Waste Heat Recovery Boiler

WASTE HEAT
RECOVERY SYSTEMS
Transparent Energy Systems Pvt. Ltd.

Pune- 37. (INDIA)
Tel : 020 – 4211347, Fax : 020 – 4212533.
E-mail : trans@pn2.vsnl.net.in & sales.pune@tespl.com
INTRODUCTION
Transparent has developed wide variety of superefficient Heat Recovery Systems for
harnessing all types of waste heat, originating from various fuels and from different industrial
sources.
The Waste Heat Recovery Boilers are provided with Economizers which improve their thermal
output and efficiency.
Transparent superefficient Waste Heat Recovery Systems find ideal applications in Cogeneration
Systems working on Reciprocating Engines and Gas Turbines.
Various sources of waste heat.
¾ Exhaust heat recovery from Reciprocating Engine driven Gen-sets used for Captive Power
Cogeneration and Independent Power Production.
- Heavy fuel fired
- Gas fired
- Diesel fired
¾ Exhaust heat recovery from Gas Turbine exhaust.
¾ Jacket heat recovery from Engine
¾ Hot Waste Gases from
- Scrap melting steel furnaces
- Cement kilns
- Industrial furnaces
- Incinerators
- Process Waste Gases
Converting into useful form

Energy is consumed in various forms like steam, hot water, Chilling, refrigeration etc. at different
places. Please refer next page for separate matrix to check different useful forms of energy to which
this waste heat can be converted. Transparent has expertise in converting this waste energy
into the most beneficial form of energy for any customer.
Various models of heat recovery systems

Transparent has developed following wide range of ‘application specific designs and
constructions’ of Waste Heat Recovery systems / HRSGs for above applications.
Various designs of Waste Heat Recovery Systems are :
Recostar – FN : Finned, Water tube, Non IBR.

Recostar – FI : Finned Water tube IBR.
Recostar – S : Smoke tube IBR.
Recostar – WC : Bare Water tube, IBR.
Recostar – WCOF : Water tube, co-flow (concurrent flue-gas flows) IBR.
Recostar – WCRF : Water tube cross tube IBR.
Recostar – CC : Cylindrical coil type once through.
Recostar – PC : Pancake coil type once through.
Recostar – SCMP : Smoke tube, composite unfired plus fired type.
Recostar – JW : Engine jacket water heat recovery system
RECOSTAR FN
Product Details
Type : Finned Water Tube, Non IBR
Installation : Horizontal & Vertical,

Indoor as well as Outdoor
Tube Orientation : Horizontal & Vertical
Fin Type : 1) ‘L’ Type steel fins with

full contact of fin base to tube
2) Integral extruded / rolled
aluminium fins on C.S. tube.
Waste Gas Flow Direction : Horizontal/ Vertical

(Upwards & Downwards)
Quality of Waste Gases : Normally clean dustfree gases
Acceptable dust in waste : Moderate dust level acceptable for vertical fin orientation with
gases mechanized soot removing and collecting facility.
Type of heat recovery output : 1) Steam–D & S / Superheated 2) Hot Water

3) Hot Thermic Fluid
Media of Waste Heat : Hot gases, Hot bulk powders, hot liquids, hot vapours.
Steam Pressure : Suitable for low as well as high pressure.
Steam Condition : Dry & saturated with external moisture separator. Superheated
steam through provision of super-heater.
Water side circulation : Once through, forced circulation
Steam Water Separation : In external moisture separator
Waste Heat source : Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust
suitability process waste gases, Incinerator exhaust, furnace exhaust.
Typical applications : Process heating, hot water generation, Thermic Fluid heating,
whenever IBR installation is desired to be avoided.
Output capacity Possibilities : Single unit output upto approx. 600 kg/hr. Multiple units can
generate proportionately higher outputs without mixing flue
gases.
Soot removal : 1) Mechanized vibrating soot removal.
2) Automatic pneumatic cylinder operated travelling type
steam jet or compressed air jet soot blower.
Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater

stages possible evaporator, economizer, water preheater
Typical lowest exhaust gas : Gases generated by diesel - 1300C, Gas generated by natural
temp. at outlet of system gas – 1100C, Gases generated by high sulphur fuels - 1500C.
Protection against sulphur : Provided by various means to ensure that metal temperature is
& corrosion on cold end maintained above the actual incipient limit.
side
FLUE GAS IN
FLUE GAS
BYPASS
TO SILENCER
AUTOMATIC 3 WAY
FINNED TUBE DIVERTOR VALVE
STEAM GENERATOR
Vibrator
F.W.PUMP
F.W. TO F.W.TANK
F.W. FROM F.W.TANK

F.W.IN
FLUE GAS OUT
BLOW
DOWN
VALVE
ECONOMIZER
Recostar FN ( Horizontal )
for 750 KVA engine
Recostar FN : Flow diagram ( Vertical )
Case study
Waste heat source : Engine generator exhaust

Capacity of Engines : 600KW X 1 No.
Fuel fired in Engines : HSD
Total flue gas quantity : 2700 Kg./Hr.
Flue gas inlet temp. : 5180C
System configuration : Main WHRB + Economizer
Flue gas outlet temp. : 1850C
Output type : Steam at 10 Bar(g)
Output at 100% load : 320 Kg./Hr (F & A 1000C)
RECOSTAR FI
Product Details
Type : Finned, Water Tube, IBR

