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WASTE HEAT

RECOVERY SYSTEMS

Transparent Energy Systems Pvt. Ltd.


Pune- 37. (INDIA)
Tel : 020 – 4211347, Fax : 020 – 4212533.
E-mail : trans@pn2.vsnl.net.in & sales.pune@tespl.com
INTRODUCTION

Transparent has developed wide variety of superefficient Heat Recovery Systems for
harnessing 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 thermal
output and efficiency.

Transparent superefficient Waste Heat Recovery Systems find ideal applications in Cogeneration
Systems working on Reciprocating Engines and Gas Turbines.

Various sources of waste heat.

¾ 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
¾ Exhaust heat recovery from Gas Turbine exhaust.
¾ Jacket heat recovery from Engine
¾ Hot Waste Gases from
- Scrap melting steel furnaces
- Cement kilns
- Industrial furnaces
- Incinerators
- Process Waste Gases

Converting into useful form


Energy 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 energy
into 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 and
constructions’ 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
RECOSTAR FN
Product Details
™ Type : Finned Water Tube, Non IBR

™ Installation : Horizontal & Vertical,


Indoor as well as Outdoor

™ Tube Orientation : Horizontal & Vertical

™ Fin Type : 1) ‘L’ Type steel fins with


full contact of fin base to tube
2) Integral extruded / rolled
aluminium fins on C.S. tube.

™ Waste Gas Flow Direction : Horizontal/ Vertical


(Upwards & Downwards)

™ Quality of Waste Gases : Normally clean dustfree gases

™ Acceptable dust in waste : Moderate dust level acceptable for vertical fin orientation with
gases mechanized soot removing and collecting facility.

™ Type of heat recovery output : 1) Steam–D & S / Superheated 2) Hot Water


3) Hot Thermic Fluid

™ Media of Waste Heat : Hot gases, Hot bulk powders, hot liquids, hot vapours.

™ Steam Pressure : Suitable for low as well as high pressure.

™ Steam Condition : Dry & saturated with external moisture separator. Superheated
steam through provision of super-heater.

™ Water side circulation : Once through, forced circulation

™ Steam Water Separation : In external moisture separator

™ Waste Heat source : Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust
suitability process waste gases, Incinerator exhaust, furnace exhaust.

™ Typical applications : Process heating, hot water generation, Thermic Fluid heating,
whenever IBR installation is desired to be avoided.

™ Output capacity Possibilities : Single unit output upto approx. 600 kg/hr. Multiple units can
generate proportionately higher outputs without mixing flue
gases.
™ Soot removal : 1) Mechanized vibrating soot removal.
2) Automatic pneumatic cylinder operated travelling type
steam jet or compressed air jet soot blower.

™ Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater


stages possible evaporator, economizer, water preheater

™ Typical lowest exhaust gas : Gases generated by diesel - 1300C, Gas generated by natural
temp. at outlet of system gas – 1100C, Gases generated by high sulphur fuels - 1500C.

™ Protection against sulphur : Provided by various means to ensure that metal temperature is
& corrosion on cold end maintained above the actual incipient limit.
side
FLUE GAS IN

FLUE GAS
BYPASS
TO SILENCER

AUTOMATIC 3 WAY
FINNED TUBE DIVERTOR VALVE
STEAM GENERATOR
Vibrator
F.W.PUMP
F.W. TO F.W.TANK

F.W. FROM F.W.TANK


F.W.IN
FLUE GAS OUT
BLOW
DOWN
VALVE
ECONOMIZER
Recostar FN ( Horizontal )
for 750 KVA engine

Recostar FN : Flow diagram ( Vertical )

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 FI
Product Details
™ Type : Finned, Water Tube, IBR

™ Installation : Horizontal & Vertical,


Indoor as well as Outdoor

™ Tube Orientation : Horizontal & Vertical

™ Fin Type : 1) ‘L’ Type steel fins with


full contact of fin base of tube
2) Integral extruded / rolled
aluminium fins on C.S. of tube.

