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.

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 Exhaust heat recovery from Gas Turbine exhaust. Jacket heat recovery from Engine 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 Recostar FI Recostar S Recostar WC Recostar WCOF Recostar WCRF Recostar CC Recostar PC Recostar SCMP Recostar JW

: Finned, Water tube, Non IBR. : Finned Water tube IBR. : Smoke tube IBR. : Bare Water tube, IBR. : Water tube, co-flow (concurrent flue-gas flows) IBR. : Water tube cross tube IBR. : Cylindrical coil type once through. : Pancake coil type once through. : Smoke tube, composite unfired plus fired type. : Engine jacket water heat recovery system

RECOSTAR FN
Product Details
Type Installation : : Finned Water Tube, Non IBR Horizontal & Vertical, Indoor as well as Outdoor Horizontal & Vertical 1) L Type steel fins with full contact of fin base to tube 2) Integral extruded / rolled aluminium fins on C.S. tube. Horizontal/ Vertical (Upwards & Downwards) Normally clean dustfree gases Moderate dust level acceptable for vertical fin orientation with mechanized soot removing and collecting facility. 1) SteamD & S / Superheated 3) Hot Thermic Fluid 2) Hot Water

Tube Orientation Fin Type

: :

Waste Gas Flow Direction

Quality of Waste Gases Acceptable dust in waste gases Type of heat recovery output Media of Waste Heat Steam Pressure Steam Condition Water side circulation Steam Water Separation Waste Heat source suitability Typical applications Output capacity Possibilities

: : : : : : : : : : :

Hot gases, Hot bulk powders, hot liquids, hot vapours. Suitable for low as well as high pressure. Dry & saturated with external moisture separator. Superheated steam through provision of super-heater. Once through, forced circulation In external moisture separator Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust. Process heating, hot water generation, Thermic Fluid heating, whenever IBR installation is desired to be avoided. Single unit output upto approx. 600 kg/hr. Multiple units can generate proportionately higher outputs without mixing flue gases. 1) Mechanized vibrating soot removal. 2) Automatic pneumatic cylinder operated travelling type steam jet or compressed air jet soot blower. 3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater Gases generated by diesel - 1300C, Gas generated by natural gas 1100C, Gases generated by high sulphur fuels - 1500C. Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

Soot removal

Number of heat recovery stages possible Typical lowest exhaust gas temp. at outlet of system Protection against sulphur & corrosion on cold end side

: : :

FLUE GAS IN

FLUE GAS BYPASS TO SILENCER

FINNED TUBE STEAM GENERATOR Vibrator F.W.PUMP

AUTOMATIC 3 WAY DIVERTOR VALVE

F.W. TO F.W.TANK F.W. FROM F.W.TANK

F.W.IN BLOW DOWN VALVE

FLUE GAS OUT

ECONOMIZER

Recostar FN ( Horizontal ) for 750 KVA engine

Recostar FN : Flow diagram ( Vertical )

Case study Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load : : : : : : : : : Engine generator exhaust 600KW X 1 No. HSD 2700 Kg./Hr. 5180C Main WHRB + Economizer 1850C Steam at 10 Bar(g) 320 Kg./Hr (F & A 1000C)

RECOSTAR FI
Product Details
Type Installation : : Finned, Water Tube, IBR Horizontal & Vertical, Indoor as well as Outdoor Horizontal & Vertical 1) L Type steel fins with full contact of fin base of tube 2) Integral extruded / rolled aluminium fins on C.S. of tube. Horizontal/ Vertical (Upwards & Downwards) Normally clean dust free gases Moderate dust level acceptable for Boilers having vertical fin orientation with mechanized soot removal and collecting facility. Steam- D&S/ Superheated, Hot Water, Hot Thermic Fluid Hot gases, Hot bulk powders, hot liquids, hot vapours. Suitable for low as well as high pressure. Dry & saturated with external moisture separator. Superheated steam through provision of superheater. Natural Circulation, forced circulation. In steam drum or in external moisture separator. Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust. Process heating, hot water generation, Thermic Fluid heating, Power generation, Cogeneration applications. Possible for gas turbine exhaust applications. No limits. 1) Mechanized vibrating soot removal. 2) Travelling type soot blower. 3) Rotory soot blower. 3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater Gases generated by diesel - 1300C, Gas generated by natural gas - 1100C, Gases generated by sulphur fuels 1500C Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

Tube Orientation Fin Type

: :

