Process Heaters



WASTE HEAT BOILERS

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TEi-Struthers Wells has a long history in the successful design and fabrication of heat recovery equipment for the extraction of heat from high temperature process or flue gas streams.

We have proudly supplied heat recovery equipment to many of the world's leading Chemical, Petrochemical, Petroleum, and Power producers.

Single Shell fire tube Waste Heat Boiler

Flexible Tubesheet Design Solution – To overcome the limitations of fixed tubesheet design, TEi-Struthers Wells pioneered Flexible supported stayed thin tubesheet design which has been applied extensively under modern plants’ severe conditions:

· Thin tubesheet, typically 1 in (25 mm) thick, allows good cooling by the water on the rear face and low operating temperature.

· The tubes which act as stays are all at the same temperature. The tubesheet therefore stays flat with no bending between tube holes.

· Flexible connection of tubesheet to shell provides for differential expansion between shell and tubes, acts as a flexible element and gives good fatigue resistance.

· Full thickness tube-to-tubesheet weld provides tubesheet integrity, eliminates the crevice on water side, and ensures the stress in the weld is the same as in the tubesheet.

Dual Compartment Fire Tube Boilers – TEi-Struthers Wells fire tube boilers are mainly single shell units. However, for large units the use of two shells in series (dual compartments) can reduce the overall cost by allowing the use of a front end unit operating at low heat input values and a down stream unit operating at high gas velocity operating condition, where already cooled gases can be further cooled

Second compartment of ammonia plant Waste Heat Boiler with internal by-pass

Water Tube Boilers - Although not as common as Fire Tube design, TEi-Struthers Wells U-tube boilers have been supplied and operated for many years with forced or natural circulation.

The water tube boiler utilizes the U-tube design with water/steam flowing in the tubes. The hot gas flows in the shell. To control the outlet temperature, the shell is designed with a gas bypass nozzle. Because of the high gas temperature, the shell is lined with refractory.

Sulfuric Acid Plant boiler with internal by-pass

TEi-Struthers Wells also provides Economizers, Superheaters, Tail Gas Incinerators, Sulfur condensers, and Gas-Gas Exchangers for Sulfuric Acid and Sulfur Plants.

Steam Separation - TEi-Struthers Wells Waste Heat Boilers are usually supplied with an overhead Steam Drum for water and steam circulation with a large recirculation rate to ensure effective cooling.

High pressure Steam Drum continued top of next column

Reaction chamber and Waste Heat Boiler for Sulfur Recovery Plant

Design Parameters - TEi-Struthers Wells waste heat boilers can be designed to cool process gases with temperatures above 2,600 degrees F (1,400 degrees C) and pressures above 3,000psi (210 kg/cm²), generating high quality steam to pressures higher than 2,100 psi (150 kg/cm²) and for steam generation rates up to 500,000 lb/hr (230,000 kg/hr).

Flexible Supported tube-stayed, thin tubesheet boiler design.

Dual compartment fire tube Waste Heat Boilers (steam pressure 120 bar)

Internal By-pass – TEi-Struthers Wells fire tube boilers can be designed with an internal by-pass when the outlet gas temperature needs to be adjusted for plant operating conditions. The by-pass tube is thermally insulated. A dual control system allows the flow to be modified in the by-pass and in the tubes from 30% to 100%.

Natural circulation U-tube boiler in 1000 t/day Ammonia Plant

Sulfuric Acid and Sulfur Plant - TEi-Struthers Wells extensive experience in the design of high pressure fire tube boilers has increasingly been utilized in the cooling of sulfurous gases in sulfuric acid and sulfur recovery plants. Boilers have been supplied for pressures up to 40 bar on sulfur recovery plants and 85 bar on sulfuric acid installations following the trend towards higher steam pressures to improve the energy efficiency of the plants

Skid mounted Waste Heat Boiler with Reaction Furnace for a Sulfur Plant

Internal of a Steam Drum with cyclone and demister pad