Indoor as well as Outdoor
Tube Orientation : Horizontal & Vertical
Fin Type : 1) ‘L’ Type steel fins with

full contact of fin base of tube
2) Integral extruded / rolled
aluminium fins on C.S. of tube.
Waste Gas Flow Direction : Horizontal/ Vertical

(Upwards & Downwards)
Quality of Waste Gases : Normally clean dust free gases
Acceptable dust in waste : Moderate dust level acceptable for Boilers having vertical fin
gases orientation with mechanized soot removal and collecting facility.
Type of output : Steam- D&S/ Superheated, Hot Water, Hot Thermic Fluid
Media of Waste Heat : Hot gases, Hot bulk powders, hot liquids, hot vapours.
Steam Pressure : Suitable for low as well as high pressure.
Steam Condition : Dry & saturated with external moisture separator. Superheated
steam through provision of superheater.
Water side circulation : Natural Circulation, forced circulation.
Steam Water Separation : In steam drum or in external moisture separator.
Waste Heat Source : Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust
Typical applications : Process heating, hot water generation, Thermic Fluid heating,
Power generation, Cogeneration applications.
Duct firing possibilities : Possible for gas turbine exhaust applications.
Output capacity possibilities : No limits.

2) Travelling type soot blower.
3) Rotory soot blower.

Typical lowest exhaust gas : Gases generated by diesel - 1300C, Gas generated by natural gas
temp. at outlet of system - – 1100C, Gases generated by sulphur fuels –1500C
corrosion on cold end side maintained above the actual incipient limit.
STEAM
OUT
PS
LT
LS
FLASH ECONOMIZER
STEAM
DRUM
FLUE GAS FLUE GAS
FROM PS OUT
ENGINE
ENTERS
FINNED TUBE
AUTOMATIC HEAT RECOVERY UNIT
3 WAY
DIVERTOR
FEED
VALVE
WATER IN
FEED WATER PUMPS
Recostar FI : Flow diagram
Case study

Capacity of Engines : 800KW X 1 No.
Fuel fired in Engines : HSD
RECOSTAR WC
Product Details
Type : Bare Water Tube, IBR
Installation : Horizontal / Vertical, Indoor as well as Outdoor.
Tube Orientation : Horizontal / Vertical.
Waste gas flow direction : Horizontal / Vertical (upwards & downwards)
Quality of Waste Gases : Gases having low to high dust load special design for high dust
load
Acceptable dust in waste : High dust level acceptable for Boilers having mechanized soot
gases removing and collecting facility.
Type of heat recovery output : Steam (D&S/ Superheated), Hot Water, Hot Thermic Fluid
Media of Waste Heat : Hot gases, hot bulk powders, hot liquids, hot vapors
Steam Pressure : Suitable for low as well as high pressure
Steam Condition : Dry & saturated and also superheated steam through provision
of superheater.
Water side circulation : Once through, Natural Circulation & Forced / Assisted
circulation
Steam Separation : In steam drum or in external moisture separator.
Waste heat source : Fuel cell exhaust, Micro / miniturbine exhaust, Gas turbine
suitability exhaust, DG set exhaust process waste gases, Incinerator
exhaust, furnace exhaust.
Typical applications : Exhaust of steel furnaces, cement kilns, metal smelters,

Incinerators, Industrial furnaces, DG set exhaust, process waste
gases, Incinerator exhaust, furnace exhaust, Gas turbine
exhaust.
Duct firing possibilities : Possible for applications on gas turbine exhaust. Heat addition
into waste gas stream by addition of hot gases generated by
separately fired hot gas generator.
Output capacity possibilities : No Limits.

Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater,

stages possible evaporator, economizer, water preheater.
Typical lowest exhaust gas : Gases generated by diesel –130oC, gas generated by Natural
temperature at final outlet of Gas – 110oC, Gases generated by high sulphur fuels – 150oC.
system
RECOSTAR S
Product Details
Type : Smoke Tube IBR

PS
PS
Installation : Horizontal & Vertical, LS LT
Indoor as well as Outdoor.

PS
Waste gas flow direction : Horizontal / Vertical
(upwards & downwards)
Quality of Waste Gases : Low dust level acceptable.
Type of heat recovery output : 1) D & S / superheated

2) Hot Water
3) Vapour phase Thermic Fluid Heating
Media of Waste Heat : Hot gases, hot liquids, hot vapors
Steam Pressure : Suitable for low as well as medium pressure
of superheater.
Water side circulation : Natural circulation internal to boiler.
Steam Separation : In Boiler drum.
Waste heat source : Fuel cell exhaust, Micro / miniturbine exhaust small gas turbine
suitability exhaust, DG set exhaust, process waste gases, Incinerator
exhaust, furnace exhaust.
Typical applications : Exhaust of steel furnaces, cement kilns, metal smelters,

Incinerators, Industrial furnaces, DG set exhaust, process waste
gases, Incinerator exhaust, furnace exhaust, Gas turbine
exhaust.
Output capacity possibilities : Typically 15 TPH
Soot removal : Sonic soot blowers can be used & also through self cleaning
velocities.
Typical lowest exhaust gas : Gases generated by diesel – 130oC, gas generated by Natural
system
Flue gas
From
Engine 1 Steam out
PS Economizer
PS
Automatic LS LT
3 way
Divertor valves
Flue gas
PS
Engine 2 Flue
gas
out
F.W. in
Recostar-S for 2 X 1 MW gas engines
F.W. pumps
Recostar-S : Typical arrangement
Recostar-S for 2 X 1 MW gas engines
Recostar-S for 3 X 1 MW F.O. engines
Case study