Waste Gas Flow Direction

Quality of Waste Gases Acceptable dust in waste gases Type of output Media of Waste Heat Steam Pressure Steam Condition Water side circulation Steam Water Separation Waste Heat Source suitability Typical applications Duct firing possibilities Output capacity possibilities Soot removal

: : : : : : : : : : : : :

Number of heat recovery stages possible Typical lowest exhaust gas temp. at outlet of system Protection against sulphur corrosion on cold end side

: : :

STEAM OUT

PS LT LS FLASH STEAM DRUM FLUE GAS FROM ENGINE ENTERS PS ECONOMIZER

FLUE GAS OUT

AUTOMATIC 3 WAY DIVERTOR VALVE

FINNED TUBE HEAT RECOVERY UNIT FEED WATER IN

FEED WATER PUMPS

Recostar FI : Flow diagram Case study Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load : : : : : : : : : Engine generator exhaust 800KW X 1 No. HSD 4000 Kg./Hr. 5180C Main WHRB + Economizer 1510C Steam at 10 Bar(g) 700 Kg./Hr (F & A 1000C)

RECOSTAR WC
Product Details
Type Installation Tube Orientation Waste gas flow direction Quality of Waste Gases Acceptable dust in waste gases Type of heat recovery output Media of Waste Heat Steam Pressure Steam Condition Water side circulation Steam Separation Waste heat source suitability Typical applications : : : : : : : : : : : : : Bare Water Tube, IBR Horizontal / Vertical, Indoor as well as Outdoor. Horizontal / Vertical. Horizontal / Vertical (upwards & downwards) Gases having low to high dust load special design for high dust load High dust level acceptable for Boilers having mechanized soot removing and collecting facility. Steam (D&S/ Superheated), Hot Water, Hot Thermic Fluid Hot gases, hot bulk powders, hot liquids, hot vapors Suitable for low as well as high pressure Dry & saturated and also superheated steam through provision of superheater. Once through, Natural Circulation & Forced / Assisted circulation In steam drum or in external moisture separator. Fuel cell exhaust, Micro / miniturbine exhaust, Gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust. Exhaust of steel furnaces, cement kilns, metal smelters, Incinerators, Industrial furnaces, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust, Gas turbine exhaust. 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. No Limits. 1) Mechanized vibrating soot removal. 2) Travelling type soot blower. 3) Rotory soot blower. 3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater. Gases generated by diesel 130oC, gas generated by Natural Gas 110oC, Gases generated by high sulphur fuels 150oC. Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

Duct firing possibilities

Output capacity possibilities Soot removal

: :

Number of heat recovery stages possible Typical lowest exhaust gas temperature at final outlet of system Protection against sulphur corrosion on cold end side

: :

RECOSTAR S
Product Details
Type Installation : : Smoke Tube IBR
PS

Horizontal & Vertical, Indoor as well as Outdoor. Horizontal / Vertical. Horizontal / Vertical (upwards & downwards) Low dust level acceptable. 1) D & S / superheated 2) Hot Water 3) Vapour phase Thermic Fluid Heating Hot gases, hot liquids, hot vapors
PS

PS LS LT

Tube Orientation Waste gas flow direction

: :

Quality of Waste Gases Type of heat recovery output

: :

Media of Waste Heat Steam Pressure Steam Condition Water side circulation Steam Separation Waste heat source suitability Typical applications

: : : : : :

Suitable for low as well as medium pressure Dry & saturated and also superheated steam through provision of superheater. Natural circulation internal to boiler. In Boiler drum. Fuel cell exhaust, Micro / miniturbine exhaust small gas turbine exhaust, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust. Exhaust of steel furnaces, cement kilns, metal smelters, Incinerators, Industrial furnaces, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust, Gas turbine exhaust. Typically 15 TPH Sonic soot blowers can be used & also through self cleaning velocities. 3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater. Gases generated by diesel 130oC, gas generated by Natural Gas 110oC, Gases generated by high sulphur fuels 150oC. Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

Output capacity possibilities Soot removal Number of heat recovery stages possible Typical lowest exhaust gas temperature at final outlet of system Protection against sulphur corrosion on cold end side

: : :

Flue gas From Engine 1 Automatic 3 way Divertor valves

PS

Steam out
PS LS LT

Economizer

Flue gas Engine 2

PS

Flue gas out F.W. in F.W. pumps

Recostar-S for 2 X 1 MW gas engines

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 Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load : : : : : : : : : Engine generator exhaust 1 MW X 1 No. Furnace oil (Heavy oil) 24000 Kg./Hr. 3050C Main WHRB + 2 stage Eco. 1810C Steam at 10 Bar(g) 1500 Kg./Hr (F & A 1000C)

