HRSG (Heat Recovery Steam Generator) are essential for increasing energy efficiency in combined cycle plants and cogeneration systems. They harness waste heat from gas turbines or industrial engines to generate saturated or superheated steam, reducing fossil fuel consumption and CO₂ emissions.
HRSG Boilers: Heat Recovery Steam Generators for Combined Cycles and Industrial Cogeneration
What is a HRSG boiler or heat recovery steam generator and how does it work?
An HRSG boiler is a heat exchanger that transforms the thermal energy contained in the exhaust gases of turbines or engines into useful steam. It does not require direct combustion, which allows its efficient integration in cogeneration and combined cycle systems.
The process is divided into three main stages:
- Economizer : Preheats the feed water with the residual heat.
- Evaporator : Converts water into saturated steam.
- Superheater : Increases the steam temperature for high demand applications.
Unlike an HRSG, designed for clean exhaust gases from gas turbines in combined cycle plants, a WHRB boiler handles dirty flue gases from industrial processes such as furnaces, refineries, or cement plants.
Heat recovery boiler HRSG
HRSG Aralar Paper
Benefits of HRSG boilers for the industry
- Energy savings: Reduces fossil fuel consumption by up to 70%, depending on the industrial process.
- Reduction of operating costs: Optimization of thermal performance and lower energy consumption.
- High thermal efficiency: Design that maximizes heat transfer.
- Emission reduction: Compatible with ISO 14001 and European Green Pact regulations.
- Adaptability: Horizontal or vertical configurations, customized pressures and temperatures.
- Easy integration: Compatible with existing industrial systems.
In AITESA we study each specific case to get the best Heat Recovery Steam Generator.
HRSG heat recovery boiler in Thailand
Where are HRSG boilers used? Common industrial applications
- Energy production and cogeneration: Combined cycles, plants with simultaneous demand for electricity and steam.
- Refineries and petrochemical industry: catalytic reforming, hydrogen production, distillation.
- Cement and glass industry: Clinker and glass melting furnaces, emission reduction.
Why choose an AITESA HRSG boiler?
- More than 5000 projects in sectors such as energy, metallurgy and industrial processes.
- High adaptability to demanding environments: Combined cycle plants, refineries, industrial sites.
- Efficient and reliable designs: Reduction of thermal losses and energy consumption.
- Full technical support: Fast assistance, guaranteed spare parts, monitoring and maintenance systems.
At AITESA we are experts in the design and supply of HRSG boilers.
Frequently Asked Questions
What is the difference between a water-tube and a shell boiler?
The difference is in how the water and flue gases are circulated:
- Water-tube boilers: Water circulates inside the tubes and gases outside. Suitable for high pressures.
- Pyrotubular boilers: The gases go inside the tubes and the water outside. Recommended for lower requirements.
What energy savings does a HRSG offer?
It can reduce fuel consumption by up to 70%, depending on the type of process. This significantly reduces operating costs and improves environmental sustainability.
What maintenance does a HRSG require?
Preventive maintenance is recommended, including component inspection, water quality control, cleaning systems review and monitoring of operating parameters. This ensures efficiency and longevity of the equipment.
Success stories
The FCC heat recovery project carried out by AITESA was a turnkey supply job (engineering, design, manufacturing, supply and installation) in a Spanish refinery located in San Roque, Cadiz, Spain.…
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Aitesa has more than 40 years of experience designing and supplying heat recovery boilers.
