Boilers and Heat Recovery for Biomass Plants

In biomass energy recovery, thermal optimization directly affects the plant’s profitability, steam generation efficiency, and compliance with emission limits. Biomass combustion presents severe thermodynamic challenges: heterogeneous fuels with high moisture variability, flue gases laden with fly ash, abrasive particles, and the presence of alkaline and chlorine-containing compounds.

AITESA designs, manufactures, and integrates custom thermal solutions for biomass applications: process gas heat recovery boilers (WHRB / HRSG), industrial boilers, economizers, combustion air preheaters (APH), and heat exchangers for hot gases.

We maximize the recovery of residual enthalpy from combustion streams, prevent aggressive fouling, control the risks of sulfur/chlorine corrosion, and adapt the equipment’s geometry to ensure maximum operational availability.

Are you considering a heating solution for a biomass plant? Tell us about the fuel, the operating conditions, and the equipment involved.

Challenges Facing Biomass Plants

In projects using biomass-derived fuels, heat exchanger design goes far beyond standard thermal sizing. The feasibility of the equipment depends on the management of complex physical and chemical phenomena:

Ash Contamination and Sintering (slagging & fouling): The presence of alkaline salts (potassium and sodium) with low melting points that condense on the tubes, forming insulating deposits that drastically reduce heat transfer.

Mechanical erosion caused by particle entrainment: High-speed entrainment of fly ash and silica, which causes abrasive wear on the outer surface of the tube bundles.

High- and low-temperature corrosion: Chemical attack by chlorides in superheated areas and risk of sulfuric acid condensation (Acid Dew Point) in economizers when cooling the gases before the bag filter.

Active Cleaning Systems and Maintenance Integration: Need to configure wide tube passages (square cross-section) and integrate sootblowers (steam or air sootblowers), wash ramps, or hammering systems to maintain thermal transmittance without unscheduled outages.

AITESA handles these projects from conceptual engineering through EPC execution. We select the optimal gas velocities to balance heat transfer without causing erosion, specify appropriate fin or smooth-tube geometries, and design strategic access points for inspection and maintenance.

Why Choose AITESA for Biomass?

With more than 40 years of experience in heat transfer engineering and heat recovery from severe flue gases, AITESA offers robust solutions tailored to plant constraints:

Engineering tailored to the type of gas: Thermal and mechanical designs specifically tailored for gases with high levels of unburned fuel and ash, using materials with high resistance to corrosion and erosion.
Capacity for Revamping and Modernization: Redesign and integration of new heat recovery modules (economizers, APH) within the existing plant enclosures or confined spaces, optimizing the pressure drop () of the flue gas circuit.
EPC Execution and Unified Responsibility: We handle comprehensive management (thermohydraulic calculations, in-house manufacturing, integration of cleaning systems, assembly, and instrumentation), minimizing interface risks and reducing downtime.

AITESA has participated in engineering, heat recovery, and thermal equipment projects for biomass plants, power generation facilities, and industrial plants that utilize waste or biogenic fuels.

Success stories

Engineering of a biomass boiler for a sugar plant in the Dominican Republic

AdminAitesa | Success stories - Biomass | No Comments

Introduction As part of the transition towards more sustainable energy models, AITESA participated in the waste-to-energy project at a sugar plant located in San Pedro de Macorís (Dominican Republic). This…

Do you need to recover heat or improve thermal efficiency at a biomass plant?

Please briefly describe your process, the fuel used, or the equipment involved. Our technical team will review the initial information and advise you on the most appropriate solution.