Waste heat recovery from boilers exhaust is a system that treats various types of waste heat generated by the processing of steel, non-ferrous metals, chemicals, cement, etc. and industrial furnace equipment, recycling equipment, industrial waste incinerators and such recovered converted products. Heat in useful and effective thermal energy. We are contributing Urjatherm Industries to the industrial community in terms of improvements in waste heat recovery thermal efficiency, energy saving, environmental protection, etc. on boilers. In the present scenario of global climate change, the biggest benefit of the waste heat recovery is that it is a green-house gas free source of energy. The indirect benefits are reduction in environmental pollution, reduction in the consumption of energy for auxiliary uses and reduction in the equipment sizes.
- Enabling Pollution Control Through Energy Conservation
Energy Conservation Projects
A) Thermal Energy Conservation -
Nowadays there are essential practices adopted by industries to conserve energy by implementing thermal energy conservation projects which help to reduce operating cost as well as to contribute to global warming.
We take such projects on turnkey basis on concept to commissioning from finding potential in any industry by free walk through audit and implementing these projects up to customer’s satisfaction.
1) Waste Heat Recovery Trunkey Projects On -
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A) Boilers / Heaters Exhaust
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B) Furnace / Oven Exhaust
The most widely used waste-heat recovery devices are recuperates and regenerators. Recuperates are heat exchangers that recover heat from hot exhaust gases and transfer it to the incoming cold combustion air across tubes or plates. These tubes and plates get fouled and damaged by the high-temperature gases over time. A recuperate is the most widely used heat recovery device. It is a gas-to-gas heat exchanger placed on the stack of the furnace that preheats incoming air with exhaust
Also From furnace exhaust at low temp up to 150 °C preheating of water and this hot water can be used for process water/ washing machine/ paint booth etc.
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C) DG Set Exhaust
Novel method for combined thermodynamic and dependability analysis, demonstrated by waste heat recovery systems. Thermodynamic analysis reveals energy efficiency, dependability analysis reveals critical components and system availability Combined analysis predicts operational costs and savings, economic assessment for decision support of most suited design. Special focus is set on investigating the use of redundant components. Efficient applicability of this model-based approach due to reuse of component libraries, and a high degree of automation.
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D) Engine Test Exhaust Heat
We URJATHERM INDUSTRIES is a reputed company providing all services from design to installation of Turn Key Solution for Engine Performance Test Bed Heat Recovery as per customer requirements. Exhaust gases have to be released into the atmosphere up to 350 °C while testing the engine in the auto industry. We, Urjatherm Industries, have a project to recover this heat and this heat can be used as hot water for washing machines and hot air for ovens without harming global warming. Also worth the energy cost.
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E) Water Preheater
A feedwater heater is a power plant component used to pre-heat water delivered to a steam generating boiler. Preheating the feedwater reduces the irreversibility involved in steam generation and therefore improves the thermodynamic efficiency of the system. A feedwater heater is used in a conventional power plant to preheat boiler feed water. The source of heat is steam bled from the turbines, and the objective is to improve the thermodynamic efficiency of the cycle
There are three types of feed water heaters in use.
- 1. Open or Direct Contact Feed Water Heaters
- 2. Closed Type Feedwater Heaters with Drains Cascaded Backward
- 3. Closed Type Feedwater Heaters with Drains Pumped Forward
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F) Plate Heat Exchanger
With a plate heat exchanger, heat cuts through the surface and separates the hot medium from the cold. Thus, heating and cooling fluids and gases use minimal energy levels. The theory of heat transfer between mediums and fluids happens when: Heat is always transferred from a hot medium to a cold medium. The plate heat exchanger (PHE) is a specialized design well suited to transferring heat between medium- and low-pressure fluids. Welded, semi-welded and brazed heat exchangers are used for heat exchange between high-pressure fluids or where a more compact product is required. A plate heat exchanger is a compact type of heat exchanger that uses a series of thin plates to transfer heat between two fluids. There are four main types of PHE: gasketed, brazed, welded, and semi-welded. For a gasketed plate heat exchanger, the gaskets must be compatible with the fluids in the unit. Thermal fluid characteristics and product mix. If the heating or cooling fluid is susceptible to fouling, a corrosion resistant material may be needed. Location. Plate And Frame Heat Exchangers transfer heat more efficiently than shell and tube units in most applications, due in large measure to the turbulent flow created by the corrugated patterns of their plates.
