type, water tube, once through

:Type

RECOSTAR PCProduct Details

Page 17: Waste Heat Recovery Boiler

Case study

Waste heat source : Engine generator exhaustCapacity of Engines : 1 MW X 1 No.Fuel fired in Engines : Natural GasTotal flue gas quantity : 5634 Kg./Hr.Flue gas inlet temp. : 4290CSystem configuration : Main TFHFlue gas outlet temp. : 2500COutput type : Hot thermic fluid at 2200COutput 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.

:Typical lowest exhaust gas temperature at final outlet of system

3 to 4 stages of heat recovery possible e.g. Super-heater evaporator, economizer, water preheater.

:Number of heat recovery 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.

:Typical applications

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

Dry & saturated and also superheated steam through provision of super-heater.

:Steam Condition

Natural Circulation internal to boiler.:Water side circulation

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

Horizontal / Vertical (upwards & downwards)

:Waste gas flow direction

Low dust level desired.:Quality of Waste Gases

1) Steam–D & S / Super-heat.2) Hot water3) 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

Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

:Protection against sulphur corrosion on cold end side

Horizontal / Vertical.:Tube Orientation

Horizontal, Vertical, Indoor.:Installation

Smoke tube, composite (I.e. unfired plus fired zone)

:Type

RECOSTAR SCMP Product Details

Page 19: Waste Heat Recovery Boiler

Case study

Waste heat source : Engine generator exhaustCapacity of Engines : 1.1 MW X 1 No.Fuel fired in Engines : Natural gasTotal flue gas quantity : 4780 Kg./Hr.Flue gas inlet temp. : 5980CSystem configuration : Main WHRB+Fired zone+ Eco.N.G. firing in fired zone : 60 SM3/Hr.Flue gas outlet temp. : 2050COutput type : Steam at 10 Bar(g) Output at 100% load : 2000 Kg./Hr (F & A 1000C)

FLUE GASFROM ENGINE ENTERS

FLUE GASFROM BURNERLEAVES

FLUE GASFROM ENGINE LEAVES

BURNER

PARTITION

ECONOMIZER

Recostar SCMP : Flow diagram ( Vertical )

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PRODUCT FEATURES

INSULATIONInsulation 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 pressure eliminating possibility of any leakage.

CUSTOM ENGINEERED / CUSTOM BUILT

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.

MAXIMUM HEAT RECOVERYHeat 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.

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 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.

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Matrix for of converting waste heat in useful form

APPLICATION SUITABILITY PRODUCT 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

HPC

AC

FGFH

GFG

HGP

SPF

CPKG

IEG

GTE

EJH

GEE

LOEE

HOEE

Source ofWaste Heat

Useful FormOf Output

HOEE : Heavy Oil Engine ExhaustLOEE : Light Oil Engine ExhaustGEE : Gas Engine ExhaustEJH : Engine Jacket HeatGTE : Gas Turbine ExhaustIEG : Incinerator Exit GasesCPKG : Cement Plant Kiln GasesSPF : Steel Plant FurnacesHGP : Hot Gases From ProcessGFG : Glass Furnace Gases FGFH : Flue Gases From Fired HeatersAC : Air CompressorsHPC : High Pressure Condensate

Source of Waste Heat

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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 GasSteam 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 Reid & Taylor (S. Kumar)

WHRB Installed at Janta Jute - Dhaka

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COMPARISION

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 Source Equipment

Back pressure control on flue gas sideTransparent 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.

Flue gas bypass

FPS

Automatic 3 wayDivertor Valve

FPS

Flue gas from Engine

pressure sensor

Back pr. limit

Safety of Waste Heat Recovery Boiler

Flue gas bypass

SPS

Steam pr. limit

Automatic 3 wayDivertor valve

Steam pr. limit

Pressure sensorSPS

High steam pressure controlTransparent 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.

Page 24: Waste Heat Recovery Boiler

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 tripTransparent 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.

Flue gas bypass

LSL

Flue gas from Engine

Automatic 3 wayDivertor Valve

Level sensor

LSL

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.

Heat From the Gases

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.

Efficiency and Outputs

Automatic3 way Divertor Valve

Flue gas from Engine at 5860C

Flue gas out from WHRB at 1340C

Page 25: Waste Heat Recovery Boiler

COMPARISIONDivertor Valve

From Engine Linearmovement

• 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.

• 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.

To WHRB

Possible leakage

From Engine

Flap

Swing typemovement

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.

Page 26: Waste Heat Recovery Boiler

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 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.

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.

DRUM

RISER

DRUM

PUMP SUCTION

DISCHARGE

PUMP

Vertical Co-flow WHRB vs. other make WHRB

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.

Page 27: Waste Heat Recovery Boiler

COMPARISION

Economizer1st stage

Economizer2nd stage

Water Pre-heater

Feed waterAt 90 Deg.C

1550 C1220 C

F.W. at 1850 C To boiler

Economizer

Feed waterAt 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.

Vertical Co-flow WHRB vs. other make WHRB

Page 28: Waste Heat Recovery Boiler

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.comCogeneration 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 - BiomassTypes 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.comWaste 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.comConservation 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 Limited7. 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.comIncinerators- 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 Private LimitedOur 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.