HEAT RECOVERY BOILERS TO PRODUCE HOT WATER, SUPERHEATED WATER AND STEAM

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HEAT RECOVERY BOILERS 3

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PRODUCT RANGE 5

RECOVERY BOILER 6

WHB series

RECOVERY BOILER 8

GXC series

Form used to request information 12

Summary

ICI CALDAIE SpA 10

Heat recovery boilers are thermal machines that employ the heat

of exhaust gases to produce hot water, superheated water or

steam.

Traditional recovery boilers do not have a furnace, as the water

inside them is not heated up with a burner, but just with the heat

of fumes conveyed in them.

This process allows most of the thermal energy to be recovered

that was, before, dissipated in the furnace. This places recovery

boilers among the most advanced tools to increase the energy

efficiency of a system.

ICI Caldaie's heat-recovery boilers are made with a design called

"fire-tube" boilers. In this kind of boiler, the fumes pass through a

bundle of tubes immersed in a volume of water in the boiler's

body.

As they pass through the bundle of tubes, the fumes transfer heat

to the water and have cooled down when they come out from the

chimney. At the same time, thanks to the heat absorbed, the

water temperature increases until it turns into steam, based on

the application required.

HEAT RECOVERY

BOILERS

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0 2000 4000 6000 8000 10000 12000 14000 16000

T = 550°C

T = 500°C

T = 450°C

T = 400°C

T = 350°C

portata fumikg/h

potenzascambio

kW

produzionevapore

kg/h

risparmiometanoNm3/h

The exhaust gases that can be used in recovery boilers may come from:

Fields of application

Benefits

Installing recovery boilers allows for considerable

benefits:

• Greater energy efficiency of the plants;

• Lower amount of fuel used;

• Lower running costs;

• Lower CO2 emissions;

• Being awarded white certificates;

• Equipment quickly pays back for itself;

• High profitability of the investment.

Equivalent fuel saved as a function of temperature and flow of the fumes.

NOTE: Temperatures Smoke out of the fireplace assumed 240 °C

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Furnaces, post-combustion chambers, incinerators.

Industrial processes with fumes at high temperatures

Biomass plants

Diesel engines, gas and biogas engines,

vegetable oil motors

Turbogas plants

Energy production plants

Industrial processes Cogenerators

PRODUCT RANGE

RECOVERY BOILER

WHB series

RECOVERY BOILER

GXC series

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RECOVERY BOILER

WHB series

The only thermal source of the WHB series heat-

recovery boilers are hot recovery fumes with no

additional combustion.

These are entirely automatic single-block

generators equipped with all the accessories to

ensure a quick activation.

The WHB series features great flexibility in terms

of design and use. The generators are custom-

made on a case-by-case basis to meet any

specific requirement in terms of use.

The efficiency of the WHB heat-recovery boilers

can be further increased by 5% if they are fitted

with an economiser, an accessory available for

any version of the product.

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• Modular versions;

• High water content;

• Assembly and testing conducted at the

manufacturer's premises;

• Simple, quick and safe installation;

• Project pressure values up to 25 bar;

• High operating flexibility;

• Minimum running costs;

• Minimum maintenance costs;

• Easy to access for internal maintenance.

Benefits

If allowed by the production cycle's technical operating parameters, the heat-recovery boilers can be fitted with economisers to

increase their efficiency.

Available versions:

- black steel: for water return temperatures > 50°C, with gas fuel

- AISI 316 stainless steel: for water return temperatures < 50°C, with gas fuel

Available versions

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WHB

single section

1 flue-gas pass

WHB

single section

2 flue-gas passes

WHB

multiple section

1 flue-gas pass

The GXC series heat-recovery boilers are innovative

generators that combine the generation of steam by

combustion with heat recovery from hot fumes from

external sources. This “free” source is primary, while

combustion can be used as a backup or provide the

power required if the recovery fumes are not enough

to meet the system's request for steam.

Combustion-based operation features three flue-gas

pass with passing flame and wet bottom. The boiler's

body is made with flanged tube plates that replace the

more traditional corner welds to ensure top safety

levels and reduce areas with thermal stress. The

recovery section is entirely separated from the

combustion section, though it is immersed in the same

boiler water. The front doors are secured to the

boiler's body with double-jointed hinges, which are

used to open and inspect the equipment with no need

to remove the boiler.

The efficiency of the GXC heat-recovery boilers can

be further increased by 5% if they are fitted with an

economiser, an accessory available for any version of

the product.

RECOVERY BOILER

GXC series

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• Modular versions;

• High water content;

• Compact solution thanks to the integration of two

operating principles in a single block;

• Assembly and testing conducted at the manufacturer's

premises;

• Simple, quick and safe installation;

• Project pressure values up to 25 bar;

• Flanged tube plates;

• High operating flexibility;

• Minimum running costs;

• Minimum maintenance costs;

• Easy to access for internal maintenance.