Capacity of Engines : 1 MW X 1 No.
Fuel fired in Engines : Furnace oil (Heavy oil)
System configuration : Main WHRB + 2 stage Eco.
RECOSTAR WCOF
Product Details
Type : Water tube, coflow
(Cocurrent gas flow) IBR
Installation : Horizontal / Vertical,

Steam
Indoor as well as Outdoor. drum
Tube Orientation : Vertical.
Waste gas flow direction : Vertical
Quality of Waste Gases : Specially suitable for dust

laden gases. Provided with
special mechanized soot
removal and collection system.
Acceptable dust in waste : High dust level readily

gases Accepted
Type of heat recovery : 1) Steam– D & S/Superheated

output 2) Hot Water
Media of Waste Heat : Hot gases, Hot vapours
Steam Condition : Dry & saturated. Superheated steam by provision of superheater.
Water side circulation : Natural Circulation / Forced (Assisted circulation)
Steam Separation : In steam drum or in external moisture separator
Waste heat source : Exhaust of steel furnaces, cement kilns, metal smelters,
suitability incinerators, industrial furnaces, DG set exhaust process waste
gases, Incinerator exhaust, Furnace exhaust, gas turbine
exhaust.
Typical applications : Process heating, hot water generation, thermic fluid heating,
power generation, cogeneration.
Duct firing possibilities : Possible for applications on gas turbine exhaust, Heat addition
into waste gas stream by firing fuel.


Typical lowest exhaust gas : Glue gas from diesel – 1300C, Flue gas from Natural Gas – 1100C,
temp. at outlet of system Flue gas from high sulphur fuels –1500C
BYPASS
AUTO. 3 WAY
HOT DIVERTOR VALVE
GAS IN
STEAM
FEED WATER
AT 180 –1850 C
Steam
drum TO CHIMNEY
HOT
GAS 155 -1600C
OUT FEED
EVAPORATOR WATER
AT 900C
180 -1850C
ECONOMIZER -II
120 -1250C
ECONOMIZER -I
Recostar WCOF : Typical arrangement
Recostar-WCOF for 3.8 MW engine
Recostar WCOF : Flow diagram ( Vertical )

Case study

Capacity of Engines : 3.8 MW X 1 No.
Fuel fired in Engines : Furnace oil ( Heavy oil )
RECOSTAR WCRF
Product Details
Type : Water tube cross flow IBR
Installation : Vertical, Indoor and Outdoor.
Tube Orientation : Vertical.
Waste gas flow direction : Horizontal
Quality of Waste Gases : Moderately clean gas desired.

Provided with mechanized
Soot removal and collection
System.
Acceptable dust in waste : Moderate dust level accepted

gases
Type of heat recovery output : 1) Steam– D & S / Super-heater

2) Hot Water
3) Vapour phase thermic fluid
Media of Waste Heat : Hot gases
of super-heater.
Water side circulation : Natural Circulation
Waste heat source : Exhaust of steel furnaces, cement kilns, metal smelters,
suitability incinerators, industrial furnaces, DG set exhaust process waste
gases, Incinerator exhaust, Furnace exhaust, gas turbine
exhaust. (Gases with temperature less than 550oC)
Typical applications : Process heating, hot water generation, thermic fluid heating,
power generation, cogeneration.
Duct firing possibilities : Possible for applications on gas turbine exhaust, Heat addition
into waste gas steam by addition of hot gases generated by

2) Travelling type steam soot blower. 3) Rotary soot blower.

system
corrosion on cold end side maintained above actual incipient limit.
STEAM OUT
STEAM
DRUM
FLUE
FLUE
GAS OUT
GAS IN
MUD
DRUM
BLOW DOWN
Recostar WCRF : Flow diagram ( Vertical )
Case study

Fuel fired in Engines : Furnace oil ( Heavy oil )
System configuration : Main WHRB
RECOSTAR CC
Product Details
Type : Cylindrical coil type,
water tube, once through
Installation : Horizontal / Vertical,


Quality of Waste Gases : Normally clean dust free

gases (special vertical design
with self cleaning velocities
available for dust laden gases
with soot blowing arrangement)
Type of heat recovery : 1) Steam – D & S / Superheated 2) Hot Water 3) Hot Thermic
output Fluid
Media of Waste Heat : Hot gases, Hot vapours, Hot liquids
Steam Condition : Dry & saturated steam with external moisture separator.
Superheated steam possible with provision of superheater and
moisture separator installed between evaporator and super-
heater.
Degree of Superheat : Superheat degree limited by lnlet gas temperature available.

