Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
HEAT RECOVERY BOILERS TO PRODUCE HOT WATER, SUPERHEATED WATER AND STEAM
1
HEAT RECOVERY BOILERS 3
2
PRODUCT RANGE 5
RECOVERY BOILER 6
WHB series
RECOVERY BOILER 8
GXC series
Form used to request information 12
Summary
ICI CALDAIE SpA 10
Heat recovery boilers are thermal machines that employ the heat
of exhaust gases to produce hot water, superheated water or
steam.
Traditional recovery boilers do not have a furnace, as the water
inside them is not heated up with a burner, but just with the heat
of fumes conveyed in them.
This process allows most of the thermal energy to be recovered
that was, before, dissipated in the furnace. This places recovery
boilers among the most advanced tools to increase the energy
efficiency of a system.
ICI Caldaie's heat-recovery boilers are made with a design called
"fire-tube" boilers. In this kind of boiler, the fumes pass through a
bundle of tubes immersed in a volume of water in the boiler's
body.
As they pass through the bundle of tubes, the fumes transfer heat
to the water and have cooled down when they come out from the
chimney. At the same time, thanks to the heat absorbed, the
water temperature increases until it turns into steam, based on
the application required.
HEAT RECOVERY
BOILERS
3
0
25
50
75
100
125
150
175
200
0
250
500
750
1000
1250
1500
1750
2000
2250
2500
0
200
400
600
800
1000
1200
1400
1600
0 2000 4000 6000 8000 10000 12000 14000 16000
T = 550°C
T = 500°C
T = 450°C
T = 400°C
T = 350°C
portata fumikg/h
potenzascambio
kW
produzionevapore
kg/h
risparmiometanoNm3/h
The exhaust gases that can be used in recovery boilers may come from:
Fields of application
Benefits
Installing recovery boilers allows for considerable
benefits:
• Greater energy efficiency of the plants;
• Lower amount of fuel used;
• Lower running costs;
• Lower CO2 emissions;
• Being awarded white certificates;
• Equipment quickly pays back for itself;
• High profitability of the investment.
Equivalent fuel saved as a function of temperature and flow of the fumes.
NOTE: Temperatures Smoke out of the fireplace assumed 240 °C
4
Furnaces, post-combustion chambers, incinerators.
Industrial processes with fumes at high temperatures
Biomass plants
Diesel engines, gas and biogas engines,
vegetable oil motors
Turbogas plants
Energy production plants
Industrial processes Cogenerators
PRODUCT RANGE
RECOVERY BOILER
WHB series
RECOVERY BOILER
GXC series
5
RECOVERY BOILER
WHB series
The only thermal source of the WHB series heat-
recovery boilers are hot recovery fumes with no
additional combustion.
These are entirely automatic single-block
generators equipped with all the accessories to
ensure a quick activation.
The WHB series features great flexibility in terms
of design and use. The generators are custom-
made on a case-by-case basis to meet any
specific requirement in terms of use.
The efficiency of the WHB heat-recovery boilers
can be further increased by 5% if they are fitted
with an economiser, an accessory available for
any version of the product.
6
• Modular versions;
• High water content;
• Assembly and testing conducted at the
manufacturer's premises;
• Simple, quick and safe installation;
• Project pressure values up to 25 bar;
• High operating flexibility;
• Minimum running costs;
• Minimum maintenance costs;
• Easy to access for internal maintenance.
Benefits
If allowed by the production cycle's technical operating parameters, the heat-recovery boilers can be fitted with economisers to
increase their efficiency.
Available versions:
- black steel: for water return temperatures > 50°C, with gas fuel
- AISI 316 stainless steel: for water return temperatures < 50°C, with gas fuel
Available versions
7
WHB
single section
1 flue-gas pass
WHB
single section
2 flue-gas passes
WHB
multiple section
1 flue-gas pass
The GXC series heat-recovery boilers are innovative
generators that combine the generation of steam by
combustion with heat recovery from hot fumes from
external sources. This “free” source is primary, while
combustion can be used as a backup or provide the
power required if the recovery fumes are not enough
to meet the system's request for steam.
Combustion-based operation features three flue-gas
pass with passing flame and wet bottom. The boiler's
body is made with flanged tube plates that replace the
more traditional corner welds to ensure top safety
levels and reduce areas with thermal stress. The
recovery section is entirely separated from the
combustion section, though it is immersed in the same
boiler water. The front doors are secured to the
boiler's body with double-jointed hinges, which are
used to open and inspect the equipment with no need
to remove the boiler.
The efficiency of the GXC heat-recovery boilers can
be further increased by 5% if they are fitted with an
economiser, an accessory available for any version of
the product.
RECOVERY BOILER
GXC series
8
• Modular versions;
• High water content;
• Compact solution thanks to the integration of two
operating principles in a single block;
• Assembly and testing conducted at the manufacturer's
premises;
• Simple, quick and safe installation;
• Project pressure values up to 25 bar;
• Flanged tube plates;
• High operating flexibility;
• Minimum running costs;
• Minimum maintenance costs;
• Easy to access for internal maintenance.
