Flue-Type Tubular Steam Generator

Duct-type Tube Steam Generator

Equipment Introduction

      With the deepening of China's reform and opening up, our national economy has developed rapidly. The development and environmental protection issues are of paramount importance to our economic growth, in response to the national call for low-carbon economic and environmental development. In the face of increasingly severe industrial waste gas pollution and outdated treatment technologies, and considering the complex characteristics of waste gas heat emission, we have developed a thermal energy recovery system for industrial waste gases, as well as systems for recovering waste heat from boilers and standardized vehicles.

      Our company adheres to the scientific design philosophy of energy conservation and environmental protection, integrating research and development, production, and manufacturing with robust advantages in products aligned with national industrial guidance and modern management. We are committed to producing high-quality products, creating greater and better economic and social benefits for corporate users. We have developed a structurally rational heat gas tube design, a heat pipe waste heat steam generator, and a modular heat transfer oil heat pipe waste heat steam generator.

Heat Recovery Steam Generator Working Principle

      Organic heat carrier boiler exhaust gas waste heat recovery unit with steam generator, comprising a flue connected to the boiler body and an air preheater installed in the flue, an air preheater blower, a chimney connected to the flue outlet end, characterized in that a steam generator composed of a shell, steam drum, tube plate, and heat transfer tubes is installed in the front section of the flue between the boiler body and the air preheater, with the heat transfer medium sealed in the heat transfer tubes, the lower part of the heat transfer tubes located in the shell, and the upper part extending into the steam drum through the tube plate, with the steam generator shell installed in the flue. The high-temperature hot air or other thermal energy from the organic heat carrier boiler is sent into the heater tubes by the blowing equipment, where the heat inside the tubes is transferred to the shell through the tube walls to heat water. The unsaturated steam produced by the heater is first sent to the separator drum and then distributed to various steam-using locations from the separator drum. Provides steam for production and daily use.

Heat Pipe Steam Generator Structure and Working Principle

      The heat pipe steam generator is primarily composed of a steam drum, heat pipes, and a flue box. The heat pipes in the flue box absorb the excess heat from flue gas and transfer it to the water in the steam drum, causing the water to heat up and vaporize, producing saturated steam for production and daily use. This equipment is mainly installed on the flue after the heat storage chamber. During operation, the waste flue gas produced by the kiln passes through the flue box of the equipment. The heat pipes in the flue box absorb the excess heat from the flue gas and transfer it to the water in the steam drum, causing the water to heat up and vaporize, generating saturated steam for production and daily use. This replaces the original steam boiler, achieving the effect of energy conservation and consumption reduction.

Performance Features of Heat Pipe Waste Heat Recovery Steam Generator Unit

      1. The installation of the heat pipe steam generator waste heat recovery unit does not require modifications to the original boiler or industrial furnace. Easy installation: The heat pipe evaporator boasts low cost, convenient installation and use, high safety, strong reliability, and low operation and maintenance costs. Its innovative and reasonable structure ensures that the operation of the entire waste heat boiler is not affected even if individual heat pipes are damaged.

      2. Safe and Reliable: Superconducting heat pipes offer excellent isothermal performance, generating self-vibration during heat conduction without producing dirt or ventilation resistance, maintaining a consistently high heat transfer efficiency.

      3. Resistant to dust accumulation, easy to clean, labor-saving, and reduces labor intensity. The heat exchange tubes of the heat pipe waste heat boiler are all made of thick-walled pipes, and they are solid tubes without any welds, thus offering the features of safety, reliability, and a long service life.

      4. The equipment is designed with a rational structure, easy to operate and manage. It employs full automatic control, requiring no dedicated personnel for management. It features automatic water level protection and automatic pressure relief in case of overpressure.

      5. Equipment operates safely and reliably, capable of continuous and stable long-term performance with a long service life: the superconducting heat pipe waste heat recovery unit has a service life of over 10 years, with individual heat pipes that can be easily removed and replaced, making maintenance simple and cost-effective.

      6. Low price, small investment, and short payback period: Full investment is typically recouped within 3 to 8 months, with substantial returns.

Economically viable

      If configured in the system, this waste heat steam generator can produce saturated steam or water at a certain pressure and temperature without the need for any additional auxiliary equipment or extra fuel consumption. This output is suitable for both production and daily use, while also reducing exhaust gas temperatures, effectively protecting the fan's operation, and lowering the insulation requirements for the flue and air ducts. Preliminary calculations show that installing a 250m² waste heat steam generator on a 3 million kcal oil furnace, running 24 hours a day, can conservatively yield 20 tons per day (heated with lukewarm water), resulting in a daily profit of 2,000 yuan. At 100 yuan per ton of steam, this equates to a monthly savings of 6,000 yuan, allowing for the investment to be recouped in just 3-4 months. Installing a 300m² waste heat steam generator on a 5 million kcal oil furnace, running 24 hours a day, can conservatively yield 35 tons per day (40 tons if using recycled hot water), resulting in a daily profit of 4,000 yuan. This translates to a monthly savings of 120,000 yuan, and over 10 months, a yearly savings of 1.2 million yuan. The investment can be recouped in just 2-3 months. Installing a 300m² heat exchanger equals 180,000 yuan plus soft water piping, valves, and installation costs, totaling approximately 250,000 yuan. With an initial investment of 250,000 yuan, the equipment can recoup 1.2 million yuan annually. This equipment does not require human labor or energy consumption; it only requires the electricity for a single pump. The estimated steam production table for the waste heat steam generator shows steam pressure of 0.6 MPa and steam production in kilograms (see table below).

Steam Pressure: 0.6 Mpa   Steam Output (D): kg/h (see table below)

Estimated annual economic benefits

      Annual profit of 2.5-4 million kcal/h thermal oil furnace = 0.55 t/h x 24 h/day x 150 yuan/t x 30 days/month x 12 months = 712,800 yuan

      1.2t/h x 24t/h x 150/t x 30 days/t x 12 months = 1.5552 million yuan per year for a 4.5-6 million BTU/h thermal oil boiler

      (Note: Exhaust gas temperature is 300°C, working conditions are based on average production output, and steam price is calculated at 150 yuan per ton.)

Principle Diagram

Performance Features

      Easy Installation: The heat pipe waste heat recovery unit is compact in size and structure, requiring no modifications to the original boiler or industrial furnace for installation.

      Safety and Reliability: Superconducting heat pipes exhibit excellent isothermal performance, generate self-vibration during heat conduction without causing clogging or increased ventilation resistance, maintaining a high thermal transfer efficiency at all times without affecting the operation of boilers or kilns.

      Long lifespan: The superconducting heat pipe waste heat recovery unit has a lifespan of over 10 years, with simple maintenance and low costs.

      Energy-saving benefits: Efficiency of large-scale industrial furnaces can be increased by over 10%, and that of small and medium-sized oil, gas, and coal-fired boilers can be improved by energy savings of up to 5%-10%.

      Short payback period: Full investment recouped in 3-6 months typically.