Possible
Water side circulation : Once through Forced circulation
Steam Separation : With external moisture separator.
Waste heat source : Fuel cell exhaust, micro gas turbine exhaust, DG set exhaust
(High gases)
Typical applications : Thermic Fluid heating, process heating, hot water generation,
superheated water generation, power generation, cogeneration.
Duct firing possibilities : Possible for gas turbine exhaust applications, heat addition into
waste gas steam by addition of hot gases generated by
Output capacity possibilities : No capacity limits as multiple units can generate higher outputs.
Soot removal : Through self cleaning velocities and pneumatic / steam soot
blowers.
Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. Super-heater,

Air bleed valve
Air bleed valve
Flue gas From

Flue gas From
Incinerator at
Incinerator at
1000 0C
1000 0C
I. D. Fan
Waste heat I. D. Fan
TIC Waste heat
recovery TIC
F. D. Fan Incinerator recovery
Thermic F. D. Fan Incinerator
Thermic
fluid heater Flue gas
Exit fluid heater
at 250 0C
3 way Divertor
3 way Divertor
Valve
Valve
T.F. From
T.F. From
Plant at 1900C
Plant at 1900C
Panel
Common Exp. Panel
Common Exp.
Tank
DPS Tank
DPS
T.F. From
T.F. From
WHRTFH
WHRTFH
at 210 0C
at 210 0C
T.F. to fired
T.F. to fired
TFH at 2050C
TFH at 2050C
Heat recovery ON Heat recovery BYPASS
Recostar FN : Flow diagram for Incinerator based

Heat recovery system
Case study
Waste heat source : Incinerator exhaust

Material incinerated : Waste from packaging industry
System configuration : Thermic fluid heater
Output type : Thermic fluid at 2100C
Output at 100% load : 4,86,202 Kcal/Hr.
RECOSTAR PC
Product Details
Type : Pancake coil type,

water tube, once through


Quality of Waste Gases : Normally clean dust free gases.
Acceptable dust in waste : Low dust level needed in

gases horizontal design high dust
level acceptable only in vertical
design with self cleaning velocities.
Type of heat recovery output : 1) Steam – D & S / Superheated

2) Hot Water
Media of Waste Heat : Hot gases, Hot vapours, Hot liquids
Steam Condition : Dry & saturated steam with external moisture separator.
Superheated steam possible with provision of superheater and
moisture separator installed between evaporator and
superheater.
Water side circulation : Once through Forced circulation.
Steam Separation : With external moisture separator.
Waste heat source : Fuel cell exhaust, micro / min gas turbine exhaust, DG set
suitability exhaust process waste gases, Incinerator exhaust, furnace
exhaust.
Typical applications : Thermic Fluid heating, process heating, hot water generation,
superheated water generation, power generation, cogeneration.
Duct firing possibilities : Possible for gas turbine exhaust applications.
Output capacity possibilities : No capacity limits as multiple units can generate higher outputs.
Soot removal : Through self cleaning velocities and pneumatic steam soot
blowers.

Hot Thermic fluid out
Pancake coils
Cold Thermic fluid in
Hot flue gas in
Recostar PC : Flow diagram
Case study

Capacity of Engines : 1 MW X 1 No.
Fuel fired in Engines : Natural Gas
System configuration : Main TFH
Output type : Hot thermic fluid at 2200C
Output at 100% load : 2,61,900 Kcal/Hr.
RECOSTAR SCMP
Product Details
Type : Smoke tube, composite

(I.e. unfired plus fired zone)
Installation : Horizontal, Vertical, Indoor.

Quality of Waste Gases : Low dust level desired.
Type of heat recovery output : 1) Steam–D & S / Super-heat.

2) Hot water
3) Vapour phase Thermic Fluid Heating.
Media of Waste Heat : Hot gases, Hot vapors, Hot liquids
Steam Pressure : Suitable for low as well as medium pressure
of super-heater.
Water side circulation : Natural Circulation internal to boiler.
Waste heat source : Fuel cell exhaust, micro / min gas turbine exhaust, Small gas
suitability turbine exhaust, DG set exhaust, process waste gases,
Incinerator exhaust, furnace exhaust, gas turbine exhaust.
Typical applications : Where heat recovery from waste heat needs to be supplemented
with fuel firing and installation of two separate boilers unfired
and fired has space limitation.
Supplemetory firing : Firing in internal furnace provided in boilers.

possibilities
Output capacity possibilities : Typically upto 20T/hr capacity.
Soot removal : By sonic soot blowers and through self cleaning velocities.
Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. Super-heater

system
FLUE GAS
FROM ENGINE ENTERS ECONOMIZER
FLUE GAS
FROM ENGINE
LEAVES
PARTITION
FLUE GAS
FROM
BURNER
BURNER LEAVES
Recostar SCMP : Flow diagram ( Vertical )
Case study

Fuel fired in Engines : Natural gas
System configuration : Main WHRB+Fired zone+ Eco.
N.G. firing in fired zone : 60 SM3/Hr.
PRODUCT FEATURES
CONTROL PANEL EASE OF FLUE GAS

SIDE INSPECTION
The Control Panel is
wired with solid Front and rear doors
conductor single strand are hinged type to
wires for easy tracebility. provide simple & quick
Indications for all opening for full access
temperatures, safety trips to fireside tube surface.
provided on panel. This job can be done by
Facilities for auto-manual a single person
switching of individual
devices provided.
MAXIMUM HEAT CUSTOM

RECOVERY ENGINEERED /
Heat recovery in multiple CUSTOM BUILT
stages ( 3 to 4) with help
of single/double stage Every TRANSPARENT
economizers plus water Boiler is specifically
preheater ensures engineered and built to
maximum possible heat every customer’s needs
recovery from the waste and specifications.
gases. Customer gets Special sizes, sources
nearly 7 to 19 % of of heat and auxiliary
additional output equipment are no
compared to other problem with
makes. TRANSPARENT.
DIVERTOR VALVE INSULATION

