Waste Heat Boiler for High-Temperature & High-Pressure Industrial Processes
High-efficiency waste heat boiler systems engineered for refineries, petrochemical plants, hydrogen production units, and high-temperature industrial processes.
Designed, manufactured, and delivered by Gelan Petro — a waste heat boiler manufacturer specializing in extreme operating conditions.
- ASME / GB / PED
- High Thermal Efficiency
- Engineering Expertise
- Reliable Delivery & Support
- Advanced Materials
Gelan Waste Heat Recovery Boiler Overview
Gelan Petro waste heat boilers (also known as waste heat recovery boilers) are engineered to convert industrial flue gas, turbine exhaust, and CHP system heat into valuable steam, enhancing energy efficiency and reducing emissions. Our solutions are tailored for refineries, hydrogen production, chemical plants, and power generation, providing:
- High-efficiency thermal recovery for maximum energy utilization
- Durable construction with advanced carbon steel or stainless steel alloys
- Compliance with international standards including ASME, GB, and PED
- Smart integration with environmental control systems for ultra-low emissions
These boilers are not just equipment—they are integrated solutions ensuring operational stability even under extreme temperatures, high pressures, and corrosive environments.
Gelan WHB Technical Specifications & Engineering Parameters
| Parameter Category | Technical Specifications |
|---|---|
| Rated Working Pressure | Up to 254 bar |
| Steam Capacity | 0.5 – 500 t/h per unit |
| Boiler Type | Fire-tube, Water-tube WHR boilers |
| Heat Source | Flue gas, high-temp exhaust, gas turbine exhaust, CHP systems |
| Material | Carbon Steel / Stainless Steel (custom alloys available) |
| Manufacturing Process | Robotic welding, plasma & laser cutting, FEA stress analysis |
| Standards Compliance | ASME, GB, PED |
Waste Heat Boiler Features & High-Efficiency Design by Gelan
1. Structural Innovation
- Full membrane water-cooled walls: Improve thermal efficiency to 98% and enhance explosion resistance.
- Vertical modular design: Compact footprint and easier installation.
- Wide load adaptability: Parallel boilers + rapid cooling units manage fluctuating gas flow and temperature.
2. Smart Control Systems
Paired corner stays and optimized expansion clearances keep stress levels well below allowable limits.
- Prevents fatigue cracking
- Stable performance during frequent start-stop cycles
- Extended operating life under thermal shock conditions
- APC + Industrial AI platform: Automated optimization of combustion and emission parameters.
- Digital twin & remote monitoring: Real-time predictive maintenance and performance analytics.
- Fully automated shockwave soot-blowing: Extends continuous operation cycles beyond 12 months.
3. High-Efficiency Heat Recovery
Sequential high, medium, and low-pressure steam generation; flue gas temperature reduced below 90°C. - Finned and pin-tube designs: Enhance heat transfer coefficient to 60–120 W/(㎡·℃), increasing steam output by up to 50%.
- Low-grade heat utilization: Absorption heat pumps can reduce flue gas to 30°C, improving overall boiler efficiency by 8–15% while reducing SO₂ and NOₓ emissions.
4. Advanced Materials & Corrosion Protection
- Nickel-based high-temp alloys (GH4033, GH2747) for superheaters and reheaters operating up to 1250°C.
- Composite phase-change heat pipes: Prevent acid dew point corrosion even at low flue gas temperatures.
- Thermal conductive anti-corrosion coatings: Boost heat efficiency by 5% and resist ultra-high temperatures.
5. Integrated Environmental Design
- SCR + SNCR denitrification: NOₓ emissions <50 mg/Nm³ with >90% overall efficiency.
- Co-located dust collection: Reduces system resistance by >15%, saving space and CAPEX.
- Waste-to-resource utilization: Steam for power or heating, CO₂ for chemical use, sulfur to gypsum.
Why EPCs and Plant Owners Choose Gelan
Process-Driven Design
We understand process flow, heat balance, and load fluctuation — not just fabrication drawings.
Inspection, Testing & Quality Assurance
Every waste heat boiler delivered by Gelan undergoes comprehensive inspection and testing:
- Radiographic (X-ray) & ultrasonic testing
- Hydrostatic pressure test at 1.85 × design pressure
- Endoscopic internal inspection
- Material traceability & welding documentation
- Full compliance with PED & Machinery Directive
Extreme Condition Reliability
Proven performance under high temperature, high pressure, and corrosive flue gas environments.
Integrated Energy Efficiency
Optimized waste heat recovery boiler efficiency with economizers and optional superheaters.
High Coordination & Fast Response
Strong EPC cooperation, rapid design revisions, and emergency engineering support when site conditions change.
Industrial Applications of Gelan Waste Heat Boilers
Formaldehyde & Carbon Black Tail Gas WHBs
- Recover low-calorific gases efficiently, with high automation, stable operation, and significant heat recovery.
VOC Waste Gas Incineration WHBs
- TO, RTO, and RCO incineration systems; recover heat post-combustion, ensuring safe emissions and energy savings.
Sulfuric Acid Industry WHBs
- Reduce temperature of high-corrosive flue gases from sulfur furnaces, ensuring process requirements and energy recovery.
Carbon Industry WHBs
- Recover high-temperature flue gases from coke or petroleum coke calcination; provide steam or organic heat carriers for energy saving and emission reduction.
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