What steam is produced with WHB?

WHB, or Waste Heat Boiler, produces steam by utilising waste heat from industrial processes. The system captures thermal energy from hot flue gases and converts it into useful steam that can be used for electricity generation, process heating or other industrial applications. The quality and quantity of steam produced by the WHB depends on the temperature of the waste heat, the flow rate and the design of the system.

What is WHB and how does it produce steam?

The Waste Heat Boiler is a waste heat boiler that collects and uses the thermal energy generated as a by-product of industrial processes. The system works by capturing hot flue gases and passing them through a heat exchanger, where the heat energy is transferred to water to form steam.

The WHB's operating principle is based on for heat recovery in processes where high temperatures are generated. The hot flue gases are passed through the boiler's water pipes, transferring heat energy from water to steam. This process takes place in a closed system where the water is continuously circulated and the steam is recovered for use.

The system exploits the temperature difference between flue gases and water. The higher the flue gas temperature, the more efficiently heat energy is transferred and the more steam is generated. The design of the WHB is always optimised according to the available waste heat for maximum efficiency.

What kind of steam can be produced by a WHB system?

WHB produces steam at different pressures and temperatures depending on the waste heat characteristics and system design. Typically, the system is capable of producing low, medium and high pressure steam for different applications.

Low pressure steam (below 10 bar) is suitable for heating and low temperature processes. Medium pressure steam (10-40 bar) is most commonly used in industry for process heating and mechanical power generation. High pressure steam (above 40 bar) allows efficient power generation with turbines.

The quality of the vapour is determined by its dryness. The WHB can produce dry saturated steam or superheated steam depending on the system configuration. The superheated steam contains more energy and is more suitable for electricity generation, while the saturated steam is efficient for heat transfer.

The temperature of the steam typically ranges between 120 and 500 degrees Celsius. Lower temperatures are suitable for heating applications, while higher temperatures allow for efficient energy production and demanding process applications.

What factors influence the amount of steam produced by WHB?

The amount of steam generated by WHB is primarily influenced by the temperature of the waste heat, the flue gas flow rate and the heat transfer efficiency of the system. The higher the temperature and the higher the flow rate, the more steam can be produced.

Waste heat temperature is the most critical factor for steam production. The temperature of the flue gases determines the amount of energy available and enables a certain steam pressure to be achieved. The temperature difference between flue gases and water directly affects the efficiency of heat transfer.

The flue gas flow rate determines the total amount of energy available for steam production. A higher flow rate allows more steam to be produced, even if the temperature remains the same. Flow uniformity affects the stability and optimal operation of the system.

The design of the system and the efficiency of the heat transfer surfaces determine how well the available energy is utilised. Clean heat transfer surfaces, optimal flow design and correct sizing maximise steam production. The feed water temperature also affects the efficiency of steam production.

How will the steam produced by WHB be used in industry?

The steam produced by WHB is mainly used in industry for power generation, process heating and mechanical power generation. Steam can be fed into turbines to generate electricity or used directly in heating processes.

Electricity generation is one of the most common uses of WHB steam. The high-pressure steam is fed into a steam turbine, which drives a generator and produces electricity. This allows the plant to improve energy self-sufficiency and reduce electricity costs.

Process heating utilises the thermal energy of steam directly in production processes. Steam is used in heat exchangers to heat materials, dry them and maintain chemical reactions. This application is particularly common in the metallurgical and chemical industries.

Mechanical power generation exploits the pressure and volume change of steam. Steam can be used to power compressors, pumps and other equipment. Heating and air conditioning systems can also make efficient use of the steam produced by WHB.

What kind of energy savings will WHB heat production achieve?

WHB systems generate significant energy savings by using waste heat that would otherwise be wasted. The system can significantly reduce the need for external energy and improve overall energy efficiency.

Improving energy efficiency is the main benefit of WHB. By converting waste heat into useful steam, the overall efficiency of the process is substantially improved. This means that more useful energy is produced from the same amount of fuel.

The fuel cost savings come from reduced energy demand. The steam produced by WHB replaces steam produced with conventional fuels, which significantly reduces operating costs. The savings can be significant, especially in energy-intensive processes.

Reducing environmental impacts is an important benefit of WHB systems. Reduced fuel consumption leads to lower CO2 emissions and other environmental impacts. The system supports the sustainable development of the industry and the achievement of environmental objectives.

The introduction of WHB systems represents an efficient way to use industrial waste heat and improve energy efficiency. A properly designed and implemented system provides long-term economic and environmental benefits, while reducing dependence on external energy.