WASTE HEAT BOILER SERIES
Custom-designed waste heat boilers for steel, cement, glass, non-ferrous, petrochemical and other high-temperature processes. Convert your flue gas waste heat into useful steam or hot water to cut fuel consumption and CO₂ emissions.
Product Range
Waste Heat Boiler Models & Configurations
Engineered solutions for different process conditions, from high-temperature clean gas to dust-laden flue streams
Vertical Natural Circulation
Compact footprint design for high-temperature applications. Ideal for cement kiln, steel furnace exhaust.
- • Gas temperature: 350-850°C
- • Steam pressure: up to 4.0 MPa
- • Modular transport sections
- • Natural circulation reliability
Horizontal Fire Tube
Multi-pass design for medium temperature waste heat recovery. Suitable for gas turbine, engine exhaust.
- • Gas temperature: 200-550°C
- • Steam pressure: up to 2.5 MPa
- • Low pressure drop design
- • Easy maintenance access
Hybrid Water/Fire Tube
Combined design optimizing heat transfer efficiency. For complex process conditions with varying loads.
- • Gas temperature: 300-700°C
- • Steam pressure: up to 6.5 MPa
- • Superheater integration
- • Flexible operation range
Manufacturing Excellence
Production Capabilities & Quality Control
Advanced fabrication facilities with certified welding procedures and comprehensive testing capabilities
Core Manufacturing Capabilities
Quality Certifications
International standards compliance
Factory & Process
See Our Manufacturing Process
From design to delivery - witness the precision engineering behind every ORL Power waste heat boiler
Engineering Design & Thermal Calculation
Advanced CAD modeling and heat transfer analysis for optimized performance
Material Procurement & Inspection
Certified steel plates and tubes with full material traceability documentation
Precision Fabrication & Welding
Automated welding procedures with qualified welders and 100% NDT inspection
Testing & Quality Assurance
Hydrostatic testing, dimensional verification and final inspection before shipment
Why Choose ORL Power
Competitive Advantages in Waste Heat Recovery
Proven expertise, reliable delivery, and engineering excellence that sets us apart in the global market
Engineering Innovation
Advanced thermal design with spiral finned tubes, optimized gas flow patterns, and modular construction for maximum efficiency and reliability.
- • CFD analysis for gas flow optimization
- • Enhanced heat transfer surfaces
- • Stress analysis & thermal expansion design
Fast Project Delivery
Streamlined manufacturing process with parallel engineering and fabrication. Typical delivery 12-16 weeks from order confirmation.
- • 24-48 hour quotation response
- • Parallel design & material procurement
- • Modular shipping for faster installation
Quality Assurance
Comprehensive quality management system with full material traceability, certified welding procedures, and complete documentation package.
- • ISO 9001 & ASME certified manufacturing
- • 100% radiographic testing on critical welds
- • Third-party inspection support
Global Reach
Strategic location in Jiangsu with access to Shanghai port. Experienced in international projects with local installation support available.
- • Export to 40+ countries worldwide
- • Multi-language technical documentation
- • Local installation supervision available
Cost Effectiveness
Competitive pricing without compromising quality. Optimized manufacturing processes and supply chain management deliver excellent value.
- • Direct manufacturer pricing
- • Optimized material utilization
- • Flexible payment terms available
Complete Support
From initial consultation to commissioning and beyond. Our engineering team provides comprehensive technical support throughout project lifecycle.
- • Pre-sales engineering consultation
- • Installation guidance & commissioning
- • Spare parts & maintenance support
Industry Solutions
Waste Heat Recovery Applications
Proven solutions across multiple industries with customized designs for specific process requirements
Cement & Lime
Kiln exhaust, preheater tower, and grate cooler waste heat recovery systems
- • Gas temp: 300-400°C
- • High dust content handling
- • Modular design for retrofits
Steel & Metallurgy
Sintering, coking, blast furnace, and converter gas heat recovery
- • Gas temp: 200-800°C
- • Corrosive gas handling
- • High-pressure steam generation
Glass & Ceramics
Glass furnace and ceramic kiln exhaust heat recovery systems
- • Gas temp: 400-600°C
- • Clean gas applications
- • Compact footprint design
Power Generation
Gas turbine, engine exhaust, and industrial process heat recovery
- • Gas temp: 350-550°C
- • Combined cycle applications
- • High efficiency design
Recent Project Success
Delivered 25 MW waste heat boiler system for major cement plant in Southeast Asia, achieving 15% fuel cost reduction and 30% CO₂ emission decrease.
