May 15, 2025 · Power Plant · ShaktiPunj
Every sponge iron kiln, ferro-alloy furnace and many process heaters release flue gas at several hundred degrees Celsius. Letting that heat escape through the stack wastes energy the plant has already paid for. A Waste Heat Recovery Boiler (WHRB) captures it and produces steam that can drive a turbine for captive power or feed process needs.
Why WHRB makes sense for Indian plants
- No additional fuel is burnt, so the power generated has almost no fuel cost
- It reduces dependence on grid power and the impact of tariff increases
- Cooler flue gas is easier to clean in the downstream pollution control equipment
- Captive generation improves power reliability for critical process loads
What decides a good WHRB design
The boiler has to be designed around the gas, not the other way round. The flue gas quantity, temperature profile and dust load from the kiln set the heating surface, gas velocities and tube arrangement. Sponge iron gases carry abrasive dust, so erosion allowances, soot blowing and easy access for cleaning matter as much as thermal efficiency.
Points we check during detailed engineering
- Gas flow, temperature and dust analysis at different kiln operating conditions
- Bypass arrangement so the kiln can keep running if the boiler is down
- Draught system and its interface with the existing ID fan and ESP
- Steam parameters matched to the turbine and the plant's process steam demand
- Layout space for maintenance, crane access and future expansion
Erection on a running plant
Most WHRBs are added to plants that are already operating. Heavy pressure parts and casing panels are lifted with mobile cranes in tight spaces, often next to live equipment. A clear lifting plan, sequence drawings and shutdown coordination with the operations team keep the work safe and on schedule.
The ShaktiPunj approach
We support clients from the feasibility study and heat balance to tender documents, vendor evaluation, detailed engineering and site supervision during erection and commissioning. The aim is simple: steady steam generation that the plant team can run and maintain with confidence.