™ Waste Gas Flow Direction : Horizontal/ Vertical


(Upwards & Downwards)

™ Quality of Waste Gases : Normally clean dust free gases

™ Acceptable dust in waste : Moderate dust level acceptable for Boilers having vertical fin
gases orientation with mechanized soot removal and collecting facility.

™ Type of output : Steam- D&S/ Superheated, Hot Water, Hot Thermic Fluid

™ Media of Waste Heat : Hot gases, Hot bulk powders, hot liquids, hot vapours.

™ Steam Pressure : Suitable for low as well as high pressure.

™ Steam Condition : Dry & saturated with external moisture separator. Superheated
steam through provision of superheater.

™ Water side circulation : Natural Circulation, forced circulation.

™ Steam Water Separation : In steam drum or in external moisture separator.

™ Waste Heat Source : Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust
suitability process waste gases, Incinerator exhaust, furnace exhaust.

™ Typical applications : Process heating, hot water generation, Thermic Fluid heating,
Power generation, Cogeneration applications.

™ Duct firing possibilities : Possible for gas turbine exhaust applications.

™ Output capacity possibilities : No limits.

™ Soot removal : 1) Mechanized vibrating soot removal.


2) Travelling type soot blower.
3) Rotory soot blower.

™ Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater


stages possible evaporator, economizer, water preheater

™ Typical lowest exhaust gas : Gases generated by diesel - 1300C, Gas generated by natural gas
temp. at outlet of system - – 1100C, Gases generated by sulphur fuels –1500C

™ Protection against sulphur : Provided by various means to ensure that metal temperature is
corrosion on cold end side maintained above the actual incipient limit.
STEAM
OUT

PS

LT
LS

FLASH ECONOMIZER
STEAM
DRUM
FLUE GAS FLUE GAS
FROM PS OUT
ENGINE
ENTERS

FINNED TUBE
AUTOMATIC HEAT RECOVERY UNIT
3 WAY
DIVERTOR
FEED
VALVE
WATER IN

FEED WATER PUMPS

Recostar FI : Flow diagram

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)
RECOSTAR WC
Product Details
™ Type : Bare Water Tube, IBR

™ Installation : Horizontal / Vertical, Indoor as well as Outdoor.

™ Tube Orientation : Horizontal / Vertical.

™ Waste gas flow direction : Horizontal / Vertical (upwards & downwards)

™ Quality of Waste Gases : Gases having low to high dust load special design for high dust
load

™ Acceptable dust in waste : High dust level acceptable for Boilers having mechanized soot
gases removing and collecting facility.

™ Type of heat recovery output : Steam (D&S/ Superheated), Hot Water, Hot Thermic Fluid
™ Media of Waste Heat : Hot gases, hot bulk powders, hot liquids, hot vapors

™ Steam Pressure : Suitable for low as well as high pressure

™ Steam Condition : Dry & saturated and also superheated steam through provision
of superheater.

™ Water side circulation : Once through, Natural Circulation & Forced / Assisted
circulation

™ Steam Separation : In steam drum or in external moisture separator.

™ Waste heat source : Fuel cell exhaust, Micro / miniturbine exhaust, Gas turbine
suitability exhaust, DG set exhaust process waste gases, Incinerator
exhaust, furnace exhaust.

™ Typical applications : Exhaust of steel furnaces, cement kilns, metal smelters,


Incinerators, Industrial furnaces, DG set exhaust, process waste
gases, Incinerator exhaust, furnace exhaust, Gas turbine
exhaust.

™ Duct firing possibilities : 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.

™ Output capacity possibilities : No Limits.

™ Soot removal : 1) Mechanized vibrating soot removal.


2) Travelling type soot blower.
3) Rotory soot blower.

™ Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater,


stages possible evaporator, economizer, water preheater.