Benefits
GXC
single section
1 flue-gas pass
GXC
single section
2 flue-gas passes
GXC
multiple section
1 flue-gas pass
9
Available versions
If allowed by the production cycle's technical operating parameters, the heat-recovery boilers can be fitted with economisers to
increase their efficiency.
Available versions:
- black steel: for water return temperatures > 50°C, with gas fuel
- AISI 316 stainless steel: for water return temperatures < 50°C, with gas fuel
residential and industrial applications. The experience gained over the years in the industrial field allowed the company to transfer the
know-how acquired in designing and making industrial steam generators to civil boilers for the residential and commercial market, with
a focus on centralised systems. ICI CALDAIE provides a range of systems that generate heat with very high efficiency levels to
systems that provide heat for individual houses. Industrial applications are scalable and range from steam generators fitted with a
burner and electronic control equipment to all-inclusive thermal systems, with a focus on solutions that allow for high energy savings.
ICI CALDAIE associates any kind of solution, whether it is residential or industrial one, with management systems that reduce
consumption, thereby optimising the operation of the generator and connected elements, along with the integration of solar systems.
Today ICI CALDAIE is a reference point among companies operating in the field of steam generators for industrial and heating
processes. The company's pioneering and innovative spirit leads it to heavily invest in the research and development of projects for
new energy systems with a low environmental impact, explore new applications, new technologies with low emissions and leads it to
working closely with top universities to develop ambitious and highly innovative research projects.
ICI CALDAIE combines all this with comprehensive customer service, offering itself as a partner and consultant with services ranging
from a preventive energy diagnosis to testing and conducting maintenance on the system and/or making all-inclusive systems.
ICI CALDAIE is a company with a more than 50-
year history and experience in managing energy and
producing heat.
It was established in 1958 in the province of Verona
as a manufacturing company making steel boilers
with a high water content for industrial processes. It
is still a leader in this sector at an international level,
providing medium and large capacity generators for
10
ICI CALDAIE SpA
standard UNI EN 29002 (IS0 9002); in June 2002 BVQI (Bureau Veritas Quality Insurance) awarded ICI CALDAIE the ISO 9001/94
certification and in April 2004 the ISO 9001/00 Vision certification.
All ICI CALDAIE models have the CE marking in accordance with applicable regulations and the high-pressure generator designed
in accordance complies with the Pressure Equipment Directive. The company also has a number of Italian certifications for exports to
many countries that require very restrictive mechanical and hydraulic tests, such as the certificates issued by the American Society for
Mechanical Engineers.
The certifications awarded acknowledge the efforts made by ICI CALDAIE and inform the market that the methods adopted comply
with international regulations to ensure the best quality standards. A Research and Development lab fitted with modern instruments to
check the reliability and performance of the boilers develops new products in accordance with the increasingly strict European
standards on consumption and emissions.
Each product is made by the Technical Department, which has modern CAD workstations with internet access. Semi-finished products
are prepared with laser cutters and numerical control machines. The elements are perfectly welded together with modern robots and
each individual boiler undergoes a strict testing process that ensures it is reliable.
Certifications
System certifications:
• ISO 9001 quality certification
• ISO 14001 environmental certification
Product certifications:
• ASME certification
– STAMP-H: Heating boilers
– STAMP-S: Power boilers
– STAMP-U: Pressure vessels
• EC certification
• SELO certification (China)
• GOST-R certification (Russia)
• GOST-U certification (Ukraine)
• GOSPROMNADZOR certification (Belarus)
• CoC RK certification (Kazakhstan)
Quality
The fierce competition in international markets, the
elimination of customs barriers and requirements
increasingly focused on high quality standards have led ICI
CALDAIE to develop a new culture of quality, focusing on
fully meeting the Customer's needs while complying with the
strictest quality standards as essential conditions to ensure
its own competitive edge.
In 1993, ICIM (Mechanics Industrial Certification Institute)
certified ICI CALDAIE's Quality System
in accordance with the Italian, European and international
11
Information
request form
12
1. Type of generator required: ❑ simple (WHB)
❑ combined (GXC)
2. Fuel originating the fumes: ❑ methane gas
❑ diesel
❑ biogas
❑ naphtha
❑ other (please specify) …..………….…
3. Incoming fumes flow rate: …………… kg/h
4. Incoming fumes temperature: …………… °C
5. Maximum allowed backpressure: …………… mbar
6. Type of fluid from the generator: ❑ hot water (<100°C)
❑ superheated water (>100°C)
❑ Saturated vapour
❑ Superheated steam
7. Operating pressure: …………… bar
8. Operating temperature: …………… °C
9. Power required on burner side (only for GXC): …………… kW
10. Fuel on burner side (only for GXC): ❑ methane gas
❑ diesel
❑ biogas
❑ naphtha
11. Power supply voltage: ❑ 400 3/N~
❑ 230 1/N~
❑ other (please specify) …..…………………
12. Frequency: ❑ 50 Hz
❑ other (please specify) …..…………………
.
13. Installation: ❑ Indoor
❑ Outdoor
14. Notes:
…………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………
13