Designed to capture waste heat from industrial processes and convert it into steam, a heat recovery steam generator (HRSG) is a key component in energy-efficient power generation systems. The steam can be used to drive a steam turbine for electricity generation or to provide heating in combined heat and power (CHP) systems. HRSGs improve overall energy efficiency by recycling otherwise lost thermal energy, reducing fuel consumption and emissions, and enhancing the environmental sustainability of power plants and industrial facilities.
When HRSG products are used to capture otherwise wasted thermal energy and put it to use, not only does the cost of operation decrease through reduced fuel purchased, but the overall plant emissions also drop proportionally.
Superior Boiler Heat Recovery Steam Boilers
Heat recovery steam generators and waste heat boilers are typically custom-designed for each application. Given the proper information, such as mass flow rates, temperatures, and chemical makeup of the exhaust gas and heat sink, our designers will select the proper materials, configuration, and arrangement to maximize the amount of thermal energy that can be recovered and used.
Koch Applied Solutions partners with Superior Boiler to provide heat recovery steam generators that are designed to deliver maximum efficiency, reliability, and durability in the most demanding applications and environments. Each boiler is engineered to fit your specific site and requirements.
In most cases, the energy recovered allows for the reduction of purchased fuel to produce steam (from boilers) or hot air (from gas-fired heaters) needed for process or space heating at a plant.
Aztec 2-Pass Heat Recovery only units are designed with a large diameter furnace for gas inlet temperatures to 2400° F, 2.5” heat transfer tubes.
- Capacity: Customized for job-specific conditions, with experience in designing units over 40,000 lb/hr.
- Fuel Capabilities: Customized for application
- Pass: 2-pass
- Tube Type: Smooth tubes or rifled tubes
- Steam Design Pressure: 150 – 300 psig
- Hot Water Design Pressure: Section I vessels 150 – 250 psig
Superior Boiler’s Cherokee Dual Chamber Units are designed to combine the advantage of waste heat recovery with the security of a fired boiler to provide steam or hot water during periods of time when waste gas is unavailable.
- Capacity: Customized for job-specific conditions, with experience in designing units over 40,000 lb/hr.
- Fuel Capabilities: Customized for application
- Pass: 2-pass all tubes
- Tube Type: Smooth tubes or rifled tubes
- Steam Design Pressure: 150 – 300 psig
- Hot Water Design Pressure: Section I vessels 150 – 250 psig
Superior Boiler’s Comanche Two Pass Heat Recovery units are designed with 2 “ & 2.5” heat transfer tubes.
Capacity: Customized for job-specific conditions, with experience in designing units over 40,000 lb/hr.- Fuel Capabilities: Customized for application
- Pass: 2-pass All tubes
- Tube Type: Smooth tubes or rifled tubes
- Steam Design Pressure: 150 – 300 psig
- Hot Water Design Pressure: Section I vessels 150 – 250 psig
The Huron HRSG (Heat Recovery Steam Generator) is available in multiple configurations: Single pass O-Type, Single pass A-Type, Cross drum multi pressure.
- Capacity: 10 – 10,000 lb/hr
- Fuel Capabilities: Customized for application
- Steam Design Pressure: Up to 1,200 psig
Kiowa Single Pass Heat Recovery only units are designed with 2” & 2 .5” heat transfer tubes.
- Capacity: Customized for job-specific conditions, with experience in designing units over 40,000 lb/hr
- Fuel Capabilities: Customized for application
- Pass: 1-pass
- Tube Type: Smooth tubes or rifled tubes
- Steam Design Pressure: 150 – 300 psig
- Hot Water Design Pressure: Section I vessels 150 – 250 psig
The Konza iHRSG Heat Recovery Steam Generator incorporates two proven technologies into one package: a single pass HRSG and multipass fresh air fired boiler.
- Capacity: Up to 1,000 HP
- Fuel Capabilities: Customized for application
- Steam Design Pressure: Up to 600 psig
Mohawk Three Pass Heat Recovery units are designed with a large diameter furnace for waste gas inlet temperatures to 2400°F with 2.5” heat transfer tubes.
- Capacity: Customized for job-specific conditions, with experience in designing units over 40,000 lb/hr.
- Fuel Capabilities: Customized for application
- Pass: 3-pass
- Tube Type: Smooth tubes or rifled tubes
- Steam Design Pressure: 150 – 300 psig
- Hot Water Design Pressure: Section I vessels 150 – 250 psig
Applications
Heat Recovery Steam Generators (HRSGs) are widely used across various industries to improve energy efficiency and reduce waste heat. Here are some common applications:
- Combined Cycle Power Plants: HRSGs capture waste heat from gas turbines to generate steam, which powers a steam turbine for additional electricity generation.
- District Heating: Areas with centralized district heating benefit from these systems that generate both electricity for the grid as well as heat for homes and businesses.
- Institutions and Campuses: When a group of buildings have diverse energy needs, cogeneration systems are a good fit for centralized energy supply.
- Industrial Manufacturing: In sectors like chemical production, refineries, and steel plants, HRSGs recover heat for further use in heating, powering equipment, or even driving turbines.
- Waste-to-Energy Plants: In waste incineration plants, HRSGs recover heat from burning waste materials to generate steam, which can then be used to produce electricity or supply district heating systems.
- Oil and Gas Processing: HRSGs are often used in oil and gas facilities to capture heat from gas-fired engines or turbines used in compression, processing, or power generation, turning it into steam for use in further plant operations.
The Koch Applied Solutions team can assist you by evaluating your project and equipment needs. We can also bring in construction and engineering resources to help see projects through to completion. Request a quote to get started today.