™ Typical lowest exhaust gas : Gases generated by diesel –130oC, gas generated by Natural
temperature at final outlet of Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
system

™ Protection against sulphur : Provided by various means to ensure that metal temperature is
corrosion on cold end side maintained above the actual incipient limit.
RECOSTAR S
Product Details

™ Type : Smoke Tube IBR


PS
PS
™ Installation : Horizontal & Vertical, LS LT
Indoor as well as Outdoor.

™ Tube Orientation : Horizontal / Vertical.


PS
™ Waste gas flow direction : Horizontal / Vertical
(upwards & downwards)

™ Quality of Waste Gases : Low dust level acceptable.

™ Type of heat recovery output : 1) D & S / superheated


2) Hot Water
3) Vapour phase Thermic Fluid Heating

™ Media of Waste Heat : Hot gases, hot liquids, hot vapors

™ Steam Pressure : Suitable for low as well as medium pressure

™ Steam Condition : Dry & saturated and also superheated steam through provision
of superheater.

™ Water side circulation : Natural circulation internal to boiler.

™ Steam Separation : In Boiler drum.

™ Waste heat source : Fuel cell exhaust, Micro / miniturbine exhaust small gas turbine
suitability exhaust, DG set exhaust, process waste gases, Incinerator
exhaust, furnace exhaust.

™ Typical applications : Exhaust of steel furnaces, cement kilns, metal smelters,


Incinerators, Industrial furnaces, DG set exhaust, process waste
gases, Incinerator exhaust, furnace exhaust, Gas turbine
exhaust.

™ Output capacity possibilities : Typically 15 TPH

™ Soot removal : Sonic soot blowers can be used & also through self cleaning
velocities.
™ Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater,
stages possible evaporator, economizer, water preheater.

™ Typical lowest exhaust gas : Gases generated by diesel – 130oC, gas generated by Natural
temperature at final outlet of Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
system

™ Protection against sulphur : Provided by various means to ensure that metal temperature is
corrosion on cold end side maintained above the actual incipient limit.
Flue gas
From
Engine 1 Steam out
PS Economizer
PS

Automatic LS LT

3 way
Divertor valves

Flue gas
PS
Engine 2 Flue
gas
out

F.W. in
Recostar-S for 2 X 1 MW gas engines
F.W. pumps

Recostar-S : Typical arrangement

Recostar-S for 2 X 1 MW gas engines

Recostar-S for 3 X 1 MW F.O. engines

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 WCOF
Product Details
™ Type : Water tube, coflow
(Cocurrent gas flow) IBR

™ Installation : Horizontal / Vertical,


Steam
Indoor as well as Outdoor. drum

™ Tube Orientation : Vertical.

™ Waste gas flow direction : Vertical

™ Quality of Waste Gases : Specially suitable for dust


laden gases. Provided with
special mechanized soot
removal and collection system.

™ Acceptable dust in waste : High dust level readily


gases Accepted

™ Type of heat recovery : 1) Steam– D & S/Superheated


output 2) Hot Water
3) Hot Thermic Fluid

™ Media of Waste Heat : Hot gases, Hot vapours

™ Steam Pressure : Suitable for low as well as high pressure

™ Steam Condition : Dry & saturated. Superheated steam by provision of superheater.

™ Water side circulation : Natural Circulation / Forced (Assisted circulation)

™ Steam Separation : In steam drum or in external moisture separator

™ Waste heat source : Exhaust of steel furnaces, cement kilns, metal smelters,
suitability incinerators, industrial furnaces, DG set exhaust process waste
gases, Incinerator exhaust, Furnace exhaust, gas turbine
exhaust.

™ Typical applications : Process heating, hot water generation, thermic fluid heating,
power generation, cogeneration.

™ Duct firing possibilities : Possible for applications on gas turbine exhaust, Heat addition
into waste gas stream by firing fuel.

™ Output capacity possibilities : No Limits.

™ Soot removal : 1) Mechanized vibrating soot removal.


2) Travelling type soot blower.
3) Rotory soot blower.

™ Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater


stages possible evaporator, economizer, water preheater

™ Typical lowest exhaust gas : Glue gas from diesel – 1300C, Flue gas from Natural Gas – 1100C,
temp. at outlet of system Flue gas from high sulphur fuels –1500C

™ Protection against sulphur : Provided by various means to ensure that metal temperature is
corrosion on cold end side maintained above the actual incipient limit.
BYPASS

AUTO. 3 WAY
HOT DIVERTOR VALVE
GAS IN
STEAM

FEED WATER
AT 180 –1850 C
Steam
drum TO CHIMNEY

HOT
GAS 155 -1600C
OUT FEED
EVAPORATOR WATER
AT 900C
180 -1850C

ECONOMIZER -II

120 -1250C

ECONOMIZER -I

Recostar WCOF : Typical arrangement

Recostar-WCOF for 3.8 MW engine

Recostar WCOF : Flow diagram ( Vertical )


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. : 1850C
‰ Output type : Steam at 10 Bar(g)
‰ Output at 100% load : 1950 Kg./Hr (F & A 1000C)
RECOSTAR WCRF
Product Details
™ Type : Water tube cross flow IBR

™ Installation : Vertical, Indoor and Outdoor.

™ Tube Orientation : Vertical.

™ Waste gas flow direction : Horizontal

™ Quality of Waste Gases : Moderately clean gas desired.


Provided with mechanized
Soot removal and collection
System.

™ Acceptable dust in waste : Moderate dust level accepted


gases

™ Type of heat recovery output : 1) Steam– D & S / Super-heater


2) Hot Water
3) Vapour phase thermic fluid

™ Media of Waste Heat : Hot gases

™ Steam Pressure : Suitable for low as well as high pressure

™ Steam Condition : Dry & saturated and also superheated steam through provision
of super-heater.

™ Water side circulation : Natural Circulation

™ Steam Separation : In steam drum or in external moisture separator.

™ Waste heat source : Exhaust of steel furnaces, cement kilns, metal smelters,
suitability incinerators, industrial furnaces, DG set exhaust process waste
gases, Incinerator exhaust, Furnace exhaust, gas turbine
exhaust. (Gases with temperature less than 550oC)

™ Typical applications : Process heating, hot water generation, thermic fluid heating,
power generation, cogeneration.

™ Duct firing possibilities : Possible for applications on gas turbine exhaust, Heat addition
into waste gas steam by addition of hot gases generated by
separately fired hot gas generator.

™ Output capacity possibilities : No Limits.

™ Soot removal : 1) Mechanized vibrating soot removal.


2) Travelling type steam soot blower. 3) Rotary soot blower.

™ Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater,


stages possible evaporator, economizer, water preheater.

™ Typical lowest exhaust gas : Gases generated by diesel – 130oC, gas generated by Natural
temperature at final outlet of Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
system

™ Protection against sulphur : Provided by various means to ensure that metal temperature is
corrosion on cold end side maintained above actual incipient limit.
STEAM OUT

STEAM
DRUM

FLUE
FLUE
GAS OUT
GAS IN

MUD
DRUM

BLOW DOWN

Recostar WCRF : Flow diagram ( Vertical )

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)
RECOSTAR CC
Product Details
™ Type : Cylindrical coil type,
water tube, once through

™ Installation : Horizontal / Vertical,


Indoor as well as Outdoor.

™ Tube Orientation : Horizontal / Vertical.

™ Waste gas flow direction : Horizontal / Vertical


(upwards & downwards)

™ Quality of Waste Gases : Normally clean dust free


gases (special vertical design
with self cleaning velocities
available for dust laden gases
with soot blowing arrangement)

™ Type of heat recovery : 1) Steam – D & S / Superheated 2) Hot Water 3) Hot Thermic
output Fluid

™ Media of Waste Heat : Hot gases, Hot vapours, Hot liquids

™ Steam Pressure : Suitable for low as well as high pressure

™ Steam Condition : Dry & saturated steam with external moisture separator.
Superheated steam possible with provision of superheater and
moisture separator installed between evaporator and super-
heater.

