Nord stone

Waste Heat Boilers – Harnessing Industrial Energy Loss for High-Value Steam Generation

Waste Heat Boilers (WHBs) utilize residual heat from industrial processes—gas turbines, furnaces, incinerators, reformers, kilns, recuperators—to generate steam or hot water, reducing energy costs and increasing plant efficiency.

Waste Heat Boilers - Industrial Energy Recovery Systems

Introduction

Waste Heat Boilers (WHBs) form the backbone of combined cycle power plants (CCPP), petrochemicals, refineries, fertilizers, steel, cement, and waste-to-energy industries. These systems capture and convert waste thermal energy into valuable steam, significantly improving overall plant efficiency.

At NORDSTONE., we engineer WHBs for high thermal efficiency, robust performance, and zero-downtime reliability. Our solutions transform industrial exhaust streams into productive energy, reducing fuel consumption, lowering emissions, and improving operational economics across diverse industries.

Energy Recovery Solutions

From high-temperature gas turbine exhaust to moderate-temperature process flue gases, our waste heat recovery systems maximize energy capture while ensuring operational reliability. Each system is custom-engineered to match specific heat source characteristics and steam requirements.

Key advantages include:

  • Zero fuel consumption – utilizes waste heat only
  • Significant reduction in energy costs and carbon footprint
  • High thermal efficiency with optimized heat transfer surfaces
  • Robust construction for harsh industrial environments
  • Custom designs for specific heat source characteristics
  • Quick ROI – typically 1-3 years
  • Compliance with international safety and quality standards

Our waste heat boilers are engineered for maximum energy recovery, operational reliability, and long-term performance in demanding industrial applications.

Waste Heat Boiler Types & Specifications

HRSG

Heat Recovery Steam Generator

The most complex and high-performance WHB used behind gas turbines in combined-cycle plants.

  • • Single, Dual or Triple Pressure
  • • Natural/Forced/Once-Through Circulation
  • • Horizontal/Vertical Gas Flow
Applications:

Combined-cycle power plants, petrochemical plants with turbines, refineries, fertilizer/ammonia plants, steel furnaces

GTB

Gas Turbine Waste Heat Recovery Boiler

Designed specifically for direct coupling with gas turbine exhausts in industrial and power applications.

  • • 450–650°C exhaust temperature
  • • 25–600 kg/s mass flow
  • • Natural or forced circulation
Applications:

Power generation, on-site cogeneration, oil & gas processing, steel rolling mills, fertilizer/methanol plants

FGB

Flue Gas Waste Heat Boiler

Captures heat from industrial flue streams including furnaces, kilns, ovens, reformers, and process heaters.

  • • 150°C to 1200°C gas temperature
  • • 0.5 – 200 TPH steam generation
  • • Fire tube/water tube/hybrid systems
Applications:

Cement plants, steel reheating furnaces, glass furnaces, calciner/rotary kilns, incinerators, chemical process heaters

IWB

Incinerator Waste Heat Boiler

Designed to harness heat from municipal, hazardous, biomedical, sludge, and industrial waste incinerators.

  • • 800–1200°C flue gas temperature
  • • 2–150 TPH steam capacity
  • • Water tube/fire tube arrangements
Applications:

Municipal waste-to-energy plants, hazardous chemical waste disposal, pharmaceutical waste incineration, biomass/sludge burning facilities

HRSG

Heat Recovery Steam Generator - Detailed Specifications

Technical Overview
  • • Recovers exhaust heat from gas turbines, diesel engines, industrial gas streams
  • • Steam generation: Single, Dual or Triple Pressure
  • • Modes: Natural/Forced/Once-Through Circulation
  • • Configurations: Horizontal/Vertical Gas Flow
Design Features
  • • Multi-pressure heat exchange stages
  • • Economizer, evaporator, superheater, reheater
  • • HP/IP/LP steam drums
  • • Supplementary firing options with duct burners
Engineering Advantages
  • • Up to 90%+ waste heat utilization
  • • Maximizes combined-cycle efficiency (55–62%)
  • • Low O&M cost due to modular design
  • • Reduces fuel consumption drastically
GTB

Gas Turbine WHB Features

  • • Tailor-made inlet ducting for exhaust gas uniformity
  • • High-alloy steel in hot zones (Inconel, Cr-Mo steels)
  • • Finned tube banks for enhanced heat transfer
  • • Integrated diverter damper system for bypass
  • • Shock-resistant tube support for turbine pulsations
Engineering Advantages:

Zero additional fuel consumption • Rapid ROI (<2 years) • Drastic reduction in plant heat rate • Lower emission footprint

FGB

Flue Gas WHB Features

  • • Shock-resistant, high-temperature tube banks
  • • Finned or spiral tubes for increased efficiency
  • • Advanced refractory for extreme temperatures
  • • Integrated soot blowers for dirty gas service
  • • Corrosion-resistant materials for harsh environments
Engineering Advantages:

Significant fuel savings • Lower cooling load & stack losses • Extended furnace/kiln life • Zero-interruption design

IWB

Incinerator WHB Design Features

High-Temperature Durability
  • • Refractory-lined furnace sections
  • • Alloy steel tube bundles (SA213-T11/T22)
  • • Inconel cladding for high erosion zones
  • • Ash-resistant design for particulate handling
Fouling & Corrosion Protection
  • • Soot blowers and pneumatic rappers
  • • Special anti-corrosion coatings
  • • Steam coil air preheaters for cold-end protection
  • • Automatic ash-cleaning systems
Engineering Advantages:

Converts waste into valuable energy • Supports waste-to-energy (WTE) systems • Low emission design • High uptime with automated systems

Key Features of Waste Heat Boilers

✔

Zero Fuel Consumption

  • • Utilizes waste heat only – no additional fuel
  • • Rapid ROI typically 1-3 years
  • • Significant reduction in energy costs
✔

High Thermal Efficiency

  • • Optimized heat transfer surfaces
  • • Multi-pressure systems for maximum recovery
  • • Pinch point optimization
✔

Robust Construction

  • • High-temperature alloy materials
  • • Corrosion and erosion-resistant design
  • • Refractory linings for extreme conditions
✔

Advanced Heat Transfer

  • • Finned tubes for enhanced efficiency
  • • Optimized tube banks for gas flow
  • • CFD modeling for flow optimization
✔

Environmental Benefits

  • • Reduces carbon footprint
  • • Lower stack temperatures
  • • Compliant with emission regulations
✔

Operational Reliability

  • • Zero-downtime design
  • • Automatic cleaning systems
  • • Comprehensive monitoring systems

🛠️ OUR DESIGN & ENGINEERING EXPERTISE

Design Standards
  • • ASME Section I
  • • ASME Section VIII
  • • IBR / PED / CE
  • • EN 12952 / EN 12953
Thermal Engineering
  • • Heat balance & pinch point analysis
  • • CFD modeling for gas flow optimization
  • • Tube bundle fatigue analysis
  • • Soot deposition prediction & mitigation
Mechanical Engineering
  • • High-temperature material selection
  • • Stress analysis using PV Elite / ANSYS
  • • Tube-to-header design
  • • Creep life assessment
Materials Expertise
  • • Carbon steel, Cr-Mo steel
  • • High-alloy / super-alloy materials
  • • Chromized coatings
  • • Composite refractory linings
Automation & Safety
  • • PLC/DCS integration
  • • Safety interlocks & permissive logic
  • • Temperature/pressure instrumentation
  • • Fuel gas/air system integration (for duct burners)

Industry Applications

Power Generation
  • • Combined-cycle power plants
  • • Cogeneration systems
  • • Gas turbine exhaust recovery
Petrochemical & Refining
  • • Furnace and heater exhaust
  • • Reformer flue gas recovery
  • • Cracker unit heat recovery
Steel & Metals
  • • Reheating furnace exhaust
  • • Annealing furnace recovery
  • • Heat treatment furnace exhaust
Cement & Glass
  • • Rotary kiln exhaust heat
  • • Preheater exhaust recovery
  • • Glass furnace exhaust
Chemical & Fertilizer
  • • Ammonia plant waste heat
  • • Methanol plant recovery
  • • Process heater exhaust
Waste-to-Energy
  • • MSW incinerator heat recovery
  • • Hazardous waste incineration
  • • Biomass combustion exhaust
Marine & Offshore
  • • Engine exhaust heat recovery
  • • Turbine exhaust recovery
  • • Platform process heat recovery
Other Industries
  • • Paper & pulp mills
  • • Food processing plants
  • • District heating systems

Integrated WHB Systems

  • • Complete heat recovery steam generator (HRSG) packages
  • • Duct burner systems for supplementary firing
  • • Bypass damper and diverter systems
  • • Soot blowing and cleaning systems
  • • Ash handling and removal systems
  • • Refractory and insulation packages
  • • Instrumentation and control systems
  • • Structural steel and platforms

Why Choose Our Waste Heat Boilers?

  • • Proven Expertise: Decades of experience in waste heat recovery system design and integration
  • • Custom Solutions: Tailored designs for specific heat source characteristics and steam requirements
  • • Maximum Efficiency: Optimized heat transfer for maximum energy recovery
  • • Reliability: Robust construction for harsh industrial environments and continuous operation
  • • Quick ROI: Significant energy savings with typical payback in 1-3 years
  • • Environmental Compliance: Reduces emissions and carbon footprint
  • • Global Standards: Compliance with ASME, IBR, EN, API, and other international codes
  • • Technical Support: Comprehensive engineering, installation, and maintenance services
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