Insulation thickness is
Automatic pneumatically selected scientifically to
operated, Linear minimize heat loss even
movement of valve, at a high flue gas temp.
Stainless steel can work (Typical thickness used
850oC continuously. is 300 mm for 5000C)
Pneumatic pressure
eliminating possibility of
any leakage.
APPLICATION SUITABILITY
PRODUCT MATRIX
Matrix for of converting waste heat in useful form

Source of H L G E G I C S H G F A H
Waste Heat O E J T P P G F G C P
O E
Useful Form E E H E K F P G F C
E G
Of Output E G H
E
Low Pressure Steam
Medium Pressure Steam
High Pressure Steam
Hot Thermic Fluid
Hot Water (Pressurized)
Hot Water (Non Pressurized)
Hot Air for Process (Dryer etc)
Chilled Water
Chilled Brine
Ice Making
Cold Storage
Waste Water Recycling
Power
Combustion Air Preheating
Inlet Air Cooling
Source of Waste Heat
HOEE : Heavy Oil Engine Exhaust

LOEE : Light Oil Engine Exhaust
GEE : Gas Engine Exhaust
EJH : Engine Jacket Heat
GTE : Gas Turbine Exhaust
IEG : Incinerator Exit Gases
CPKG : Cement Plant Kiln Gases
SPF : Steel Plant Furnaces
HGP : Hot Gases From Process
GFG : Glass Furnace Gases
FGFH : Flue Gases From Fired Heaters
AC : Air Compressors
HPC : High Pressure Condensate
WHRB INSTALLATION
WHRB Installed at Square Spinnings Ltd., Bangladesh,

Natural Gas Fired Engine,
Steam Pressure – 10.54 kg/cm2 (g).
WHRB Installed at Reid & Taylor (S. Kumar)
WHRB Installed at Heubach Colour Ltd.,

Natural Gas
Steam Pressure – 10.54 kg/cm2 (g)
WHRB Installed at Tesitura Monti (I) Pvt. Ltd.
Heavy Fuel Oil
Steam Pressure – 14 Kg/cm2 (g)
WHRB Installed at Hindustan Mills Ltd WHRB Installed at Janta Jute - Dhaka
COMPARISION
Safety of Source Equipment
Flue gas
from Engine Flue gas bypass
Back pr. limit FPS

FPS
pressure
sensor
Automatic
3 way
Divertor Valve
Back pressure control on flue gas side

Transparent provides automatic flue gas monitoring & control system. If the steam pressure exceeds
the predetermined value, the flue gases automatically diverted to stack. This saves the source
(Engine or turbine) from getting subjected to excessive back pressure.
No such system exists in other make whrb (standard model). This is quite unsafe for the engine or
turbine on which the WHRB is installed.
Note : In case of gas fired engines or turbines, eventhough there is very little possibility of carbon
accumulation but other possibilities do exist for excessive back pressure on flue gas side. It can
happen either due to leakage of boiler tube or lube oil vapour condensation in abnormal conditions.
Hence even in case of gas engines/turbines, above safety feature is of paramount importance.
Safety of Waste Heat Recovery Boiler

Steam pr. limit
Pressure sensor Flue gas bypass Steam pr. limit
SPS
SPS
Automatic 3 way
Divertor valve
High steam pressure control

Transparent provides automatic steam pressure monitoring & control system. If the steam pressure
exceeds the predetermined value, the flue gases are automatically diverted to stack. This eliminates
frequent operation of safety relief valve.
No such system exists in other make whrb (standard model). This is quite unsafe for the WHRB. In
such case one has to solely depend on safety valve.
Note : Frequent operation of safety valve is an undesirable situation since it is meant for ultimate
safety of boiler & supposed to operate once in a while.
COMPARISION
Safety of Waste Heat Recovery Boiler
Flue gas bypass

Level sensor
Flue gas
from Engine
LSL LSL
Automatic 3 way
Divertor Valve
Low water level safety trip

Transparent provides automatic boiler water level monitoring & control system.In case the level falls
below safe level, the flue gases automatically bypass the WHRB & go to stack. This eliminates boiler
tubes overheating.
No such system exists in other make WHRB (standard model). This is quite unsafe for the WHRB.
Overheating of tubes can result into cracking & leakage.
Note : Generally the feed pump & drum level controller system maintains desired level. Anyhow in
case of abnormal situation the level can drop in spite of above system due to various reasons such as
unavailability of water in F.W. tank, malfunctioning of drum level controller etc.
Efficiency and Outputs

Heat From the Gases
Flue gas from Engine
at 5860C Transparent WHRB recovers
Flue gas out from
WHRB at 1340C maximum possible heat from
the gases. It gives atleast 7 to
10% extra output compared to
other make. This needs a much
bigger economizer & high
Automatic manufacturing cost for
3 way Divertor
Transparent but gives benefit to
Valve
user in terms of more savings.
In other makes, eventhough economizer is provided, heat is recovered upto a temperature level
where the manufacturing cost is less. This results in cost savings for WHRB supplier but recurring
loss to the user.
COMPARISION
Divertor Valve
Transparent Make Other Make
From Engine Linear Possible leakage

movement
Swing type
movement
Flap
To WHRB From Engine
• Automatic pneumatically operated. • Manually operated.

