Design, manufacture and supply of equipment, construction and installation, warranty and maintenance of energy facilities.

Waste heat recovery boilers

The main direction of our enterprise is the modern waste – heat boilers manufacture for their using in the power -Intensive engineering in the chemical and petrochemical industry. The boiler designs have been developed on the base of home and foreign experience and they have passed the test to satisfaction in the field service. The waste-heat and heat-recovery boilers are the constituent part of the process lines because the main process of the product manufacture without them is not possible in the up-to-date conditions.

The design of the waste-heat boilers is differ: 

  • by the type of heat exchange (radiant, radiant-convective and convective)
  • by the design (water-tube and gas-tube)
  • by the water circulation (natural, forced, combined and once-through)
  • by the gas duct arrangement (П,Г,T,Л,У-shape, updraft, horizontal and the others)
  • by the kind of the firing and cooling technological material( for example, hydrogen sulphide gases, refined petroleum gases, cooling of the process off-gases)
  • by the plant type ( open, semiclosed, closed)
  • by draft( balanced, blast, furnace draft)
  • by construction (for seismic and non-seismic)

The design of the waste-heat boilers and their operating conditions are determined by the properties of the warming-up heat carriers i.e. they depend on the process source-unit. Waste gases of the heat engineering processes and units may contain corrosive gaseous components as well as solid or liquid carry-over and it influences upon the choice of the waste-heat boiler design and operating conditions. The leading specialists working in the engineering centre of the Works took part in the designing and realization of the waste-heat and heat-recovery boilers for different process lines of the large enterprises. Constant improving and application of the modern solutions reduces the harmful ejection influence upon the environment up to the level which meets the requirements of the rigid international standards. The new designs of the waste-heat and heat-recovery boilers meet the customer requirements taking into account their operating experience in the chemical and petrochemical industry. We introduce the new design solutions in order to increase the boiler service life and operate reliability. We develop the designs for modernization and replacement of the process lines of home and foreign waste-heat and heat-recovery boilers which have been installed before as well as we supply the spare parts.

Design series of waste heat boilers

 Waste heat gas boilers are a separate type of boilers, in which the utilisation gas passes through evaporation surface pipes.

Thanks to the impermeability of the whole structure, this design series of boilers is widespread in the chemical and petrochemical industries. This property permits the use of these boilers in the following areas:

  • cooling of process and waste aggressive and non-aggressive gases;
  • neutralisation of hydrogen sulphide gases;
  • high-temperature conversion of hydrogen sulphide by combustion;
  • production plants for weak nitric acid;
  • various processes for obtaining elementary sulphur.

When cooling the supplied gases, the gas boilers produce saturated or superheated steam, depending on the company’s process requirements; this design series does not require any special bricking and is characterised by high gas-tightness, comfortable operation, reduced requirements for feed water, and an environmentally friendly attitude to production.

The use of unit design facilitates installation and increases maintenance and repair ability.

Waste heat boilers are equipped with platforms and ladders for maintenance and repairs, necessary closing and control fittings, safety valves, accessories, inspection and metering instruments.

Схема газотрубных котлов-утилизаторов
1. Inlet chamber 2. Cylinder 3. Outlet chamber 4. Pre-heater

Газотрубный котёл-утилитизатор

 Design series of water-tube tunnel boilers

Water-tube tunnel boilers have a horizontal layout and the heated medium passes inside evaporation surface tubes.

This design series is most efficiently used in the dust-laden environments of the chemical and petrochemical industries.

An example of application of tunnel boilers: process plants for catalytic cracking, in which the utilisation gas contaminated by the catalyst passes through the boiler, emitting the heat necessary for producing the steam. The water-tube boilers of this type can produce both saturated and superheated steam, depending on the company’s process requirements.

The primary purpose of these boilers is working with highly dust-laden gases, where other boilers have to undergo periodic shutdowns with manual cleaning; another advantage is the ease of installation and operation.

Water-tube tunnel boilers are designed with respect to fully automated cleaning of heating areas and with minimum maintenance costs.

The boilers are supplied in transport units, parts, components. The unit design reduces the transport and installation costs, and increases maintenance and repair ability. Waste boilers are equipped with platforms and ladders for maintenance and repairs, necessary closing and control fittings, safety valves, accessories, inspection and metering instruments.

Схема водотрубных тунельнных котлов
1. Cylinder 2. Superheater 3. Evaporation sections 4. Pre-heater

Водотрубный тунельный котёл

Design series of waste heat convection boilers

Convection boilers are water-tube boilers with a towerlike layout, designed for high flow rates of utilisation gases.

This design series of waste heat convection boilers has been designed as an optimum solution to process plants with gas temperatures up to 700 °С.

Structurally speaking, these waste heat boilers are a load-bearing structure bricked on the inside, comprising a gas channel with cladding plates welded along its perimeter.

An example of application of convection boilers is process plants for catalytic cracking, in which the utilisation gas contaminated by the catalyst passes through the boiler, emitting the heat necessary for producing the steam.

The boilers are supplied in transport units, parts, components. The unit design reduces the transport and installation costs, and increases maintenance and repair ability.

Waste boilers are equipped with platforms and ladders for maintenance and repairs, necessary closing and control fittings, safety valves, accessories, inspection and metering instruments.

Схема конвективных котлов утилизаторов
1. Cylinder 2. Superheater 3. Preliminary section 4. Evaporation section

Design series of waste heat radiation-convection boilers

The radiation-convection boilers are multi-path and have a U-shaped design. The boiler operation is boosted by auxiliary heating if the utilisation gas temperature is insufficient for steam production.

The primary purpose for which this type of boilers has been designed is the increasing tendency to destroy high-temperature contaminated gases (~1200°С).

The solution to the problem is a three-path system of gas movement and use of gas-tight membrane panels. Thanks to this system as well, the boilers are capable of obtaining steam with energy generation parameters and then using it in a steam turbine to produce electricity. The burner devices used in the boilers make it possible to burn attendant petroleum gases and gases produced in crude oil processing with a wide range of calorific capacities.

This series of waste heat boilers has a large number of application options:

  • production of heat and electricity for industrial purposes from combusting attendant petroleum gas in facilities extracting and producing crude oil;
  • combustion and utilisation of heating gases (gases from crude oil processing);
  • utilisation of heat in process gases in production plants for catalytic cracking or catalytic reforming for superheated steam production;
  • cooling of waste gases from afterburning furnaces in facilities for petroleum bitumen production.

The boilers are supplied in transport units, parts, components. The unit design reduces the transport and installation costs, and increases maintenance and repair ability.

Waste boilers are equipped with platforms and ladders for maintenance and repairs, necessary closing and control fittings, safety valves, accessories, inspection and metering instruments.

Схема радиационно-конвективных котлов-утилизаторов
1. Cylinder 2. Burner 3. Screens 4. Pre-heater 5. Superheater 6. Radiation chamber