Product Description
Manufactured within our 13,800+ square meter heavy manufacturing complex in Jingjiang, our Heat Recovery Steam Generator is an industrial-grade waste heat boiler engineered to capture thermal energy from hot flue gases discharged by petrochemical fired heaters, ethylene crackers, and industrial furnaces to generate high-pressure saturated or superheated steam. Backed by 26 years of heavy fabrication experience and certified under ASME "S" and "U" stamps as well as Class A boiler manufacturing licenses, we build each Heat Recovery Steam Generator with optimized bare and finned tube banks, heavy-gauge pressure drums, and precision circulation circuits configured for either natural or forced circulation. By recovering high-grade waste heat that would otherwise be lost to the stack, this durable Heat Recovery Steam Generator lowers refinery fuel consumption, improves overall plant thermal efficiency to over 92%, and reduces greenhouse gas emissions, giving plant operators and global EPC contractors an energy-saving asset built for long-term continuous service.
Applications
Petrochemical Fired Heater Waste Heat Recovery: Generating medium-to-high pressure steam from flue gases discharged by crude distillation heaters, reformers, and vacuum furnaces.
Ethylene Plant Transfer Line Exchanger (TLE) Systems: Operating as secondary quench boilers and convection steam generators downstream of ethylene cracking furnaces.
Refinery Utility Steam Systems: Providing high-pressure steam for plant power generation, process stripping, steam turbine drives, and plant heating networks.
Industrial Flue Gas Heat Recovery: Capturing waste heat from metallurgical furnaces, incinerators, and chemical reactors to improve plant thermal efficiency.
Technical Specifications
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Design & Fabrication Standards |
ASME Section I (Power Boilers, "S" Stamp), ASME Section VIII Div. 1 ("U" Stamp), ASME B31.1, Class A Boiler Manufacturing License |
|
Circulation Types |
Natural circulation (thermosiphon) or forced circulation with dedicated circulation pump skids |
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Steam Generation Capacity |
5 tons/hour to over 120 tons/hour per unit |
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Steam Pressure Rating |
1.0 MPa to 10.0 MPa (Gauged to refinery utility steam headers) |
|
Steam Temperature |
Saturated steam up to superheated steam at 510°C |
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Flue Gas Inlet Temperature |
350°C to 950°C |
|
Heat Transfer Tube Banks |
High-frequency resistance-welded solid or serrated finned tubes and bare shielding rows |
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Pressure Drum Construction |
Heavy-wall carbon steel (SA-516 Gr. 70) with internal steam-water cyclonic separators and chevron mist eliminators |
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Thermal Heat Recovery Efficiency |
Increases overall furnace-boiler combined efficiency to 92% – 95% |
Customization Capabilities
Flexible Modular Configurations: Building horizontal or vertical gas-path configurations tailored to available plot space, duct arrangements, and foundation loads.
Complete Multi-Stage Preheating Integration: Integrating superheater, evaporator, economizer, and boiler feed water preheating coils within a single modular casing.
Custom Steam Drum Internals: Engineering internal steam-water cyclonic separators, chemical dosing manifolds, and continuous blowdown headers to ensure steam purity exceeding 99.5%.
Modular Pre-Assembled Construction: Fabricating modular casing blocks with pre-installed insulation and tube bundles to minimize field installation time and crane hours.
Zero MOQ Flexibility: Supplying single custom waste heat boiler units for turnaround revamps as well as complete multi-unit boiler plants for new grassroots industrial facilities.
Quality Control
Certified Boiler Accreditations: Manufactured under ASME "S" (Power Boilers) and "U" stamps, Class A Boiler Manufacturing License, and ISO 9001:2015 quality standards.
Component-Level QR Code Traceability: Every boiler drum plate, header pipe, finned tube spool, and pressure fitting is tracked through a serialized QR code linked directly to mill test reports and inspection records.
100% Comprehensive NDT & Inspection: 100% Radiographic Testing (RT) / Ultrasonic Testing (UT) on all longitudinal and circumferential drum welds, 100% Positive Material Identification (PMI), and hydrostatic pressure testing witnessed by certified boiler inspectors.
Third-Party Inspection Coordination: Full facilitation of customer audits and third-party inspections by BV, SGS, DNV, or TÜV at all critical quality hold points.
Export-Grade Heavy Packaging: Heavy-duty structural steel transport saddles, internal nitrogen purging for tube bundles, and weatherproof vacuum-barrier wraps for ocean transit.
FAQ
Q: How do you prevent low-temperature acid dew-point corrosion in the economizer section of the boiler?
A: We calculate the acid dew-point based on the sulfur content of the fuel gas and design the economizer inlet water temperature to remain safely above this threshold, using corrosion-resistant tube materials or air preheat integration where necessary.
Q: What is the typical fabrication lead time for a complete Heat Recovery Steam Generator?
A: Custom boiler fabrication typically requires 4 to 6 months from technical drawing approval and material procurement to final inspection and testing. Standard replacement tube bundles can be completed in approximately 3 months.
Q: What warranty coverage do you provide for international deliveries?
A: We provide an 18-month warranty from site arrival or 12 months from commercial operation (whichever comes first), backed by responsive technical engineering support.
Q: What payment terms and currencies do you accept for export contracts?
A: We support EXW and FOB shipping terms. Our standard commercial milestones are 30% advance deposit, 40% manufacturing milestone payment, and 30% balance prior to factory dispatch, payable in USD, EUR, or RMB.
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