RECOSTAR WCOF
Product Details
Type Installation Tube Orientation Waste gas flow direction Quality of Waste Gases : : : : : Water tube, coflow (Cocurrent gas flow) IBR Horizontal / Vertical, Indoor as well as Outdoor. Vertical. Vertical Specially suitable for dust laden gases. Provided with special mechanized soot removal and collection system. High dust level readily Accepted 1) Steam D & S/Superheated 2) Hot Water 3) Hot Thermic Fluid Hot gases, Hot vapours Suitable for low as well as high pressure Dry & saturated. Superheated steam by provision of superheater. Natural Circulation / Forced (Assisted circulation) In steam drum or in external moisture separator Exhaust of steel furnaces, cement kilns, metal smelters, incinerators, industrial furnaces, DG set exhaust process waste gases, Incinerator exhaust, Furnace exhaust, gas turbine exhaust. Process heating, hot water generation, thermic fluid heating, power generation, cogeneration. Possible for applications on gas turbine exhaust, Heat addition into waste gas stream by firing fuel. No Limits. 1) Mechanized vibrating soot removal. 2) Travelling type soot blower. 3) Rotory soot blower. 3 to 4 stages of heat recovery possible e.g. super-heater evaporator, economizer, water preheater Glue gas from diesel 1300C, Flue gas from Natural Gas 1100C, Flue gas from high sulphur fuels 1500C Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.
Steam drum

Acceptable dust in waste gases Type of heat recovery output Media of Waste Heat Steam Pressure Steam Condition Water side circulation Steam Separation Waste heat source suitability

: :

: : : : : :

Typical applications Duct firing possibilities Output capacity possibilities Soot removal

: : : :

Number of heat recovery stages possible Typical lowest exhaust gas temp. at outlet of system Protection against sulphur corrosion on cold end side

: : :

BYPASS AUTO. 3 WAY DIVERTOR VALVE STEAM FEED WATER AT 180 1850 C

HOT GAS IN

Steam drum TO CHIMNEY HOT GAS OUT EVAPORATOR

155 -1600C

FEED 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 Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load : : : : : : : : : Engine generator exhaust 3.8 MW X 1 No. Furnace oil ( Heavy oil ) 32180 Kg./Hr. 3270C Main WHRB + Economizer 1850C Steam at 10 Bar(g) 1950 Kg./Hr (F & A 1000C)

RECOSTAR WCRF
Product Details
Type Installation Tube Orientation Waste gas flow direction Quality of Waste Gases : : : : : Water tube cross flow IBR Vertical, Indoor and Outdoor. Vertical. Horizontal Moderately clean gas desired. Provided with mechanized Soot removal and collection System. Moderate dust level accepted 1) Steam D & S / Super-heater 2) Hot Water 3) Vapour phase thermic fluid Hot gases Suitable for low as well as high pressure Dry & saturated and also superheated steam through provision of super-heater. Natural Circulation In steam drum or in external moisture separator. Exhaust of steel furnaces, cement kilns, metal smelters, incinerators, industrial furnaces, DG set exhaust process waste gases, Incinerator exhaust, Furnace exhaust, gas turbine exhaust. (Gases with temperature less than 550oC) Process heating, hot water generation, thermic fluid heating, power generation, cogeneration. 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. No Limits. 1) Mechanized vibrating soot removal. 2) Travelling type steam soot blower. 3) Rotary soot blower.

Acceptable dust in waste gases Type of heat recovery output

: :

Media of Waste Heat Steam Pressure Steam Condition Water side circulation Steam Separation Waste heat source suitability

: : : : : :

Typical applications Duct firing possibilities

: :

Output capacity possibilities Soot removal Number of heat recovery stages possible Typical lowest exhaust gas temperature at final outlet of system Protection against sulphur corrosion on cold end side

: : : :

3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater. Gases generated by diesel 130oC, gas generated by Natural Gas 110oC, Gases generated by high sulphur fuels 150oC. Provided by various means to ensure that metal temperature is maintained above actual incipient limit.