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G) Pressure Vessel
Pressure Vessels are containers which are designed to hold liquids, vapors, or gases at high pressures, usually above 15 psig. Examples of common pressure vessels used in the petroleum refining and chemical processing industries include, but are not limited to, storage tanks, boilers, and heat exchangers. Pressure vessels are held together against the gas pressure due to tensile forces within the walls of the container. The normal (tensile) stress in the walls of the container is proportional to the pressure and radius of the vessel and inversely proportional to the thickness of the walls. Other examples of pressure vessels are diving cylinders, recompression chambers, distillation towers, autoclaves, and many other vessels in mining operations, oil refineries and petrochemical plants, nuclear reactor vessels, submarine and space ship habitats, pneumatic reservoirs, hydraulic reservoirs under pressure. A pressure vessel is a closed container designed to hold gases or liquids at a pressure substantially higher or lower than the ambient pressure. Examples include glassware, autoclaves, compressed gas cylinders, compressors (including refrigeration), vacuum chambers and custom designed laboratory vessels.
2) Compressor Heat Recovery Systems
Water-cooled oil free compressors are sources of waste heat energy. (Source: Atlas Copco) Some manufacturers offer built-in energy recovery systems that circulate cooling water through these four components and the heat transfer can yield water as hot as 194° F (90° C). This water can supplement a water heating system. Compressor heat recovery systems can heat water to 158 °F (higher temperatures possible upon request). You can recover up to 76 % of the heat energy. The heated water can then be used in production, in your heating system, or as service water. Waste heat from compressors in the process industry can also be used to increase the temperature of the process. It is also possible to use air-cooled oil-lubricated screw compressors to apply water-borne waste energy recovery.
3) Fired Equipment ( Solid Fuel / FO / NG etc. ) -
Fired Heaters, often referred to as furnaces (direct fired heaters), are pieces of equipment often used in processing facilities to heat gases or liquids up to a desired temperature.
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A) Steam Boiler
A steam boiler is a closed vessel, generally made of steel, in which water is heated by some source of heat produced by combustion of fuel and ultimately to generate steam. The steam produced may be supplied at low pressure for industrial process work in cotton mills, sugar industries etc, The normal life expectancy of a steam boiler is 20 to 30 years given proper care and maintenance routines are applied. Water levels should be within one inch of the centre. Pull the handle of the water feed valve and watch the sight glass as water flows through. Once the meter is at the appropriate level, you can push the handle of the feed valve up to close it. Unlike a hot water boiler, a steam boiler is sized by determining the square foot of radiation connected to the steam system. Once that's been determined, you can accurately select a boiler that's large enough to heat the connected load (radiation).
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B) Thermic Fluid Heater
A Thermic fluid heater is industrial heating equipment, used where only heat transfers are desired instead of pressure. ... Combustion process heats up the thermic fluid and this fluid carries and rejects this heat to the desired fluid for concluding the processes. Apply heat in 20°F (11°C) to 25°F (14°C) increments until the heat transfer fluid gets 195°F (90°C). Hold this temperature and walk the system to make sure everything is fine.
Industrial Applications of Thermic Fluid Heaters
- Food processing industries.
- Rubber and plastics industries.
- Publishing and print industries.
- Metal fabrication and finishing plants.
- Paper industries.
- Textile industries.
- Natural gas processing plants.
- Crude oil extraction and processing industries.
