118336089 waste heat recovery boiler
TRANSCRIPT
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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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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. 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.
: 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 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.
Flue gas inlet temp. : 5180C
System configuration : Main WHRB + Economizer
Flue gas outlet temp. : 1510C
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.
: 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 waste
gases, 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 WC
Product 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 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
Exhaust of steel furnaces, cement kilns, metal smelters,
Incinerators, Industrial furnaces, DG set exhaust, process waste
gases, Incinerator exhaust, furnace exhaust, Gas turbineexhaust.
: 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 Water
3) 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 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
Waste heat source : Engine generator exhaust
Capacity 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. : 3050C
System configuration : Main WHRB + 2 stage Eco.
Flue gas outlet temp. : 1810C
Output 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 Water
3) 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 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.
: 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 exhaust
Capacity 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. : 3270C
System configuration : Main WHRB + Economizer
Flue gas outlet temp. : 1850
C Output 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 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
Exhaust of steel furnaces, cement kilns, metal smelters,
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.
: Typical applications
Possible for applications on gas turbine exhaust, Heat additioninto 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 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 )
Total flue gas quantity : 32180 Kg./Hr.
Flue gas inlet temp. : 3270C
System configuration : Main WHRB
Flue gas outlet temp. : 2050C
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.
: 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 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
Horizontal / Vertical
(upwards & downwards)
: Waste gas flow direction
Normally clean dust free
gases (special vertical design
with self cleaning velocitiesavailable for dust laden gases
with 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 CC
Product Details
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Case study
Waste heat source : Incinerator exhaust
Material incinerated : Waste from packaging industry
Total flue gas quantity : 2450 Kg./Hr.
Flue gas inlet temp. : 10000C
System configuration : Thermic fluid heater
Flue gas outlet temp. : 2500C
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.
: 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 Water
3) 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 in
horizontal 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 and
superheater.
: 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 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
Total flue gas quantity : 5634 Kg./Hr.
Flue gas inlet temp. : 4290C
System configuration : Main TFH
Flue gas outlet temp. : 2500C
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.
: Typical lowest exhaust gas
temperature at final outlet ofsystem
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) 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
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
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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
Total flue gas quantity : 4780 Kg./Hr.
Flue gas inlet temp. : 5980C
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)
Output at 100% load : 2000 Kg./Hr (F & A 1000C)
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
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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 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
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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
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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.
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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
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.
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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.
Vertical Co-flow WHRB vs. other make WHRB
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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.