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WASTE HEAT BOILERS

Steam from the heat your process throws away.

Fire tube or water tube, our waste heat recovery boilers take hot process gas and turn it into steam for power or process. More than 550 of them are in service worldwide.

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REFORMED GAS IN up to 920°C
PROCESS GAS BOILER
STEAM 68 kg/cm²
CAPACITY up to 128 TPH

128 TPH

118 kg/cm²

560°C

550+ installations

What it is

A waste heat boiler recovers heat from high-temperature process gas, with no fuel of its own, and converts it into useful steam. The gas decides the design: clean, pressurised gas from a reformer or an acid plant suits a fire-tube boiler, where the gas passes through tubes and the shell generates steam; dusty, high-volume gas from a kiln, coke oven, smelter or calciner suits a water-tube boiler, where the gas passes over tubes and the dust can be shed and collected.
  • Fire Tube design with(out) Hot / Cold Bypass
  • Design consideration for high gas side operating pressure
  • Single piece / extended ferrules
  • Special consideration for Metal dusting issues
  • GAPFREE WELDING to avoid CREVICE CORROSION
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Fire tube waste heat boilers

Gas through the tubes, water in the shell, with a refractory-lined inlet channel, ferrules at the tube inlets and internal or external gas bypass for outlet temperature control. 300+ installations: sulphuric acid plants, spent acid regeneration, sulphur recovery, hydrogen and methanol units, nitric acid, carbon black and more.

How we build it

  • Fire tube: refractory inlet channel, ferrules, gap-free tube-to-tubesheet welding, gas bypass, integral or elevated drum
  • Water tube: vertical or horizontal, natural or forced circulation, inline or offset to suit the plant
  • Online cleaning: rapping, hammering, soot blowing to suit the dust
  • Modular construction for transport and site assembly; overseas shipment to over 40 countries
  • Designed and manufactured in-house under ASME S and U stamps, IBR and PED
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Reaction Furnace (MCC)

In the Claus process, H2S-rich acid gas is burned in the reaction furnace, generating gas at around 1,300 °C. The furnace outlet gas is quenched in the MCC waste heat boiler, generating HP/MP steam.

Thermal Systems supplies complete Reaction Furnace (MCC) packages — burner, chamber, boiler and EBOP — in fire tube construction, with superheaters suitable for internal and import steam.

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Spent sulphuric acid is thermally decomposed in the regeneration furnace, generating high-temperature gas that is recovered in a waste heat boiler producing high-pressure steam.

Thermal Systems supplies fire tube waste heat recovery boilers (WHRB) for SARU service, including the world’s largest operating installation on a 1,000 TPD SARU.

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Spent sulphuric acid is thermally decomposed in the regeneration furnace, generating high-temperature gas that is recovered in a waste heat boiler producing high-pressure steam.

Thermal Systems supplies fire tube waste heat recovery boilers (WHRB) for SARU service, including the world’s largest operating installation on a 1,000 TPD SARU.

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In weak nitric acid plants, ammonia oxidation is highly exothermic and the converter outlet gas must follow a precise temperature profile.

Thermal Systems designs and supplies converter boilers, WHBs and economisers with start-up heaters — fire tube construction with natural circulation — suited to licensor specifications and existing plant layouts.

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In methanol plants, hot synthesis gas leaving the reformer is cooled in a process-gas waste heat boiler, generating HP/LP steam.

Thermal Systems provides single or twin boiler designs combined with a common steam drum and superheater as per licensor and plant requirements, in gas-tight construction with gap-free welding.

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In carbon black manufacture, hot reactor gases are cooled in inline boilers (Tread / Carcass black), and off-gases are fired in tail gas boilers generating high-pressure steam for power.

Thermal Systems’ designs offer turn-down of 25% to 110% of MCR without support fuel and combustion control by fuel-gas temperature sensing, for smooth, trip-free operation.

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