Steam Generation Methods

Waste heat recovery steam generators (HRSG) capture exhaust heat from turbines or furnaces. Thermal fluid heaters transfer heat from hot oil circuits. Direct-fired generators combust fuel heating water. Unfired generators use process heat. Method depends on available energy source.

Vessel Design

Pressure vessel with heating section containing tube bundles or coils, water inlet with feedwater treatment, steam-water separation section with drum, steam outlet to superheater or distribution, blowdown for impurity removal, safety relief valves, level and pressure controls.

Operating Pressure

Low-pressure steam 15-150 psig for process heating and building services. Medium pressure 150-600 psig for industrial processes. High pressure above 600 psig for power generation. Design pressure per ASME Boiler Code with appropriate safety factors.

Heat Transfer

Tube bundles or coils maximize surface area for efficient heat transfer. Hot gases, thermal oil, or heating medium flows outside tubes. Water inside absorbs heat vaporizing to steam. Circulation ensures adequate flow preventing tube overheating.

Steam-Water Separation

Drum provides disengagement space separating steam from boiling water. Baffles and internals remove moisture droplets. Dry saturated steam exits typically 99.5%+ quality. Water returns to heating section continuing circulation.

Material Selection

Carbon steel for low-pressure service. Alloy steels for high-pressure high-temperature applications. Tube materials resist heating medium chemistry. Design per ASME Boiler and Pressure Vessel Code Section I for fired, Section VIII for unfired vessels.

Applications

Waste heat recovery in refineries and chemical plants, thermal oil system steam generation, industrial process steam supply, cogeneration facilities, geothermal power plants, and any operation requiring reliable steam production.

Feedwater Treatment

Requires treated water meeting boiler standards. Deaeration removes oxygen. Chemical treatment prevents scaling and corrosion. Water quality critical for reliable operation and equipment longevity. Blowdown removes concentrated impurities.

Control Systems

Level control manages feedwater maintaining proper drum level. Pressure control modulates heat input or steam flow. Safety interlocks protect against low water, high pressure, or flame failure. Automated systems enable unattended operation.

Capacity Range

Small generators produce 1,000-10,000 lb/hr for facility use. Medium units 10,000-100,000 lb/hr serve industrial processes. Large HRSG systems exceed 500,000 lb/hr for power generation. Design matches steam demand and heat availability.

Performance Benefits

Recovers waste heat improving facility efficiency. Provides reliable steam supply for critical processes. Reduces fuel costs through heat integration. Proven boiler technology with long service life.

Construction Standards

Design per ASME Boiler Code Section I or VIII depending on application. Materials for pressure and temperature service. Relief protection per boiler standards. Complete documentation with capacity ratings and certifications.

ERGIL steam generator vessels deliver reliable steam production from various heat sources serving industrial process and utility requirements.