™ Degree of Superheat : Superheat degree limited by lnlet gas temperature available.


Possible

™ Water side circulation : Once through Forced circulation

™ Steam Separation : With external moisture separator.

™ Waste heat source : Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust
suitability process waste gases, Incinerator exhaust, furnace exhaust.
(High gases)

™ Typical applications : Thermic Fluid heating, process heating, hot water generation,
superheated water generation, power generation, cogeneration.

™ Duct firing possibilities : Possible for gas turbine exhaust applications, heat addition into
waste gas steam by addition of hot gases generated by
separately fired hot gas generator.

™ Output capacity possibilities : No capacity limits as multiple units can generate higher outputs.

™ Soot removal : Through self cleaning velocities and pneumatic / steam soot
blowers.

™ Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. Super-heater,


stages possible evaporator, economizer, water preheater.
Air bleed valve
Air bleed valve

Flue gas From


Flue gas From
Incinerator at
Incinerator at
1000 0C
1000 0C

I. D. Fan
Waste heat I. D. Fan
TIC Waste heat
recovery TIC
F. D. Fan Incinerator recovery
Thermic F. D. Fan Incinerator
Thermic
fluid heater Flue gas
Exit fluid heater
at 250 0C
3 way Divertor
3 way Divertor
Valve
Valve

T.F. From
T.F. From
Plant at 1900C
Plant at 1900C
Panel
Common Exp. Panel
Common Exp.
Tank
DPS Tank
DPS

T.F. From
T.F. From
WHRTFH
WHRTFH
at 210 0C
at 210 0C

T.F. to fired
T.F. to fired
TFH at 2050C
TFH at 2050C

Heat recovery ON Heat recovery BYPASS

Recostar FN : Flow diagram for Incinerator based


Heat recovery system

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 2100C
‰ Output at 100% load : 4,86,202 Kcal/Hr.
RECOSTAR PC
Product Details

™ Type : Pancake coil type,


water tube, once through

™ Installation : Horizontal & Vertical,


Indoor as well as Outdoor.

™ Tube Orientation : Horizontal / Vertical.

™ Waste gas flow direction : Horizontal / Vertical


(upwards & downwards)

™ Quality of Waste Gases : Normally clean dust free gases.

™ Acceptable dust in waste : Low dust level needed in


gases horizontal design high dust
level acceptable only in vertical
design with self cleaning velocities.

™ Type of heat recovery output : 1) Steam – D & S / Superheated


2) Hot Water
3) Hot Thermic Fluid

™ Media of Waste Heat : Hot gases, Hot vapours, Hot liquids

™ Steam Pressure : Suitable for low as well as high pressure

™ Steam Condition : Dry & saturated steam with external moisture separator.
Superheated steam possible with provision of superheater and
moisture separator installed between evaporator and
superheater.

™ Water side circulation : Once through Forced circulation.

™ Steam Separation : With external moisture separator.

™ Waste heat source : Fuel cell exhaust, micro / min gas turbine exhaust, DG set
suitability exhaust process waste gases, Incinerator exhaust, furnace
exhaust.

™ Typical applications : Thermic Fluid heating, process heating, hot water generation,
superheated water generation, power generation, cogeneration.

™ Duct firing possibilities : Possible for gas turbine exhaust applications.

™ Output capacity possibilities : No capacity limits as multiple units can generate higher outputs.

™ Soot removal : Through self cleaning velocities and pneumatic steam soot
blowers.

™ Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater,


stages possible evaporator, economizer, water preheater.
Hot Thermic fluid out

Pancake coils

Cold Thermic fluid in

Hot flue gas in

Recostar PC : Flow diagram

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.
RECOSTAR SCMP
Product Details

™ Type : Smoke tube, composite


(I.e. unfired plus fired zone)

™ Installation : Horizontal, Vertical, Indoor.