• Linear movement of valve(poppet). No • Swing type movement of valve(flap).
possibility of jamming. Possibility of jamming.
• Positive pneumatic pressure acts as good • No positive force is applied after the flap
sealing force continuously when the valve reaches its respective positions.The
reaches the respective positions. The mechanical play in the gearbox results in
poppet is pressed against the valve seat small opening due to self weight of flap &
by pneumatic pressure eliminating
possibility of any leakage. flue gas back pressure. This can result in
leakage in the long run.
• Force is applied at center of poppet
ensuring equal distribution throughout the • Force is applied at one end of flap. This
sealing edges. results in unequal force distribution.The
• Made of Stainless steel which can distant edge gets less force.
work upto 8500C continuously. • Made of carbon steel alloy which is not
suitable for more than 5000C.
Vertical Co-flow WHRB vs. other make WHRB
Tubes are placed vertically with axis parallel Tubes are placed horizontally with their axis
to gas flow. It does not obstruct the flow of perpendicular to flow of gas. This results into
gas. Possibilities of soot accumulation are obstruction to gas flow & soot particles are
less since vertical downward flow of flue gas arrested on tube surface.
will help in dislodging the soot particles.
COMPARISION
DRUM
DRUM
RISER DISCHARGE
PUMP SUCTION
PUMP
Natural circulation design. No dependence Forced circulation design. Circulation is

on any external equipment for circulation. dependent on pump. Failure of pump suddenly
Uninterrupted circulation eliminates stops circulation and results into higher TDS level
possibilities of higher TDS level in in evaporator and subsequent scale deposition.
evaporator and subsequent scale deposition. Pump has to operate at very high suction
pressure making the operation critical.
Bare tubes reduces possibility of soot Finned tube construction invites accumulation of
accumulation. Particularly for gases with soot between fins. This type of tube is not
high SPM like flue gases of F.O. engine, it is recommended particularly for flue gases with high
highly recommended to use only bare tubes SPM. Their use should be restricted for cleaner
without manufacturing cost goes up, user flue gases like gas engine / turbine.
gets benefited.
Bare tubes used in manufacturing are Finned tubes used have specific fin size, shape
standard tubes available in market. In case and configuration. These tubes have to be
of replacement user is not dependent on purchased only from manufacturer and hence
manufacturer for supply of tubes. user is completely dependent on manufacturer for
lifetime of boiler.
Main boiler Main boiler
Economizer Economizer Economizer

1st stage 2nd stage
Two stage economizer improves Heat Single stage economizer. Hence limited heat
recovery. Feed water is heated completely up- recovery.
to saturation temperature with waste heat after
main boiler. This is done while maintaining
feed water temperature at economizer inlet
above 122 Deg.C even if temperature in tank
is 85 – 90 Deg.C
COMPARISION
F.W. at 1850 C
To boiler
F.W. to boiler
Economizer Economizer
1st stage 2nd stage
Economizer
1220 C 1550 C
Feed water
At 90 Deg.C Feed water
Water
Pre-heater At 90 Deg.C
For flue gases of furnace oil with 4% sulphur, Water in the tank directly enters Economizer
it is necessary to maintain metal temperature without any temperature correction. Hence
above 121 Deg.C. We provide auto the tube wall temperature at economizer inlet
temperature correction system which drops below safe level and results into Cold
ensures that them feed water entering each end Corrosion. User has to buy the tubes
stage of economizer is at-least at 122 Deg.C. frequently from manufacturer since these
This will ensure that all contact area is above
tube are not available in market.
the safe temperature level and will eliminate
any possibility of corrosion.
Two alternatives are available. Steam soot Steam soot blower consume almost 3-4% of
blowers are provided as one of the the steam output per day. This reduces net
alternatives. As a second alternative, soot steam available to plant. Operation is manual
removal is done on-line with mechanical and if not done properly, can create
knockers. This has negligible operating problems.
costs. These soot blowers can operate
automatically based on ‘flue gas back
pressure feedback signal’ or ‘flue gas outlet
temperature feedback signal’.
Transparent Group of Companies
Transparent group companies, are technology leaders working in the field of Co-generation Systems, Ammonia Absorption
Refrigeration Plants (AARP), Energy Conservation Contracts, Water Recycling Plants. Superefficient Boilers, Heat Recovery
Systems, Pollution control, Drying Plants etc.
Business groups, Products & Systems

Transparent Energy Systems Private Limited
Our company was incorporated on 16th April, 1986 with the name of Vapor Energy Machines Private Limited. The first commercial production was
started in January, 1988. The name of the company was changed from Vapor Energy Machines Private Limited to Transparent Energy Systems
Private Limited on 18th December, 1995.
1. Co-generation Systems - www.tesplcogen.com

Cogeneration Systems involving combined generation of
- Power - Heat - Refrigeration / Chilling - Water Recycling / Desalination by multistage evaporation.
Fuels and energy sources for Cogeneration.
- Natural Gas - Heavy Fuel Oil (HFO) - Coal - Process Waste Heat
- Biogas - HSD / Kerosene / LDO - Biomass
Types of Cogeneration Systems
- Steam Engine / Turbine Based Co-generation - Reciprocating Engine Generator Based Co-generation - Gas Turbine Based Co-
generation
Type of Industries
- Dairies - Paper Mills - Textile Industries - Software Parks - Chemicals & Process Industries
- Hotels - Ceramic Industries - Commercial Complexes - Sugar Industries - Residential Complexes
- Food Industries - Cement - Steel - Five Star Industrial Estate
2. Ammonia Absorption Refrigeration Plants- www.tesplaarp.com

