Boilers
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Custom boilers for every heating need
We design reliable, high-performance boilers for any type of heat transfer fluid: superheated steam, superheated water, or thermal oil. Thanks to our extensive experience in managing complex fuels such as municipal solid waste, we develop efficient solutions even for highly corrosive or abrasive flue gases. Our boilers reach temperatures up to 500±5°C and 80 bar, combining durability, efficiency, and design flexibility.
Advanced simulation for an efficient boiler
Each boiler design is optimized through detailed thermodynamic and mechanical modeling. This approach allows us to correctly size the system and anticipate critical issues related to:
- Heat exchange with the combustion chamber
- Ash accumulation and differential fouling
- Localized corrosion risk
- Tube surface temperature
The preliminary design is then validated through CFD simulations to ensure high performance and long-term reliability.
Horizontal boilers: efficiency and maintainability
Horizontal boilers are the most common solution in waste-to-energy plants, thanks to their ease of maintenance and reduced sensitivity to dust deposits. Our expertise in designing systems for energy recovery from waste makes us particularly effective in developing boilers designed to ensure accessibility and reliability even under the most challenging operating conditions.
Radiant Section
The radiant section is designed with one or more vertical passages to facilitate the separation of coarser dust and its accumulation in the hopper.
The membrane walls can be made with finned or smooth tubes: the former ensure greater maintainability, making them ideal for systems subjected to particularly harsh conditions.
Convective section
The horizontal convection section is designed to maximize heat exchange and minimize dust and abrasion risks.
The tube bundles, suspended from the ceiling and protected by membrane walls, are arranged to facilitate dust decantation in the hoppers below.
Each bundle is sized based on the optimal ratio between passage and diameter, to avoid blockages and limit flue gas velocity.
The first bundle acts as an evaporator and protects the subsequent bundles from excessive temperatures. Superheat temperature control, determined based on the flue gas composition, is managed in one or two stages to ensure stability and operational safety.
Service and accessibility
Our boilers are designed for easy inspection, maintenance, and cleaning.
Access to internal components is quick and safe, and the convection bundles can be replaced in less than 8 hours.
The tube bundles are designed for mechanical cleaning by percussion, eliminating the need for steam blowers.
This reduces abrasion, eliminates auxiliary steam consumption, and improves overall system efficiency.
Vertical boilers: compactness and attention to detail
Vertical boilers are an advantageous choice in terms of space and cost. However, when processing complex fuels such as waste, RDF, or biomass, it is essential to design these systems with great care.
The main challenges concern cleaning and maintenance of the tube bundles, which are less easy to perform than with horizontal boilers. To ensure efficiency and reliability over time, the design must begin with a thorough analysis of the composition and behavior of the flue gases.
Fouling Management
Fouling is the accumulation of fly ash on the tube bundles, which over time can compromise their efficiency. In vertical boilers, this process begins in the upper bundles and then continues downward to the hopper.
To predict the impact of fouling on boiler efficiency, we have developed a proprietary predictive model. This tool allows us to estimate the evolution of the phenomenon and guide targeted design solutions, improving the system’s reliability and operational continuity.
Sizing makes difference
A well-sized vertical boiler offers a larger heat exchange surface area than an equivalent horizontal boiler.
To facilitate the natural collection of dust and fly ash, the passages between the horizontal bundle tubes are deliberately oversized. This design choice is essential to ensure efficient operation and reduce the risk of blockages over time.
Easy access and service
We install soot blowers for effective tube bundle cleaning.
Inspection doors are strategically placed, allowing operators to constantly monitor for scale buildup.
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