™ Tube Orientation : Horizontal / Vertical.

™ Waste gas flow direction : Horizontal / Vertical


(upwards & downwards)

™ Quality of Waste Gases : Low dust level desired.

™ Type of heat recovery output : 1) Steam–D & S / Super-heat.


2) Hot water
3) Vapour phase Thermic Fluid Heating.

™ Media of Waste Heat : Hot gases, Hot vapors, Hot liquids

™ Steam Pressure : Suitable for low as well as medium pressure

™ Steam Condition : Dry & saturated and also superheated steam through provision
of super-heater.

™ Water side circulation : Natural Circulation internal to boiler.

™ Steam Separation : In steam drum or in external moisture separator.

™ Waste heat source : Fuel cell exhaust, micro / min gas turbine exhaust, Small gas
suitability turbine exhaust, DG set exhaust, process waste gases,
Incinerator exhaust, furnace exhaust, gas turbine exhaust.

™ Typical applications : 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.

™ Supplemetory firing : Firing in internal furnace provided in boilers.


possibilities

™ Output capacity possibilities : Typically upto 20T/hr capacity.

™ Soot removal : By sonic soot blowers and through self cleaning velocities.

™ Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. Super-heater


stages possible evaporator, economizer, water preheater.

™ Typical lowest exhaust gas : Gases generated by diesel – 130oC, gas generated by Natural
temperature at final outlet of Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
system

™ Protection against sulphur : Provided by various means to ensure that metal temperature is
corrosion on cold end side maintained above the actual incipient limit.
FLUE GAS
FROM ENGINE ENTERS ECONOMIZER
FLUE GAS
FROM ENGINE
LEAVES

PARTITION

FLUE GAS
FROM
BURNER
BURNER LEAVES

Recostar SCMP : Flow diagram ( Vertical )

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. : 2050C
‰ Output type : Steam at 10 Bar(g)
‰ Output at 100% load : 2000 Kg./Hr (F & A 1000C)
PRODUCT FEATURES

CONTROL PANEL EASE OF FLUE GAS


SIDE INSPECTION
The Control Panel is
wired with solid Front and rear doors
conductor single strand are hinged type to
wires for easy tracebility. provide simple & quick
Indications for all opening for full access
temperatures, safety trips to fireside tube surface.
provided on panel. This job can be done by
Facilities for auto-manual a single person
switching of individual
devices provided.

MAXIMUM HEAT CUSTOM


RECOVERY ENGINEERED /
Heat recovery in multiple CUSTOM BUILT
stages ( 3 to 4) with help
of single/double stage Every TRANSPARENT
economizers plus water Boiler is specifically
preheater ensures engineered and built to
maximum possible heat every customer’s needs
recovery from the waste and specifications.
gases. Customer gets Special sizes, sources
nearly 7 to 19 % of of heat and auxiliary
additional output equipment are no
compared to other problem with
makes. TRANSPARENT.

DIVERTOR VALVE INSULATION


Insulation thickness is
Automatic pneumatically selected scientifically to
operated, Linear minimize heat loss even
movement of valve, at a high flue gas temp.
Stainless steel can work (Typical thickness used
850oC continuously. is 300 mm for 5000C)
Pneumatic pressure
eliminating possibility of
any leakage.
APPLICATION SUITABILITY
PRODUCT MATRIX

Matrix for of converting waste heat in useful form


Source of H L G E G I C S H G F A H
Waste Heat O E J T P P G F G C P
O E
Useful Form E E H E K F P G F C
E G
Of Output E G H
E

Low Pressure Steam

Medium Pressure Steam

High Pressure Steam

Hot Thermic Fluid

Hot Water (Pressurized)

Hot Water (Non Pressurized)

Hot Air for Process (Dryer etc)

Chilled Water

Chilled Brine

Ice Making

Cold Storage

Waste Water Recycling

Power

Combustion Air Preheating

Inlet Air Cooling

Source of Waste Heat

™ 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
WHRB INSTALLATION

WHRB Installed at Square Spinnings Ltd., Bangladesh,


Natural Gas Fired Engine,
Steam Pressure – 10.54 kg/cm2 (g).

