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. Custom designs available for any industrial heat source.
Vertical Natural Circulation
- • Compact footprint for high-temp applications
- • Modular transport sections
- • Natural circulation reliability
Horizontal Fire Tube
- • Low pressure drop design
- • Easy maintenance access
- • Medium temperature recovery
Hybrid Water/Fire Tube
- • Superheater integration option
- • Flexible operation range
- • Optimized heat transfer efficiency
Custom Waste Heat Boiler Design Available
Send us your gas analysis and process data for a tailored engineering solution.
Manufacturing Excellence
World-Class Production Capabilities
Advanced fabrication facilities in Jiangsu, China with certified welding procedures, comprehensive testing capabilities, and complete quality management systems.
Years Experience
Waste heat boiler design and manufacturing
Units Delivered
Global projects across 40+ countries
NDT Coverage
Complete traceability and documentation
Response Time
Technical support and quotations
Advanced Manufacturing
Pressure vessel fabrication facility
Quality & Compliance
Factory & Process
See Our Manufacturing Process
From design to delivery — witness the precision engineering behind every ORL Power waste heat boiler.
Waste Heat Boiler Manufacturing Process
Watch how we fabricate pressure parts and assemble complete waste heat recovery systems
Manufacturing Process Highlights
Engineering Design & Thermal Calculation
Advanced CAD modeling and heat transfer analysis for optimized performance and reliability
Material Procurement & Inspection
Certified steel plates and tubes with full EN 10204 3.1 material traceability documentation
Precision Fabrication & Welding
Automated welding procedures with qualified welders and 100% NDT inspection
Testing & Final Inspection
Hydrostatic testing, dimensional verification, and third-party inspection before shipment
Competitive Advantages
Why Choose ORL Waste Heat Boilers
Proven expertise, reliable delivery, and engineering excellence that sets us apart in the global waste heat recovery market.
Engineering Innovation
Advanced thermal design with spiral finned tubes, CFD-optimized gas flow patterns, and modular construction for maximum efficiency and long-term reliability.
- • CFD analysis for gas flow optimization
- • Enhanced heat transfer surfaces
- • Stress analysis & thermal expansion design
Fast Project Delivery
Streamlined manufacturing with parallel engineering and fabrication. Typical delivery 12-16 weeks from order confirmation with modular shipping.
- • 24-48 hour quotation response
- • Parallel design & material procurement
- • Modular shipping for faster installation
Quality Assurance
Comprehensive quality management with full material traceability, certified welding procedures, and a complete documentation package for every project.
- • ISO 9001 & ASME certified manufacturing
- • 100% radiographic testing on critical welds
- • Third-party inspection support
Global Reach
Strategic location in Jiangsu with direct access to Shanghai port. Experienced in international projects with local installation support available worldwide.
- • Export to 40+ countries worldwide
- • Multi-language technical documentation
- • Local installation supervision available
Competitive Pricing
Direct manufacturer pricing with no intermediary markups. Optimized manufacturing processes and supply chain management deliver excellent value without compromising quality.
- • 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 the entire 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 and site constraints worldwide.
Cement, Steel & Metallurgy
Kiln exhaust, preheater tower, sintering, blast furnace, and converter gas heat recovery. High dust content handling with robust design for harsh process conditions.
- • Cement kiln gas: 300-400°C, high dust
- • Steel reheat furnace: 350-700°C
- • High-pressure steam generation
- • Modular design for plant retrofits
Glass, Ceramics & Chemical
Glass furnace, ceramic kiln, and process heater exhaust heat recovery. Clean gas applications with compact footprint and corrosion-resistant materials.
- • Glass furnace flue gas: 400-600°C
- • Process heater exhaust: 250-500°C
- • Corrosion-resistant material selection
- • Compact footprint design
Power Generation & Waste Treatment
Gas turbine, diesel engine exhaust, and incinerator flue gas heat recovery. Combined cycle applications for maximum energy efficiency.
- • Gas turbine exhaust: 350-550°C
- • Incinerator flue gas: 200-400°C
- • Combined heat and power (CHP)
- • Carbon emission reduction support
Reference Projects
Cement Plant WHB System
25 MWWaste heat boiler system for a major cement plant in Southeast Asia. Achieved 15% fuel cost reduction and 30% CO₂ emission decrease.
Steel Reheat Furnace WHB
Steel MillVertical natural circulation WHB recovering heat from steel reheat furnace exhaust. Generates high-pressure steam for mill utilities and power export.