STEAM OUT

STEAM DRUM
FLUE GAS IN FLUE GAS OUT

MUD DRUM

BLOW DOWN

Recostar WCRF : Flow diagram ( Vertical )

Case study Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load : : : : : : : : : Engine generator exhaust 3.8 MW X 1 No. Furnace oil ( Heavy oil ) 32180 Kg./Hr. 3270C Main WHRB 2050C Steam at 10 Bar(g) 1500 Kg./Hr (F & A 1000C)

RECOSTAR CC
Product Details
Type Installation Tube Orientation Waste gas flow direction : : : : Cylindrical coil type, water tube, once through Horizontal / Vertical, Indoor as well as Outdoor. Horizontal / Vertical. 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) 1) Steam D & S / Superheated 2) Hot Water 3) Hot Thermic Fluid Hot gases, Hot vapours, Hot liquids Suitable for low as well as high pressure Dry & saturated steam with external moisture separator. Superheated steam possible with provision of superheater and moisture separator installed between evaporator and superheater. Superheat degree limited by lnlet gas temperature available. Once through Forced circulation With external moisture separator. Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust. (High gases) Thermic Fluid heating, process heating, hot water generation, superheated water generation, power generation, cogeneration. Possible for gas turbine exhaust applications, heat addition into waste gas steam by addition of hot gases generated by separately fired hot gas generator. No capacity limits as multiple units can generate higher outputs. Through self cleaning velocities and pneumatic / steam soot blowers. 3 to 4 stages of heat recovery possible e.g. evaporator, economizer, water preheater. Super-heater,

Type of heat recovery output Media of Waste Heat Steam Pressure Steam Condition

: : : :

Degree of Superheat Possible Water side circulation Steam Separation Waste heat source suitability Typical applications Duct firing possibilities

: : : :

: :

Output capacity possibilities Soot removal Number of heat recovery stages possible

: : :

Air bleed valve

Air bleed valve

Flue gas From Incinerator at 1000 0C

Flue gas From Incinerator at 1000 0C

F. D. Fan

TIC Incinerator

Waste heat recovery Thermic fluid heater

I. D. Fan

Flue gas Exit at 250 0C 3 way Divertor Valve

F. D. Fan

TIC Incinerator

Waste heat recovery Thermic fluid heater

I. D. Fan

3 way Divertor Valve T.F. From Plant at 1900C

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

Panel DPS

T.F. From WHRTFH at 210 0C

T.F. From WHRTFH at 210 0C

T.F. to fired TFH at 2050C

T.F. to fired TFH at 2050C

Heat recovery ON

Heat recovery BYPASS

Recostar FN : Flow diagram for Incinerator based Heat recovery system

Case study Waste heat source Material incinerated Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load : : : : : : : : Incinerator exhaust Waste from packaging industry 2450 Kg./Hr. 10000C Thermic fluid heater 2500C Thermic fluid at 2100C 4,86,202 Kcal/Hr.

RECOSTAR PC
Product Details

Type

Pancake coil type, water tube, once through Horizontal & Vertical, Indoor as well as Outdoor. Horizontal / Vertical. Horizontal / Vertical (upwards & downwards) Normally clean dust free gases. Low dust level needed in horizontal design high dust level acceptable only in vertical design with self cleaning velocities. 1) Steam D & S / Superheated 2) Hot Water 3) Hot Thermic Fluid Hot gases, Hot vapours, Hot liquids Suitable for low as well as high pressure Dry & saturated steam with external moisture separator. Superheated steam possible with provision of superheater and moisture separator installed between evaporator and superheater. Once through Forced circulation. With external moisture separator. Fuel cell exhaust, micro / min gas turbine exhaust, DG set exhaust process waste gases, Incinerator exhaust, furnace exhaust. Thermic Fluid heating, process heating, hot water generation, superheated water generation, power generation, cogeneration. Possible for gas turbine exhaust applications. No capacity limits as multiple units can generate higher outputs. Through self cleaning velocities and pneumatic steam soot blowers. 3 to 4 stages of heat recovery possible e.g. super-heater, evaporator, economizer, water preheater.

Installation

Tube Orientation Waste gas flow direction

: :

Quality of Waste Gases Acceptable dust in waste gases

: :

Type of heat recovery output

Media of Waste Heat Steam Pressure Steam Condition

: : :

Water side circulation Steam Separation Waste heat source suitability Typical applications

: : :

Duct firing possibilities Output capacity possibilities Soot removal Number of heat recovery stages possible

: : : :

Hot Thermic fluid out

Pancake coils Cold Thermic fluid in

Hot flue gas in

Recostar PC : Flow diagram

Case study Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration Flue gas outlet temp. Output type Output at 100% load : : : : : : : : : Engine generator exhaust 1 MW X 1 No. Natural Gas 5634 Kg./Hr. 4290C Main TFH 2500C Hot thermic fluid at 2200C 2,61,900 Kcal/Hr.

