waste heat recovery boiler
TRANSCRIPT
WASTE HEAT RECOVERY SYSTEMS
Transparent Energy Systems Pvt. Ltd.Pune- 37. (INDIA)Tel : 020 – 4211347, Fax : 020 – 4212533.E-mail : [email protected] & [email protected]
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
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
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
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
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
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
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
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
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
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 )
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
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 )
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
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
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
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
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
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 )
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.
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
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
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.
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
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.
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.
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
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.