Main Execution Types
ENERGO.DESIGN waste heat boilers are developed in two main configurations - for steam or hot water production - depending on the process duty, heat source parameters, and system integration concept.
Steam Waste Heat Boiler
A solution for recovering heat from exhaust and flue gases to generate steam for industrial processes and plant energy systems.
Hot Water Waste Heat Boiler
A solution for transferring heat from exhaust and flue gases to a hot water circuit, with due regard to system parameters and operating conditions.
Turnkey solution
We design and configure waste heat recovery systems for the specific conditions of each project — from the heat recovery block to controls, exhaust gas ducting, and commissioning. The scope of supply is defined by the heat source configuration, allowable back pressure, operating modes, and integration requirements.
Heat recovery block
The heat recovery block is engineered for the specific machine, exhaust gas parameters, and the required steam or hot-water output. During development, we take the allowable system back pressure into account and align the design parameters with the CHP manufacturer or another source of exhaust gases. Depending on the operating regime, the block may also include an economizer. The scope of supply may include factory-applied thermal insulation, as well as the required shut-off, control, and safety valves, feed pumps for steam systems, or recirculation pumps for hot-water systems.
Exhaust gas path
The exhaust gas path is designed for the layout of the specific site and may include ducting, a bypass line, compensators, supports, and insulation. We design and manufacture exhaust gas valves that take part in capacity control and in the boiler protection logic. Valve actuators can be based on pneumatic or electric drives. For such systems, it is critical to consider not only the duct geometry, but also thermal expansion, aerodynamic resistance, and emergency operating modes.
Automation and controls
The control system is developed on freely programmable controllers and includes PLC, HMI, a control cabinet, and a full set of field instrumentation. Depending on the project configuration, operation can be organized via a local operator panel near the boiler, a tablet interface, or a remote workstation. The automation system ensures control logic for stable operating parameters, coordinated operation with the exhaust gas source, a complete set of protections, and correct response to changing operating conditions. For CHP applications, this is especially important because the waste heat boiler becomes part of the overall engine system rather than a standalone heat exchanger.
Engineering, modular execution, and commissioning
The scope of supply may include design documentation, supervision of installation, commissioning, testing, and start-up support. For steam systems, containerized or modular execution may be used to simplify installation and protect equipment and piping from external conditions, especially at low ambient temperatures. We support the project from concept development and technical coordination through commissioning and achievement of operating conditions.
Other execution variants
The main execution directions do not limit the possible system configurations. Depending on site layout, the number of exhaust gas sources, allowable back pressure, transport constraints, and integration requirements, we can offer other technical solutions - including group configurations for several CHP units or split execution with separate assemblies.
Group configuration for multiple CHP units
One waste heat boiler can serve several CHP units within a group configuration. This solution can reduce CAPEX at the level of automation, piping, and equipment metal consumption, but it requires correct design of the gas path, allowable back pressure, and control algorithms.
Split execution with a separate upper steam drum
For larger installations, the steam volume, evaporation zone, and evaporating section can be arranged in a separate upper drum. This configuration helps keep the main block within transport dimensions, simplifies logistics and installation, and provides greater flexibility when arranging the equipment on site.
Selected Waste Heat Recovery Projects
Steam and hot-water systems for CHP units and industrial exhaust gases
What we need to prepare a quotation
Send us the basic data on the exhaust gas source and the required output parameters. We will prepare a technical concept and a commercial proposal for your project.