RECOSTAR SCMP
Product Details
Type : Smoke tube, composite (I.e. unfired plus fired zone) Horizontal, Vertical, Indoor. Horizontal / Vertical. Horizontal / Vertical (upwards & downwards) Low dust level desired. 1) SteamD & S / Super-heat. 2) Hot water 3) Vapour phase Thermic Fluid Heating. Hot gases, Hot vapors, Hot liquids Suitable for low as well as medium pressure Dry & saturated and also superheated steam through provision of super-heater. Natural Circulation internal to boiler. In steam drum or in external moisture separator. Fuel cell exhaust, micro / min gas turbine exhaust, Small gas turbine exhaust, DG set exhaust, process waste gases, Incinerator exhaust, furnace exhaust, gas turbine exhaust. 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. Firing in internal furnace provided in boilers. Typically upto 20T/hr capacity. By sonic soot blowers and through self cleaning velocities. 3 to 4 stages of heat recovery possible e.g. evaporator, economizer, water preheater. Super-heater

Installation Tube Orientation Waste gas flow direction

: : :

Quality of Waste Gases Type of heat recovery output

: :

Media of Waste Heat Steam Pressure Steam Condition Water side circulation Steam Separation Waste heat source suitability

: : : : : :

Typical applications

Supplemetory firing possibilities Output capacity possibilities Soot removal Number of heat recovery stages possible Typical lowest exhaust gas temperature at final outlet of system Protection against sulphur corrosion on cold end side

: : : :

Gases generated by diesel 130oC, gas generated by Natural Gas 110oC, Gases generated by high sulphur fuels 150oC. Provided by various means to ensure that metal temperature is maintained above the actual incipient limit.

FLUE GAS FROM ENGINE ENTERS

ECONOMIZER

FLUE GAS FROM ENGINE LEAVES

PARTITION

BURNER

FLUE GAS FROM BURNER LEAVES

Recostar SCMP : Flow diagram ( Vertical ) Case study Waste heat source Capacity of Engines Fuel fired in Engines Total flue gas quantity Flue gas inlet temp. System configuration N.G. firing in fired zone Flue gas outlet temp. Output type Output at 100% load : : : : : : : : : : Engine generator exhaust 1.1 MW X 1 No. Natural gas 4780 Kg./Hr. 5980C Main WHRB+Fired zone+ Eco. 60 SM3/Hr. 2050C Steam at 10 Bar(g) 2000 Kg./Hr (F & A 1000C)

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

MAXIMUM HEAT RECOVERY Heat recovery in multiple stages ( 3 to 4) with help of single/double stage economizers plus water preheater ensures maximum possible heat recovery from the waste gases. Customer gets nearly 7 to 19 % of additional output compared to other makes.

CUSTOM ENGINEERED / CUSTOM BUILT Every TRANSPARENT Boiler is specifically engineered and built to every customers needs and specifications. Special sizes, sources of heat and auxiliary equipment are no problem with TRANSPARENT.

DIVERTOR VALVE Automatic pneumatically operated, Linear movement of valve, Stainless steel can work continuously. 850oC Pneumatic pressure eliminating possibility of any leakage.

INSULATION Insulation thickness is selected scientifically to minimize heat loss even at a high flue gas temp. (Typical thickness used is 300 mm for 5000C)

APPLICATION SUITABILITY PRODUCT MATRIX

Matrix for of converting waste heat in useful form
Useful Form Of Output
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

H O E E

L O E E

G E E

E J H

G T E

I E G

C P K G

S P F

H G P

G F G

F G F H

A C

H P C

Source of Waste Heat

HOEE LOEE GEE EJH GTE IEG CPKG SPF HGP GFG FGFH AC HPC : : : : : : : : : : : : : Heavy Oil Engine Exhaust Light Oil Engine Exhaust Gas Engine Exhaust Engine Jacket Heat Gas Turbine Exhaust Incinerator Exit Gases Cement Plant Kiln Gases Steel Plant Furnaces Hot Gases From Process Glass Furnace Gases Flue Gases From Fired Heaters Air Compressors 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
Back pr. limit
FPS

Flue gas bypass

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
SPS SPS

Flue gas bypass

Steam pr. limit

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 Flue gas from Engine Level sensor

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 Flue gas out from WHRB at 1340C

Automatic 3 way Divertor Valve

Transparent WHRB recovers 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 manufacturing cost for Transparent but gives benefit to 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
From Engine Linear movement

Other Make
Possible leakage Swing type movement Flap To WHRB From Engine

Automatic pneumatically operated. Linear movement of valve(poppet). No possibility of jamming. Positive pneumatic pressure acts as good sealing force continuously when the valve reaches the respective positions. The poppet is pressed against the valve seat by pneumatic pressure eliminating possibility of any leakage. Force is applied at center of poppet ensuring equal distribution throughout the sealing edges. Made of Stainless steel which can work upto 8500C continuously.