WHRB Installed at Reid & Taylor (S. Kumar)

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 Oil
Steam Pressure – 14 Kg/cm2 (g)

WHRB Installed at Hindustan Mills Ltd WHRB Installed at Janta Jute - Dhaka
COMPARISION
Safety of Source Equipment
Flue gas
from Engine Flue gas bypass

Back pr. limit FPS


FPS
pressure
sensor
Automatic
3 way
Divertor Valve

Back pressure control on flue gas side


Transparent provides automatic flue gas monitoring & control system. If the steam pressure exceeds
the predetermined value, the flue gases automatically diverted to stack. This saves the source
(Engine or turbine) from getting subjected to excessive back pressure.

No such system exists in other make whrb (standard model). This is quite unsafe for the engine or
turbine on which the WHRB is installed.
Note : In case of gas fired engines or turbines, eventhough there is very little possibility of carbon
accumulation but other possibilities do exist for excessive back pressure on flue gas side. It can
happen either due to leakage of boiler tube or lube oil vapour condensation in abnormal conditions.
Hence even in case of gas engines/turbines, above safety feature is of paramount importance.

Safety of Waste Heat Recovery Boiler


Steam pr. limit
Pressure sensor Flue gas bypass Steam pr. limit
SPS
SPS

Automatic 3 way
Divertor valve

High steam pressure control


Transparent provides automatic steam pressure monitoring & control system. If the steam pressure
exceeds the predetermined value, the flue gases are automatically diverted to stack. This eliminates
frequent operation of safety relief valve.

No such system exists in other make whrb (standard model). This is quite unsafe for the WHRB. In
such case one has to solely depend on safety valve.

Note : Frequent operation of safety valve is an undesirable situation since it is meant for ultimate
safety of boiler & supposed to operate once in a while.
COMPARISION
Safety of Waste Heat Recovery Boiler

Flue gas bypass


Level sensor
Flue gas
from Engine
LSL LSL

Automatic 3 way
Divertor Valve

Low water level safety trip


Transparent provides automatic boiler water level monitoring & control system.In case the level falls
below safe level, the flue gases automatically bypass the WHRB & go to stack. This eliminates boiler
tubes overheating.

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.

Efficiency and Outputs


Heat From the Gases
Flue gas from Engine
at 5860C Transparent WHRB recovers
Flue gas out from
WHRB at 1340C maximum possible heat from
the gases. It gives atleast 7 to
10% extra output compared to
other make. This needs a much
bigger economizer & high
Automatic manufacturing cost for
3 way Divertor
Transparent but gives benefit to
Valve
user in terms of more savings.

In other makes, eventhough economizer is provided, heat is recovered upto a temperature level
where the manufacturing cost is less. This results in cost savings for WHRB supplier but recurring
loss to the user.
COMPARISION
Divertor Valve

Transparent Make Other Make

From Engine Linear Possible leakage


movement
Swing type
movement
Flap

To WHRB From Engine

• Automatic pneumatically operated. • Manually operated.


• Linear movement of valve(poppet). No • Swing type movement of valve(flap).
possibility of jamming. Possibility of jamming.
• Positive pneumatic pressure acts as good • No positive force is applied after the flap
sealing force continuously when the valve reaches its respective positions.The
reaches the respective positions. The mechanical play in the gearbox results in
poppet is pressed against the valve seat small opening due to self weight of flap &
by pneumatic pressure eliminating
possibility of any leakage. flue gas back pressure. This can result in
leakage in the long run.
• Force is applied at center of poppet
ensuring equal distribution throughout the • Force is applied at one end of flap. This
sealing edges. results in unequal force distribution.The
• Made of Stainless steel which can distant edge gets less force.
work upto 8500C continuously. • Made of carbon steel alloy which is not
suitable for more than 5000C.