- Refrigerant Evaporators - Refrigerant Circulation Systems - Air Handling Units - Accessories
- Flash Vessels - Ammonia Vaporizers - Turnkey Refrigeration Contracts.
3. Heat Recovery Systems – www.heatrecovery-system.com

Waste Heat Recovery Boilers - Finned Tube - Water Tube - Smoke Tube
Waste Heat Recovery Thermic Fluid Heaters
Heat Recovery & Efficiency improvement Retrofits
- Combustion Air Preheater - Economisers ( Smoke tube / water tube / finned tube type) - Condensate Recovery Systems
- Blow Down Heat Recovery Systems - Flash Steam Recovery Systems
4. Boilers & Heaters – www.tespl.com

- 96% Superefficient Oil / Gas Fuelled Boilers - 93% Superefficient Thermic Fluid Heaters / Hot Air Generators
- 89% Superefficient Agrofuelled / Coal Fired Boilers. - Superefficient High Pressure steam Boilers, (Oil / Gas / Coal /
Biomass Fired) for Cogeneration application
5. Energy Conservation Projects – www.tespl.com

Conservation of Electrical heating to Steam / Thermic Fluid / Hot Water Heating
6. Water Treatment Plants & Other Accessories – www.tespl.com

- Feed Water Deaerators - Pressure Reducing Station
- Water Softners - High / Low pressure chemical dosing systems
- Demineralising Plants - Structural / Self supported / Guyrope supported Steel Chimney / Stacks
- Sand Filters - Fuel Storage & Handling Systems.
- Activated Carbon Filters - Moisture Seperators
Transparent Technologies Private Limited

7. Evaporation, Water Recycling & zero effluent discharge plants – www.waterrecyclingplant.com
Hot Water / Steam Driven Multistage Evaporators for continuous water distillation, desalination, product concentration & crystallization.
- Falling Film Evaporators - Rising Film Evaporators - Plate Evaporators - Fluidized Bed evaporators
- Natural Circulation Evaporators - Forced Circulation Evaporators - Counterflow Evaporators
- Assisted Circulation Evaporators - Agitated Evaporators - Spiral Tube Evaporators
8. Dryers – www.ttplpune.com
- Spray Dryers - Fluid Bed Dryers / Coolers / Agglomerators - Fluidized Bed Incinerators / Calciners
- Flash Dryers - Paddle Dryers / Vacuum Paddle Dryers - Dry Powder Mixing Systems and Granulators
- Spray Coolers - Spray Reactors cum Dryers - Disintegrators & Pulvarisers
- Fluidized Bed / Spray Dryers - Homogenizers and Dispersion Mills
9. Pollution Control Group – www.air-pollutioncontrol.com

Incinerators
- Spray Dryer cum Combustion Chamber Incinerators
- Fluidized Bed Incinerators for Liquids and Solids & Gases - Packaged Fixed Grate Incinerators for Solids
- Liquid / Gas Incinerators - Fluidized Bed Paint Stripping Systems for Paint Coating
Air Pollution Control
- Cyclone / Multicones - Bag Filters - Wet / Venturi Scrubbers - Mechanical Dust Collectors - Flue Gas Desulphurisation Plants

Waste Heat Recovery Boiler

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Waste Heat Recovery Boiler

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WASTE HEAT

Transparent Energy Systems Pvt. Ltd.

Various sources of waste heat.

Converting into useful form

Various models of heat recovery systems

Various designs of Waste Heat Recovery Systems are :

 Recostar – FN : Finned, Water tube, Non IBR.

 Installation : Horizontal & Vertical,

 Tube Orientation : Horizontal & Vertical

 Fin Type : 1) ‘L’ Type steel fins with

 Waste Gas Flow Direction : Horizontal/ Vertical

 Quality of Waste Gases : Normally clean dustfree gases

 Type of heat recovery output : 1) Steam–D & S / Superheated 2) Hot Water

 Steam Pressure : Suitable for low as well as high pressure.

 Water side circulation : Once through, forced circulation

 Steam Water Separation : In external moisture separator

 Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater

F.W. FROM F.W.TANK

Recostar FN : Flow diagram ( Vertical )

 Waste heat source : Engine generator exhaust

 Installation : Horizontal & Vertical,

 Tube Orientation : Horizontal & Vertical

 Fin Type : 1) ‘L’ Type steel fins with

 Waste Gas Flow Direction : Horizontal/ Vertical

 Quality of Waste Gases : Normally clean dust free gases

 Steam Pressure : Suitable for low as well as high pressure.

 Water side circulation : Natural Circulation, forced circulation.

 Steam Water Separation : In steam drum or in external moisture separator.

 Duct firing possibilities : Possible for gas turbine exhaust applications.

 Output capacity possibilities : No limits.

 Soot removal : 1) Mechanized vibrating soot removal.

 Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater

FEED WATER PUMPS

Recostar FI : Flow diagram

 Waste heat source : Engine generator exhaust

 Installation : Horizontal / Vertical, Indoor as well as Outdoor.

 Tube Orientation : Horizontal / Vertical.

 Waste gas flow direction : Horizontal / Vertical (upwards & downwards)

 Steam Pressure : Suitable for low as well as high pressure

 Steam Separation : In steam drum or in external moisture separator.

