Powerful FGR-ST heat recovery boilers for producing steam and hot water from waste heat from various industries

Steam and hot water heat recovery boiler FGR-ST

The FGR-ST heat recovery boiler is a steam or hot water boiler that does not have its own burner for burning fuel and uses the heat of the exhaust gases of technological fuel-using units for various purposes. The heat generated by the heat recovery boiler in the form of water vapor, heated water or heated air flow is used in the same or other technological processes.

The design of the FGR-ST heat recovery boilers provides that the pipes through which the hot flue gases formed during combustion flow, are located inside the water jacket of the boiler, are discharged in a horizontal or vertical arrangement. This series of boilers does not require special brickwork and is characterized by high gas tightness, ease of maintenance, reduced requirements for feed water. The use of a block design facilitates installation and increases maintainability. Depending on the request and operating parameters, FGR-ST heat exchangers can be made of both carbon and stainless steel.

Working environments that are heated:

• warm water;
• triethylene glycol;
• thermal oil;
• steam.

Technical characteristics:

• capacity – 250-1500 kW;
• steam capacity – from 0.3 to 2 t/h;

exhaust gas side:

• maximum inlet temperature – 600 °C;
• minimum outlet temperature – depends on the type of fuel and exhaust gas composition used;
• pressure drop – according to the customer’s technical specifications;

working environment side:

• design water pressure (excess) – 0.9 MPa;
• design water temperature: inlet – 70 °C, outlet – 95 °C.

Projects with waste heat boilers with an outlet temperature of 114 °C are also being implemented.

• steam pressure up to 1.4 MPa, steam temperature without a superheater up to 190 °C.

Weight and dimensions:

• weight (with thermal insulation): from 400 to 3900 kg;
• diameter (with thermal insulation): from 950 to 1870 mm;
• height (with thermal insulation): from 1700 to 2800 mm;
• inlet/outlet diameter for coolant: DN100;
• inlet/outlet diameter for gases: from DN100 to DN1000;
• thickness of thermal insulation: 150 mm.

SCOPE OF SUPPLY

The main equipment included in the delivery set of the heat recovery steam boiler FGR-ST :

• thermal insulation;
• steam valve at the boiler outlet;
• a set of drainage circuit fittings installed;
• a set of supply circuit fittings installed;
• two direct-acting level indicators with flange connections, with drain and shut-off valves;
• two safety spring valves;
• pressure gauge;
• pressure sensor;
• water temperature sensor;
• exhaust gas temperature sensor;
• automatic water level control group;
• flow control relay;
• boiler automation set;
• built-in flue gas bypass.

The basic equipment of FGR-ST gas-tube boilers does not include economizers or superheaters, the boilers can be made with a vertical housing layout. In some cases, gas-tube boilers have an exclusive design intended for certain technological units of the chemical and petrochemical industries, non-ferrous metallurgy and other industries.

There is a complete set of a heat recovery unit module for gas turbine and gas piston power generation plants. This module can accommodate steam and hot water recovery units, an antifreeze heat recovery unit, along with auxiliary equipment: an exhaust gas flow switch with control; antifreeze and network water piping; bypass pipeline with rotary valves; frame base; instrument control set; automatic control cabinet. In addition, the heat recovery unit delivery set may include: antifreeze and network water pumps, a protective casing for installing the TM on the street/roof of the container, a low-potential heat recovery system, a network heat exchanger, a low-noise muffler, a smoke pipe.

Execution
Installations based on boiler-recovery units for industrial heating plants are designed taking into account the individual needs of the customer. For the design of a waste heat boiler, the following data are important, among others:

• exhaust gases (quantity, temperature, composition);
• coolant (hot water, saturated steam, superheated steam);
• capacity indicators (steam productivity, permissible operating pressure, permissible pressure losses in gas ducts);
• operating principle (priority of electricity generation, priority of heat generation, partial loads, load fluctuations);
• permissible content of pollutants in emissions;
• installation conditions.

Therefore, within the framework of an individual order, we perform basic design, thermal calculations, hydraulic calculations, strength calculations and develop design documentation for our boilers, which allows us to offer our customers the most efficient and high-quality systems on the most favorable terms. The introduction of technology for the utilization of thermal energy that comes with waste gases in any production process almost always allows for additional reductions in energy consumption and related financial costs.