Vertical Co-flow WHRB vs. other make WHRB

Tubes are placed vertically with axis parallel Tubes are placed horizontally with their axis
to gas flow. It does not obstruct the flow of perpendicular to flow of gas. This results into
gas. Possibilities of soot accumulation are obstruction to gas flow & soot particles are
less since vertical downward flow of flue gas arrested on tube surface.
will help in dislodging the soot particles.
COMPARISION
Vertical Co-flow WHRB vs. other make WHRB

DRUM
DRUM

RISER DISCHARGE

PUMP SUCTION

PUMP

Natural circulation design. No dependence Forced circulation design. Circulation is


on any external equipment for circulation. dependent on pump. Failure of pump suddenly
Uninterrupted circulation eliminates stops circulation and results into higher TDS level
possibilities of higher TDS level in in evaporator and subsequent scale deposition.
evaporator and subsequent scale deposition. Pump has to operate at very high suction
pressure making the operation critical.
Bare tubes reduces possibility of soot Finned tube construction invites accumulation of
accumulation. Particularly for gases with soot between fins. This type of tube is not
high SPM like flue gases of F.O. engine, it is recommended particularly for flue gases with high
highly recommended to use only bare tubes SPM. Their use should be restricted for cleaner
without manufacturing cost goes up, user flue gases like gas engine / turbine.
gets benefited.

Bare tubes used in manufacturing are Finned tubes used have specific fin size, shape
standard tubes available in market. In case and configuration. These tubes have to be
of replacement user is not dependent on purchased only from manufacturer and hence
manufacturer for supply of tubes. user is completely dependent on manufacturer for
lifetime of boiler.

Main boiler Main boiler

Economizer Economizer Economizer


1st stage 2nd stage

Two stage economizer improves Heat Single stage economizer. Hence limited heat
recovery. Feed water is heated completely up- recovery.
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
COMPARISION
Vertical Co-flow WHRB vs. other make WHRB

F.W. at 1850 C
To boiler
F.W. to boiler
Economizer Economizer
1st stage 2nd stage
Economizer
1220 C 1550 C
Feed water
At 90 Deg.C Feed water
Water
Pre-heater At 90 Deg.C

For flue gases of furnace oil with 4% sulphur, Water in the tank directly enters Economizer
it is necessary to maintain metal temperature without any temperature correction. Hence
above 121 Deg.C. We provide auto the tube wall temperature at economizer inlet
temperature correction system which drops below safe level and results into Cold
ensures that them feed water entering each end Corrosion. User has to buy the tubes
stage of economizer is at-least at 122 Deg.C. frequently from manufacturer since these
This will ensure that all contact area is above
tube are not available in market.
the safe temperature level and will eliminate
any possibility of corrosion.

Two alternatives are available. Steam soot Steam soot blower consume almost 3-4% of
blowers are provided as one of the the steam output per day. This reduces net
alternatives. As a second alternative, soot steam available to plant. Operation is manual
removal is done on-line with mechanical and if not done properly, can create
knockers. This has negligible operating problems.
costs. These soot blowers can operate
automatically based on ‘flue gas back
pressure feedback signal’ or ‘flue gas outlet
temperature feedback signal’.
Transparent Group of Companies
Transparent 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.

Business groups, Products & Systems


Transparent Energy Systems Private Limited
Our company was incorporated on 16th April, 1986 with the name of Vapor Energy Machines Private Limited. The first commercial production was
started 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.

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


Incinerators
- Spray Dryer cum Combustion Chamber Incinerators
- Fluidized Bed Incinerators for Liquids and Solids & Gases - Packaged Fixed Grate Incinerators for Solids
- Liquid / Gas Incinerators - Fluidized Bed Paint Stripping Systems for Paint Coating
Air Pollution Control
- Cyclone / Multicones - Bag Filters - Wet / Venturi Scrubbers - Mechanical Dust Collectors - Flue Gas Desulphurisation Plants