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In Non-recovery coke plants, the carbonization process takes place in large oven chambers where Primary air for combustion is introduced into the oven chamber. Combusted gases / Waste Gas exit through common tunnel is fed into a waste heat recovery boiler to convert waste heat into steam for power generation.
Check out various applications for Water Tube type Waste Heat Recovery Boilers
Tail gas leaving the SRU is thermally incinerated before discharge. The hot incinerator flue gas is cooled in a waste heat recovery boiler of fire tube or water tube construction.
Thermal Systems' incinerator packages are of modular construction for ease of site assembly, with references including a 600 TPD SRU at Essar, Vadinar.
In tail gas treatment units, the treated gas stream is incinerated and its heat recovered in a waste heat boiler cum superheater.
Thermal Systems has supplied TGTU packages including 2 × 100 TPD TGTU boilers at HPCL Mumbai.
For sulphuric acid plants, Thermal Systems supplies water tube waste heat boilers with provision for future capacity expansion, steam-flooded air heaters and custom gas–gas heat exchangers.
These cover the sulphur-burning, metallurgical off-gas and spent-acid routes, up to 5,500+ TPD.
Calciner exhaust gas — high-temperature, dust-laden, with fluctuating flow — is recovered in vertical, 2-pass, natural-circulation, single-drum water tube boilers with membrane-wall first pass, proven in India and overseas.
Waste flue gas from by-product and non-recovery coke oven batteries is recovered in WHRBs generating HP steam for power.
Inline and offset configurations suit the battery layout, with references including India's largest installation of 8 × 57 TPH boilers on a single non-recovery coke oven plant.
Hot, dust-laden kiln exhaust from sponge-iron rotary kilns is recovered in vertical/horizontal water tube WHRBs — natural and forced circulation, inline and offset arrangements, with proven cleaning systems.
References include India's largest WHB for a 1,250 TPD DRI kiln.
For copper smelters, Thermal Systems supplies waste heat recovery boilers (WHRB) on smelter and converter off-gases — 3 Pass Uptake–Downtake–Convection design with water-cooled ducts and online rapping.
For the acid plant section, Thermal Systems supplies gas–gas heat exchangers and pre-heating units, shop- or site-assembled.
Zinc concentrate is roasted at about 950–1,000 °C, producing high-dust off-gas that is cooled in a roaster waste heat recovery boiler ahead of the sulphuric acid plant.
Thermal Systems' boilers feature 3 Pass Uptake–Downtake–Convection design, water-cooled horizontal ducts and online hammering/rapping systems proven on high-dust service.