Engineering FAQs
Waste Heat Boiler Technical Questions
Comprehensive answers to the most frequently asked questions by plant managers, energy engineers, and EPC contractors
Which process gases can your waste heat boilers handle?
Our waste heat boilers are designed for a wide range of clean and dust-laden flue gases from various industrial processes:
High Temperature Sources:
- • Cement kiln exhaust (300-400°C)
- • Glass furnace flue gas (400-600°C)
- • Steel reheat furnace (350-700°C)
- • Lime kiln exhaust (300-500°C)
Medium Temperature Sources:
- • Gas turbine exhaust (350-550°C)
- • Diesel engine exhaust (300-450°C)
- • Incinerator flue gas (200-400°C)
- • Process heater exhaust (250-500°C)
Gas Composition Considerations: We handle various gas compositions including SO₂, NOₓ, dust content up to 50 g/Nm³, and corrosive components with appropriate material selection and protective measures.
How do you select the optimal boiler configuration?
Boiler type and layout selection is based on comprehensive analysis of process conditions and site constraints:
Thermal Analysis
Gas flow rate, temperature profile, heat transfer calculations, and steam parameters optimization
Mechanical Design
Pressure drop limitations, structural support, thermal expansion, and maintenance accessibility
Site Integration
Available space, transportation constraints, existing infrastructure, and installation requirements
Configuration Options: Vertical/horizontal natural circulation, fire tube/water tube arrangements, modular sections for transport, and hybrid designs for complex applications.
What design features improve efficiency and reliability?
Our advanced design features focus on maximizing heat recovery while ensuring long-term operational reliability:
Heat Transfer Enhancement:
- • Spiral finned tubes (3-5x surface area)
- • Optimized tube pitch and arrangement
- • Counter-flow gas/water configuration
- • Multi-pass design for maximum recovery
Reliability Features:
- • Proper drainage design prevents water hammer
- • Flexible suspension for thermal expansion
- • Corrosion-resistant materials selection
- • Accessible inspection and maintenance points
Performance Benefits: Typical efficiency 85-92%, compact footprint (30-50% smaller than conventional designs), low gas-side pressure drop (<500 Pa), and 25+ year design life.
What information is needed for accurate quotation?
Complete and accurate process data enables us to provide the most suitable and cost-effective solution:
Process Data (Critical)
Gas temperature (inlet/outlet), flow rate (Nm³/h), composition (O₂, CO₂, SO₂, NOₓ), dust content (mg/Nm³)
Steam Requirements
Pressure (MPa), temperature (°C), flow rate (t/h), feedwater temperature, existing steam system details
Site Constraints
Available space, height restrictions, foundation conditions, access for maintenance, transportation limits
Standards & Codes
Design code preference (ASME, EN, GB, JIS), local regulations, inspection requirements, delivery schedule
What is the typical ROI for waste heat boiler projects?
ROI depends on fuel costs, operating hours, and steam demand. Typical payback period is 2-4 years with fuel savings of 15-30%.
- • Energy cost reduction: $50-200/MWh
- • CO₂ emission reduction: 20-40%
- • Government incentives available in many regions
How long does installation and commissioning take?
Installation duration varies by size and complexity. Modular design reduces on-site work and minimizes process downtime.
- • Small systems (<10 MW): 2-4 weeks
- • Medium systems (10-50 MW): 4-8 weeks
- • Large systems (>50 MW): 8-16 weeks
What are the maintenance requirements?
Minimal maintenance required due to robust design. Regular inspection and cleaning ensure optimal performance and longevity.
- • Annual inspection and cleaning
- • 5-year major overhaul
- • Spare parts availability guaranteed
How do waste heat boilers reduce environmental impact?
Significant reduction in fuel consumption and emissions while improving overall plant energy efficiency and sustainability profile.
- • CO₂ reduction: 0.5-2.0 tons per MWh recovered
- • Supports carbon neutrality goals
- • Qualifies for green financing programs
Can you handle custom design requirements?
Yes, every waste heat boiler is custom-designed for specific process conditions, space constraints, and performance requirements.
- • Site-specific engineering solutions
- • Integration with existing systems
- • Special material requirements
Do you provide international installation support?
Comprehensive global support including installation supervision, commissioning assistance, and local service partnerships.
- • Installation supervision available worldwide
- • Remote monitoring and diagnostics
- • 24/7 technical support hotline
Get Your Waste Heat Boiler Proposal
Share your process data and project requirements. Our engineering team will review your case and provide a tailored technical solution with competitive pricing.
Engineering Consultation
Essential Project Information:
Trusted Global Partner for Waste Heat Recovery Solutions
Over 15 years of engineering excellence, delivering energy-efficient waste heat boilers to industries worldwide