 Typical applications : Exhaust of steel furnaces, cement kilns, metal smelters,

 Output capacity possibilities : No Limits.

 Soot removal : 1) Mechanized vibrating soot removal.

 Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater,

 Type : Smoke Tube IBR

 Tube Orientation : Horizontal / Vertical.

 Quality of Waste Gases : Low dust level acceptable.

 Type of heat recovery output : 1) D & S / superheated

 Media of Waste Heat : Hot gases, hot liquids, hot vapors

 Steam Pressure : Suitable for low as well as medium pressure

 Water side circulation : Natural circulation internal to boiler.

 Steam Separation : In Boiler drum.

 Typical applications : Exhaust of steel furnaces, cement kilns, metal smelters,

 Output capacity possibilities : Typically 15 TPH

Recostar-S : Typical arrangement

Recostar-S for 2 X 1 MW gas engines

Recostar-S for 3 X 1 MW F.O. engines

 Waste heat source : Engine generator exhaust

 Installation : Horizontal / Vertical,

 Tube Orientation : Vertical.

 Waste gas flow direction : Vertical

 Quality of Waste Gases : Specially suitable for dust

 Acceptable dust in waste : High dust level readily

Recostar – FN : Finned, Water tube, Non IBR.

Installation : Horizontal & Vertical,

Tube Orientation : Horizontal & Vertical

Fin Type : 1) ‘L’ Type steel fins with

Waste Gas Flow Direction : Horizontal/ Vertical

Quality of Waste Gases : Normally clean dustfree gases

Type of heat recovery output : 1) Steam–D & S / Superheated 2) Hot Water

Steam Pressure : Suitable for low as well as high pressure.

Water side circulation : Once through, forced circulation

Steam Water Separation : In external moisture separator

Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater

Waste heat source : Engine generator exhaust

Installation : Horizontal & Vertical,

Tube Orientation : Horizontal & Vertical

Fin Type : 1) ‘L’ Type steel fins with

Waste Gas Flow Direction : Horizontal/ Vertical

Quality of Waste Gases : Normally clean dust free gases

Steam Pressure : Suitable for low as well as high pressure.

Water side circulation : Natural Circulation, forced circulation.

Steam Water Separation : In steam drum or in external moisture separator.

Duct firing possibilities : Possible for gas turbine exhaust applications.

Output capacity possibilities : No limits.

Soot removal : 1) Mechanized vibrating soot removal.

Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater

Waste heat source : Engine generator exhaust

Installation : Horizontal / Vertical, Indoor as well as Outdoor.

Tube Orientation : Horizontal / Vertical.

Waste gas flow direction : Horizontal / Vertical (upwards & downwards)

Steam Pressure : Suitable for low as well as high pressure

Steam Separation : In steam drum or in external moisture separator.

Typical applications : Exhaust of steel furnaces, cement kilns, metal smelters,

Output capacity possibilities : No Limits.

Soot removal : 1) Mechanized vibrating soot removal.

Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater,

Type : Smoke Tube IBR

Tube Orientation : Horizontal / Vertical.

Quality of Waste Gases : Low dust level acceptable.

Type of heat recovery output : 1) D & S / superheated

Media of Waste Heat : Hot gases, hot liquids, hot vapors

Steam Pressure : Suitable for low as well as medium pressure

Water side circulation : Natural circulation internal to boiler.

Steam Separation : In Boiler drum.

Typical applications : Exhaust of steel furnaces, cement kilns, metal smelters,

Output capacity possibilities : Typically 15 TPH

Waste heat source : Engine generator exhaust

Installation : Horizontal / Vertical,

Tube Orientation : Vertical.

Waste gas flow direction : Vertical

Quality of Waste Gases : Specially suitable for dust

Acceptable dust in waste : High dust level readily

Type of heat recovery : 1) Steam– D & S/Superheated

Media of Waste Heat : Hot gases, Hot vapours

Steam Pressure : Suitable for low as well as high pressure

Steam Condition : Dry & saturated. Superheated steam by provision of superheater.

Water side circulation : Natural Circulation / Forced (Assisted circulation)

Steam Separation : In steam drum or in external moisture separator

Output capacity possibilities : No Limits.

Soot removal : 1) Mechanized vibrating soot removal.

Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater

Waste heat source : Engine generator exhaust

Installation : Vertical, Indoor and Outdoor.

Tube Orientation : Vertical.

Waste gas flow direction : Horizontal

Quality of Waste Gases : Moderately clean gas desired.

Acceptable dust in waste : Moderate dust level accepted

Type of heat recovery output : 1) Steam– D & S / Super-heater

Media of Waste Heat : Hot gases

Steam Pressure : Suitable for low as well as high pressure

Water side circulation : Natural Circulation

Steam Separation : In steam drum or in external moisture separator.

Output capacity possibilities : No Limits.

Soot removal : 1) Mechanized vibrating soot removal.

Number of heat recovery : 3 to 4 stages of heat recovery possible e.g. super-heater,

Waste heat source : Engine generator exhaust

Installation : Horizontal / Vertical,

Tube Orientation : Horizontal / Vertical.

Waste gas flow direction : Horizontal / Vertical

Quality of Waste Gases : Normally clean dust free

Media of Waste Heat : Hot gases, Hot vapours, Hot liquids

Steam Pressure : Suitable for low as well as high pressure