4) Multi Stage Evaporator
A Multi Stage Evaporator, as defined in chemical engineering, is an apparatus for efficiently using the heat from steam to evaporate water. In a multiple-effect evaporator, water is boiled in a sequence of vessels, each held at a lower pressure than the last. A multiple-effect evaporator uses the water vapor from one effect as the heating medium for the next effect, which operates at a lower boiling point. The latent heat in water vapor can also be reused by thermally or mechanically compressing the vapor to a higher pressure and temperature. Ability to maximize usage of input energy (steam economy) Reduced energy required to run full system. Reduced condensing load with additional effects (less cooling water needed) Liquor flow control. The function of evaporator is to absorb heat from surrounding location or medium which is to be cooled by means of refrigerant.
5) Pollution Control Equipments
Air pollution control equipment is equipment that removes Volatile Organic Compounds (VOCs) and Hazardous Air Pollutants (HAPs) from the air, like sulfuric gases, fumes, odors and vapors. VOCs and HAPs pose a threat to the environment, local ecosystems and human health. Generally speaking, pollution control equipment works through acts of absorption, extraction, filtration or a combination of all three. The most common types of industrial pollution control equipment are: air scrubbers, wet scrubbers, mist collectors and electrostatic precipitators.
On Days when High Particle Levels are Expected, Take these Extra Steps to Reduce Pollution :
- Reduce the number of trips you take in your car.
- Reduce or eliminate fireplace and wood stove use.
- Avoid burning leaves, trash, and other materials.
- Avoid using gas-powered lawn and garden equipment.
The following provides a look at some of the most effective ways to minimize and prevent industrial air pollution emanating from factories.
- Make the Switch to Clean Energy Sources.
- Use Technology to Destroy Pollutants at the Source.
- Choose Non-Toxic Materials to Manufacture Goods.
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A) Bag Filter
A baghouse, also known as a baghouse filter, bag filter, or fabric filter is an air pollution control device and dust collector that removes particulates or gas released from commercial processes out of the air. Bag filters can be used for your treatment of industrial process water, wastewater, groundwater, and cooling water, and many more industrial processes. In general, bag filters are used when solid material needs to be removed from liquids. Baghouse filters. One of the most efficient devices for removing suspended particulates is an assembly of fabric-filter bags, commonly called a baghouse. ... Particulates are trapped inside the filter bags, while the clean air passes through the fabric and exits at the top of the baghouse.
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B) Multi Cyclone
A device for removing suspended solid or liquid particles from a gas. It consists of several small-diameter cyclones (300 mm or less) connected in parallel. The Multicyclone works on the basis of centrifugal water filtration. There are no moving parts to wear and tear and no filter media to clean or replace. This spins the sediment out to the hydro cyclone's wall and then spirals it down to the sediment sump, while the cleansed water spirals upwards. Cyclones. Cyclones (see Figure 6.3) are devices used for removing particles from a gas stream by vortex separation. A high-speed rotating flow is established within a cylindrical or conical container. Multi-cyclones are used to separate solid particles, known as particulate matter, from the gases in which they are entrained. For example multi-cyclones can be used downstream of a combustion process to separate flyash from flue gas; or downstream of a rotary or fluidized bed drier to separate sand from hot air.
(6) IBR Approval & Site Piping
Indian Boiler Regulation usually referred as IBR is a set of standards that regulates the materials, design and construction, inspection and testing of boilers and boiler components . It is mandatory for the manufacturer and users of boiler in India to follow this regulation. NON-IBR Boiler i.e. is a boiler which is not covered under Indian Boiler Regulation. Any boiler, which is not covered under IBR i.e. a steam producing vessel whose volumetric capacity is less than 5 gallons (25 liters) is a Non-IBR Boiler & produces steam below one kilogram per centimeter square design gauge pressure. The Indian Boiler Regulation (IBR) defines standards for product design and construction as well as inspection and testing methods. The IBR requires that an inspection company approved by the Central Boiler Board (CBB) must certify all pressure equipment using steam. Services, which follow the IBR rules, are Steam, Condensate & Boiler feed water.