Manually operated. Swing type movement of valve(flap). Possibility of jamming. No positive force is applied after the flap reaches its respective positions.The mechanical play in the gearbox results in small opening due to self weight of flap & flue gas back pressure. This can result in leakage in the long run. Force is applied at one end of flap. This results in unequal force distribution.The distant edge gets less force. 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 to gas flow. It does not obstruct the flow of gas. Possibilities of soot accumulation are less since vertical downward flow of flue gas will help in dislodging the soot particles.

Tubes are placed horizontally with their axis perpendicular to flow of gas. This results into obstruction to gas flow & soot particles are arrested on tube surface.

COMPARISION
Vertical Co-flow WHRB vs. other make WHRB
DRUM RISER DRUM DISCHARGE

PUMP SUCTION PUMP

Natural circulation design. No dependence on any external equipment for circulation. Uninterrupted circulation eliminates possibilities of higher TDS level in evaporator and subsequent scale deposition. Bare tubes reduces possibility of soot accumulation. Particularly for gases with high SPM like flue gases of F.O. engine, it is highly recommended to use only bare tubes without manufacturing cost goes up, user gets benefited. Bare tubes used in manufacturing are standard tubes available in market. In case of replacement user is not dependent on manufacturer for supply of tubes.
Main boiler

Forced circulation design. Circulation is dependent on pump. Failure of pump suddenly stops circulation and results into higher TDS level in evaporator and subsequent scale deposition. Pump has to operate at very high suction pressure making the operation critical. Finned tube construction invites accumulation of soot between fins. This type of tube is not recommended particularly for flue gases with high SPM. Their use should be restricted for cleaner flue gases like gas engine / turbine.

Finned tubes used have specific fin size, shape and configuration. These tubes have to be purchased only from manufacturer and hence user is completely dependent on manufacturer for lifetime of boiler.
Main boiler

Economizer 1st stage

Economizer 2nd stage

Economizer

Two stage economizer improves Heat recovery. Feed water is heated completely upto 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

Single stage economizer. Hence limited heat recovery.

COMPARISION
Vertical Co-flow WHRB vs. other make WHRB
F.W. at 1850 C To boiler Economizer 1st stage Feed water At 90 Deg.C 1220 C Water Pre-heater Economizer 2nd stage 1550 C

F.W. to boiler

Economizer

Feed water At 90 Deg.C

For flue gases of furnace oil with 4% sulphur, it is necessary to maintain metal temperature above 121 Deg.C. We provide auto temperature correction system which ensures that them feed water entering each stage of economizer is at-least at 122 Deg.C. This will ensure that all contact area is above the safe temperature level and will eliminate any possibility of corrosion. Two alternatives are available. Steam soot blowers are provided as one of the alternatives. As a second alternative, soot removal is done on-line with mechanical knockers. This has negligible operating costs. These soot blowers can operate automatically based on flue gas back pressure feedback signal or flue gas outlet temperature feedback signal.

Water in the tank directly enters Economizer without any temperature correction. Hence the tube wall temperature at economizer inlet drops below safe level and results into Cold end Corrosion. User has to buy the tubes frequently from manufacturer since these tube are not available in market.

Steam soot blower consume almost 3-4% of the steam output per day. This reduces net steam available to plant. Operation is manual and if not done properly, can create problems.

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 Cogeneration 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 - 89% Superefficient Agrofuelled / Coal Fired Boilers. Biomass Fired) for Cogeneration application

- 93% Superefficient Thermic Fluid Heaters / Hot Air Generators - Superefficient High Pressure steam Boilers, (Oil / Gas / Coal /

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 - Flash Dryers - Spray Coolers - Fluidized Bed / Spray Dryers

- Fluid Bed Dryers / Coolers / Agglomerators - Paddle Dryers / Vacuum Paddle Dryers - Spray Reactors cum Dryers - Homogenizers and Dispersion Mills

- Fluidized Bed Incinerators / Calciners - Dry Powder Mixing Systems and Granulators - Disintegrators & Pulvarisers

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