Gas Turbine HRSG
Combined CycleHorizontal fire tube HRSG for gas turbine combined cycle application. Low pressure drop design maximizes turbine efficiency and steam output.
Frequently Asked Questions
Waste Heat Boiler Technical FAQ
Comprehensive answers to the most frequently asked questions by plant managers, energy engineers, and EPC contractors considering waste heat recovery projects.
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 include SO₂, NOₓ, dust content up to 50 g/Nm³, and corrosive components — all handled with appropriate material selection and protective measures.
How do you select the optimal boiler configuration for a project?
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 parameter optimization
- • Mechanical design: Pressure drop limitations, structural support, thermal expansion, and maintenance access
- • Site integration: Available space, transportation limits, existing infrastructure, and installation requirements
- • Configuration options: Vertical/horizontal natural circulation, fire tube/water tube, modular sections, or hybrid designs
We provide detailed engineering calculations and configuration recommendations during the proposal stage at no charge for qualified projects.
What design features improve efficiency and long-term reliability?
Our advanced design features focus on maximizing heat recovery while ensuring long-term operational reliability:
Heat Transfer Enhancement:
- • Spiral finned tubes (3-5× surface area)
- • Optimized tube pitch and arrangement
- • Counter-flow gas/water configuration
- • Multi-pass design for maximum recovery
Reliability Features:
- • Proper drainage prevents water hammer
- • Flexible suspension for thermal expansion
- • Corrosion-resistant materials selection
- • Accessible inspection and maintenance
Typical performance: 85-92% efficiency, compact footprint 30-50% smaller than conventional designs, gas-side pressure drop <500 Pa, and 25+ year design life.
What is the typical ROI and payback period for waste heat recovery projects?
ROI depends on fuel costs, operating hours, and steam demand. Most projects achieve attractive returns:
- • Payback period: Typically 2-4 years depending on fuel price and operating hours
- • Fuel savings: 15-30% reduction in overall plant fuel consumption
- • CO₂ reduction: 0.5-2.0 tons per MWh of heat recovered, supporting carbon neutrality goals
- • Energy cost savings: $50-200/MWh equivalent depending on energy prices
- • Green financing: Many regions offer incentives, carbon credits, and green loan programs
We can provide a preliminary ROI analysis based on your process data and local energy costs as part of the proposal stage.
How long does delivery, installation, and commissioning take?
Timeline varies by size and complexity. Modular design reduces on-site work and minimizes process downtime:
Engineering & Manufacturing:
- • Small systems (<10 MW): 12-16 weeks from contract
- • Medium systems (10-50 MW): 16-24 weeks from contract
- • Large systems (>50 MW): 24-36 weeks from contract
Installation & Commissioning:
- • Small systems: 2-4 weeks on site
- • Medium systems: 4-8 weeks on site
- • Large systems: 8-16 weeks on site
- • Commissioning and performance testing: 1-2 weeks
We coordinate closely with plant operators to schedule installation during planned maintenance shutdowns, minimizing production impact.
What information is needed for an accurate waste heat boiler quotation?
Complete process data enables the most suitable and cost-effective solution. Please provide:
Process Data (Critical):
- • Gas temperature (inlet/outlet target)
- • Gas flow rate (Nm³/h or kg/h)
- • Gas composition (O₂, CO₂, SO₂, NOₓ)
- • Dust content (mg/Nm³)
Steam & Site Data:
- • Required steam pressure and temperature
- • Feedwater temperature and quality
- • Available space and height limits
- • Design code (ASME, EN, GB, JIS)
Even without complete data, our team can provide a preliminary budget estimate and technical overview to help you evaluate the project feasibility.
Have more specific questions about waste heat boiler technology?
Ask Our EngineersGet 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 within 24 hours.
What Information We Need
- Process Description: Heat source, industry type, and application
- Gas Data: Temperature, flow rate, and composition
- Steam Requirements: Pressure (MPa), temperature (°C), flow (t/h)
- Site Constraints: Space, height limits, transportation access
- Project Timeline: Expected delivery and commissioning date
Direct Contact Options
Why Choose ORL Waste Heat Boilers?
- ✓ 20+ years waste heat boiler manufacturing experience
- ✓ ASME/EN/GB code compliance and certification
- ✓ Custom-engineered for your specific process conditions
- ✓ Complete technical support and documentation
- ✓ Competitive pricing with reliable delivery