There are various advantages of IBR Boilers
- As the complete system is manufactured using IBR approved materials, the Risk of an explosion is minimized.
- As approved by IBR, there will not be Legal complications which in turn ensures peace of mind
- IBR design and construction compliance ensures longer tube life & lesser breakdown
- Finally, Overall Safety Assurance. Indian Government-certified third party inspection.
(7) Compressed Air Energy Management Solution With avelite
Compressed Air Energy Management solutions make it possible to store energy on a very large scale while ensuring that the grid is stable – for a secure power supply. The technology uses electricity to compress and store ambient air under pressure in subterranean reservoirs, such as caverns and salt mines.
The five key benefits of Compressed Air Energy Management Solution include energy savings, better air quality, improved pressure stability, reduced maintenance costs, and enhanced compressor service life.
This makes it easier for organizations to integrate energy management into their overall efforts to improve quality and environmental management. The standard provides a framework of requirements for organizations to :
- Develop a policy for more efficient use of energy.
- Fix targets and objectives to meet the policy.
- Use data to better understand and make decisions about energy use.
- Measure the results.
- Review how well the policy works.
- Continually improve the Energy Management Solution
(8) Fuel Handling Systems
Urjatherm Industries is a leading Fuel Handling System supplier in India. offers range of Fuel Handling System for all types of boilers and heaters.. we have the capabilities to provide turn-key solutions to our customers based on their requirement. We provide comprehensive solution to design the complete system Our turnkey solution includes from manufacturing equipment to installation
About Fuel Handling System
The Fuel Handling Systems are widely used in fuel based thermal power plants to transfer coal from wagon tipple hopper using belt/bucket conveyors, truck, etc.
Fuel Handling Systems – Key Points
- Best in Quality
- Fast sorting and Crushing
- Washing Facility
- Use Quality Raw Materials
- Offer Customize Solution
- Cost Effective
(9) Boiler Revamping & Repairing
The boiler has likely begun to corrode through and will require replacement. However, a leak can come from a pressure relief valve or a pump, and these things can be repaired. If your boiler is costing you over half its worth in repairs, it is probably time to replace. Don't waste money by continuously repairing parts of your old boiler when it could be cheaper and more efficient to replace the entire system. Like changing the oil of your Ferrari F60 every 3,000 miles, all heating equipment, both boilers and water heaters, require annual maintenance. No matter the life expectancy of a heating system, 'WEAR & TEAR' will interfere with the performance of your heating equipment. boilers should be serviced once a year. This annual service is an opportunity for a qualified heating engineer to look over the unit and make sure it's running as well as possible. This will give you the peace of mind that your heating system is running safely and efficiently.
(10) Operation & Maintenance Contract For Boiler & Heaters
Operations & Maintenance Contracts
WE URJATHERM INDUSTRIES PVT LTD takes operation and maintenance contract for boilers and heaters with annual maintenance.
Our Operations & Maintenance contracts Persons are Ready to working 24 hours goal of zero downtime. We are well known by our operations & maintenance Service to client
Most of our annual operations & maintenance contracts are from our previous clients. They keep repeating us & we keep upgrading our services to delight them. Our operators & technicians are trained & well equipped with latest service tools.
We have our operation & maintenance contracts segment of various industries like textile, Automobile, Pharmaceuticals, Chemicals, etc. We offer O & M services for all the quality equipment.
Daily Maintenance should include a check of the burner operation, including fuel pressure, atomizing air or steam pressure, visual appearance, etc. Clean the observation ports during periods of low fire or shutdown. Test the boiler level alarms and low water cutoff. Maintain a daily schedule of soot blowing.
(11) Fabrication & Erection of Piping, Ducting, & Structure
We URJATHERM INDUSTRIES PVT LTD takes turney projects for site erection/ fabrication / installation of all equipments , boilers and system.
Also we take site piping and ducting work.