The Future of Everyting

Waste Heat Steam Boilers

Waste Heat Recovery Systems
Industrial Boilers

WHRB (Waste Heat Recovery Boiler): converts waste heat into steam/power, cuts fuel costs and emissions, and removes the need for auxiliary boilers.

WHRB: converts process exhaust to steam—up to 20,000 kg/h, ~14,000 kW (~20,000 hp), 25 bar (363 psig).

Waste Heat Steam Boiler Advantages;

It responds to sudden vapour draws.
It is a clean energy supply.
It has a large evaporation surface and vapour volume.
It is possible to intervene in the smoke pipes from the front and back doors of our Waste Heat Steam Boiler, the man hole on the boiler and the water side through at least two hand holes.
Special design is made according to customer needs.
Many years of experience in industrial/commercial boiler technology.
Precise steam pressure control
Low maintenance and service costs
Easy user interface with Tsb Energy control system.
High process reliability, remote control is available.
Low electricity consumption through the use of efficient electric motors.
Offers zero emissions at the user site, no COx, NOx and SOx,
Customer-specific software revision specific to your company with our expert staff.
The boiler can optionally be equipped with a PLC with different communication protocols such as Modbus, Profibus, etc. and thus boiler integration into any industrial process can be provided.

Almost all industrial processes require heat. Allowing the heat energy from chimneys to be discharged into the atmosphere is wasteful and seriously damaging to the environment, as well as being subject to serious legislation. Recovering and reusing this heat provides a more sustainable operation and provides serious economic gains as well as complying with environmental legislation. This is what Heat Recovery Systems are for; they collect and redirect waste heat, feed it back into their own process or utilise it for other processes.

Every 1000kg/h - 700kW of recovered heat energy eliminates 975 tonnes of CO2 and 302kg each, 666 lbs NOx and CO per year to help meet emission reduction and decarbonisation targets.

It should not be forgotten that each 20 °C recovery from the hot smoke gas discharged into the chimney increases the efficiency of the device by 1%.

Waste Heat Steam Boiler Working Principle;

The exhaust flue gases are passed through a smoke-tube heat recovery device, whereby the waste heat energy is transferred to the water, causing the water to change state under pressure.

Design: Our high pressure, smoke tube, cylindrical, vertical or horizontal type waste heat steam boilers are designed and manufactured according to TS EN 12953, Loyd rules, TRD, DIN, EN, PED 2014/68/EC and ASME Section VIII Div 1. All electrical components are UL labelled and wired in accordance with the applicable National Electrical Code requirements.

The waste heat steam boiler is delivered compactly on a single chassis ready for operation. The only action required is to connect it to electricity, feed water and steam users.

Ease of Operation and Maintenance: User-friendly controls and easy access to components simplify operation and maintenance, minimising downtime and operating costs. Thanks to a control panel with one-button start-up, self-checking of the device to stop the system against possible faults, and summary maintenance instructions with warnings according to the duration of use, boiler operation has become very reliable and understandable for the boiler operator.

All security devices are monitored by PLC. Necessary safety measures are taken in case of alarm. Boiler control is carried out by the boiler operator via HMI. Active alarms and past alarms are monitored via the same HMI. Alarm and running information is transmitted to other systems via digital contacts (dry contact). Remote data collection and boiler status information are available via ModBus, Modbus TCP/IP and Profinet protocols.

Safety: Safety and standards are our top priority. Our boilers are equipped with advanced safety features such as overpressure protection, sequential water level guards, flue temperature and steam temperature monitoring and emergency boiler shutdown mechanisms.

Material: Envelopes and mirrors of our waste heat steam boilers are made of P355GH boiler sheet in accordance with EN 10028-2 or AISI304 - AISI316 stainless steel for corrosive gases such as biogas. Boiler tubes are manufactured from P235GH or P265GH steel drawn boiler tubes conforming to EN 10216-2 or AISI304 - AISI316 - AISI316TI stainless tubes for corrosive gases.

Efficiency: As a result of the long-term studies of our university-supported R&D department with analysis programmes, the pipe diameters of our waste heat boilers have been narrowed and the length of the boilers has been extended, thus the velocity of the smoke gases in the boiler has been increased at ideal counter pressure and advanced efficiency has been achieved.

100mm thick high density front and rear door insulation provides low heat loss from radiation. The thermal insulation is covered with galvanised and painted DKP sheet with low lambda value. All insulation has low conductivity and high density materials.

In addition, in order to increase the efficiency of our waste heat steam boilers, aluminium turbulators are optionally placed in the smoke pipes to ensure maximum heat transfer from smoke gases in smaller areas.

Environmentally Friendly Design: Our zero emission waste heat steam boilers offer clean energy as an alternative to your industrial system, helping you reduce your carbon footprint and achieve your carbon neutral goals.

Customisation: We know that every manufacturing and process has its own unique differences, and we customise our proven equipment based on the analysis of your process to make it the most suitable and ideal for you. Designing and manufacturing waste heat steam boilers and, more importantly, providing the necessary engineering support and personnel for a successful installation requires exceptional expertise. You will not only buy a boiler from us, but also years of experience and know-how. If you have any further questions, please do not hesitate to request an individual expert consultation.

Our customers are offered the following extensions for each boiler:

Automation and control technology
Water treatment systems and analysis
Feedwater tank and other thermal tanks
Pipework and chimney systems
Low emissions
Simple and easy maintenance
Robust design for very long life
Condensing economiser option
A fully integrated waste heat steam boiler solution.

What is Waste Heat Steam Boiler? When to Use Waste Heat Steam Boiler?

Waste heat vapour boilers are closed pressurised vessels with water as a heat receiving fluid on one side of their surfaces, and on the other side there are paths through which heat-giving waste smoke gases circulate, and waste heat energy is transferred to water by radiation and conduction.

In all facilities where a fuel is burned, there is smoke, i.e. waste heat emission from the chimney. It is not correct to make a waste heat boiler in every facility with waste heat release. A very good feasibility should be made in the enterprise where the waste heat boiler will be built and the enterprise should have a process where the waste heat can be used. Therefore, if we use the recovered heat energy efficiently somewhere, the business can get the return on investment. With an efficient project, the depreciation period of the device is also low.