A WHRB (Waste Heat Recovery Boiler) recovers waste heat generated in industrial processes with dirty exhaust gases, such as those from smelting furnaces, refineries, or cement plants. This type of water-tube boiler converts that heat into useful steam for thermal processes, reducing primary energy consumption and pollutant emissions.
WHRB Boilers: Heat Recovery in Industrial Processes with Exhaust Gases
How does a WHRB boiler work?
WHRB boilers operate on the principle of waste heat recovery. The exhaust gases, often loaded with particulates and corrosive components, transfer their thermal energy to a fluid that is converted into steam. The system is divided into three main zones:
- Economizer: Heats the inlet water using the hot gases.
- Evaporator: Performs the conversion of water into steam in a controlled manner.
- Superheater : Adjusts the steam temperature according to the end use.
These boilers are manufactured with corrosion resistant materials and can include automatic cleaning systems to remove solid deposits, ensuring continuous and efficient operation.
Unlike an HRSG, typically used with clean exhaust gases from gas turbines in combined cycle plants, a WHRB is engineered to handle dirty, particle-laden flue gases from industrial processes.
Bramsken WHRB
WHRB Aralar Paper
Benefits of WHRB boilers for industrial energy efficiency
- Energy savings: Reduction in the use of fossil fuels up to 70% depending on the process.
- Reduced operating costs: Lower energy consumption and efficient maintenance.
- Operational continuity: Self-cleaning systems that avoid unexpected shutdowns for maximum process efficiency.
- Compliance: ISO 14001 and European Green Pact compliant.
- Adaptability: Modular design adjusted to pressure, temperature and available space.
- Easy integration: Installation in existing industrial plants without major modifications.
In AITESA we study each specific case to get the best heat recovery boiler.
Moeve WHRB in Energy Park San Roque
Typical applications of WHRB boilers in industry
- Power generation and cogeneration: Optimization of fuel efficiency in combined cycle plants.
- Trigeneration: Production of electricity, heat and cold in chemical and food industries.
- Refineries and petrochemical plants: Catalytic cracking heat recovery, distillation and hydrogen production.
- Cement and glass industry: Thermal recovery in clinker and glass melting furnaces.
At AITESA we are experts in the design and supply of waste heat recovery boilers.
Heat recovery boiler in Brazil
Why choose an AITESA boiler waste heat recovery system?
- More than 5000 projects carried out in strategic industrial sectors.
- More than 40 years of experience in the design of industrial heat recovery boilers.
- High efficiency and minimal environmental impact thanks to robust and proven designs.
- Comprehensive technical service, guaranteed spare parts and scheduled preventive maintenance.
Do you need a customized solution for your industry? Contact us and we will design the ideal boiler for your process.
At AITESA we are experts in the design and supply of WHRB.
Frequently Asked Questions
What distinguishes a watertube boiler from a firetube boiler?
The main difference between the two types of boilers lies in the way in which the heat exchange takes place:
– Water-tube boilers: Water circulates inside the tubes and gases circulate outside. They reach high pressures and thermal efficiency.
– Pyrotubular boilers: The gases circulate inside the tubes and the water circulates outside. They are more compact and for lower pressure.
How much can you save with a Waste Heat Boiler?
The WHRB boiler can reduce fuel consumption by up to 70% by recovering waste heat from industrial processes. This lowers operating costs, improves return on investment (ROI) and enables compliance with environmental regulations and sustainability plans. The investment can pay for itself in a few years depending on the design and process conditions.
What kind of maintenance does a WHRB boiler require?
Preventive maintenance ensures efficient and safe operation. It should include:
– Cleaning of heat exchange surfaces.
– Periodic inspections for corrosion or wear.
– Control of the water/steam circuit.
– Verification of automatic cleaning systems.
– Monitoring of steam pressure and temperature.
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.…
Talk to an expert
Aitesa has more than 40 years of experience designing and supplying heat recovery boilers.