Benefits

GXC

single section

1 flue-gas pass

GXC

single section

2 flue-gas passes

GXC

multiple section

1 flue-gas pass

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Available versions

If allowed by the production cycle's technical operating parameters, the heat-recovery boilers can be fitted with economisers to

increase their efficiency.

Available versions:

- black steel: for water return temperatures > 50°C, with gas fuel

- AISI 316 stainless steel: for water return temperatures < 50°C, with gas fuel

residential and industrial applications. The experience gained over the years in the industrial field allowed the company to transfer the

know-how acquired in designing and making industrial steam generators to civil boilers for the residential and commercial market, with

a focus on centralised systems. ICI CALDAIE provides a range of systems that generate heat with very high efficiency levels to

systems that provide heat for individual houses. Industrial applications are scalable and range from steam generators fitted with a

burner and electronic control equipment to all-inclusive thermal systems, with a focus on solutions that allow for high energy savings.

ICI CALDAIE associates any kind of solution, whether it is residential or industrial one, with management systems that reduce

consumption, thereby optimising the operation of the generator and connected elements, along with the integration of solar systems.

Today ICI CALDAIE is a reference point among companies operating in the field of steam generators for industrial and heating

processes. The company's pioneering and innovative spirit leads it to heavily invest in the research and development of projects for

new energy systems with a low environmental impact, explore new applications, new technologies with low emissions and leads it to

working closely with top universities to develop ambitious and highly innovative research projects.

ICI CALDAIE combines all this with comprehensive customer service, offering itself as a partner and consultant with services ranging

from a preventive energy diagnosis to testing and conducting maintenance on the system and/or making all-inclusive systems.

ICI CALDAIE is a company with a more than 50-

year history and experience in managing energy and

producing heat.

It was established in 1958 in the province of Verona

as a manufacturing company making steel boilers

with a high water content for industrial processes. It

is still a leader in this sector at an international level,

providing medium and large capacity generators for

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ICI CALDAIE SpA

standard UNI EN 29002 (IS0 9002); in June 2002 BVQI (Bureau Veritas Quality Insurance) awarded ICI CALDAIE the ISO 9001/94

certification and in April 2004 the ISO 9001/00 Vision certification.

All ICI CALDAIE models have the CE marking in accordance with applicable regulations and the high-pressure generator designed

in accordance complies with the Pressure Equipment Directive. The company also has a number of Italian certifications for exports to

many countries that require very restrictive mechanical and hydraulic tests, such as the certificates issued by the American Society for

Mechanical Engineers.

The certifications awarded acknowledge the efforts made by ICI CALDAIE and inform the market that the methods adopted comply

with international regulations to ensure the best quality standards. A Research and Development lab fitted with modern instruments to

check the reliability and performance of the boilers develops new products in accordance with the increasingly strict European

standards on consumption and emissions.

Each product is made by the Technical Department, which has modern CAD workstations with internet access. Semi-finished products

are prepared with laser cutters and numerical control machines. The elements are perfectly welded together with modern robots and

each individual boiler undergoes a strict testing process that ensures it is reliable.

Certifications

System certifications:

• ISO 9001 quality certification

• ISO 14001 environmental certification

Product certifications:

• ASME certification

– STAMP-H: Heating boilers

– STAMP-S: Power boilers

– STAMP-U: Pressure vessels

• EC certification

• SELO certification (China)

• GOST-R certification (Russia)

• GOST-U certification (Ukraine)

• GOSPROMNADZOR certification (Belarus)

• CoC RK certification (Kazakhstan)

Quality

The fierce competition in international markets, the

elimination of customs barriers and requirements

increasingly focused on high quality standards have led ICI

CALDAIE to develop a new culture of quality, focusing on

fully meeting the Customer's needs while complying with the

strictest quality standards as essential conditions to ensure

its own competitive edge.

In 1993, ICIM (Mechanics Industrial Certification Institute)

certified ICI CALDAIE's Quality System

in accordance with the Italian, European and international

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Information

request form

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1. Type of generator required: ❑ simple (WHB)

❑ combined (GXC)

2. Fuel originating the fumes: ❑ methane gas

❑ diesel

❑ biogas

❑ naphtha

❑ other (please specify) …..………….…

3. Incoming fumes flow rate: …………… kg/h

4. Incoming fumes temperature: …………… °C

5. Maximum allowed backpressure: …………… mbar

6. Type of fluid from the generator: ❑ hot water (<100°C)

❑ superheated water (>100°C)

❑ Saturated vapour

❑ Superheated steam

7. Operating pressure: …………… bar

8. Operating temperature: …………… °C

9. Power required on burner side (only for GXC): …………… kW

10. Fuel on burner side (only for GXC): ❑ methane gas

❑ diesel

❑ biogas

❑ naphtha

11. Power supply voltage: ❑ 400 3/N~

❑ 230 1/N~

❑ other (please specify) …..…………………

12. Frequency: ❑ 50 Hz

❑ other (please specify) …..…………………

.

13. Installation: ❑ Indoor

❑ Outdoor

14. Notes:

…………………………………………………………………………………………………………………………………………

…………………………………………………………………………………………………………………………………………

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