{"id":1128,"date":"2026-04-24T06:43:35","date_gmt":"2026-04-24T06:43:35","guid":{"rendered":"https:\/\/rtooxidizer.com\/?post_type=product&p=1128"},"modified":"2026-04-24T06:52:31","modified_gmt":"2026-04-24T06:52:31","slug":"modular-waste-heat-boiler","status":"publish","type":"product","link":"https:\/\/rtooxidizer.com\/nl\/product\/modular-waste-heat-boiler\/","title":{"rendered":"Modular Waste Heat Boiler"},"content":{"rendered":"

<\/p>\n

\n
\n
2\u201380 t\/h<\/div>\n
Steam Capacity Range<\/div>\n<\/div>\n
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400\u20131200 \u00b0C<\/div>\n
Inlet Gas Temperature<\/div>\n<\/div>\n
\n
\u2265 90%<\/div>\n
Heat Recovery Efficiency<\/div>\n<\/div>\n
\n
~8 weeks<\/div>\n
Typical Site Erection Time<\/div>\n<\/div>\n<\/div>\n

<\/p>\n

What Is a Modular Waste Heat Boiler?<\/h2>\n

The Ever-power modular waste heat boiler<\/strong> is a skid-mounted, pre-assembled heat recovery steam generator (HRSG) engineered to capture thermal energy from hot flue gas produced by incinerators, rotary kilns, thermal oxidisers and other high-temperature processes. Instead of venting 800\u20131,200 \u00b0C gas to atmosphere, the unit cools it through radiant and convective sections, delivering saturated or superheated steam for in-plant use or power generation.<\/p>\n

What distinguishes this product from a stick-built boiler is its modular architecture. Pressure parts, drums, economiser coils, steel frame and piping arrive on site pre-fabricated and hydro-tested. Bolt-up erection replaces most field welding, which cuts installation time by roughly 40% and keeps the critical path of a waste liquid incinerator retrofit under control. For Australian brownfield projects where shutdown windows are measured in days not weeks, that speed matters.<\/p>\n

The product line covers 2 t\/h package units through to 80 t\/h industrial trains, with steam pressures from 0.8 MPa to 5.3 MPa. Every configuration is fired by process heat alone \u2014 no fuel burner \u2014 so the payback comes entirely from avoided gas purchases or new power generation revenue. Thermal efficiency above 90% is routine, and tube metallurgy is selected to match the dew-point chemistry of your specific flue gas.<\/p>\n

\"Modular<\/p>\n

Compatible Upstream Heat Sources<\/h2>\n
\n
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Hazardous Waste Incinerators<\/h3>\n

Rotary kiln and static hearth units producing 900\u20131,100 \u00b0C flue gas. Integrates directly with the secondary combustion chamber outlet.<\/p>\n<\/div>\n

\n

Liquid Injection & Thermal Oxidisers<\/h3>\n

Post-oxidiser heat recovery for VOC, tail gas and waste-liquid destruction systems at chemical and pharmaceutical sites.<\/p>\n<\/div>\n

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Municipal Waste-to-Energy<\/h3>\n

Moving-grate boiler back-ends for Australian MSW plants. Designed for high chloride and alkali metal content.<\/p>\n<\/div>\n

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Rotary Kilns & Sponge Iron<\/h3>\n

Post-combustion chamber gas at 900\u2013950 \u00b0C feeds a water-tube radiant section sized for dusty, abrasive service.<\/p>\n<\/div>\n

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Gasifier & Syngas Off-Gas<\/h3>\n

Biomass and coal gasifier tail-gas streams with low calorific value \u2014 custom burner inlets maintain stable combustion.<\/p>\n<\/div>\n

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Process Furnaces & Kilns<\/h3>\n

Cement pre-heater exhaust, glass melting furnace off-gas, non-ferrous smelter off-take and steel reheating flue gas.<\/p>\n<\/div>\n<\/div>\n

<\/p>\n

How the Modular Waste Heat Boiler Works<\/h2>\n

Heat is transferred from flue gas to water and steam in four engineered stages, arranged in a counter-flow geometry that maximises log-mean temperature difference and extends tube life.<\/p>\n

\n
\n
STEP 01<\/div>\n

Gas Inlet & Distribution<\/h3>\n

A refractory-lined inlet chamber distributes flue gas evenly across the tube bundle. Sacrificial erosion shields protect leading-edge tubes in dusty service.<\/p>\n<\/div>\n

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STEP 02<\/div>\n

Radiant Cooling Section<\/h3>\n

Membrane water-wall panels drop gas temperature from ~1,100 \u00b0C to about 650 \u00b0C. Natural circulation draws heat to a mud drum and steam drum.<\/p>\n<\/div>\n

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STEP 03<\/div>\n

Convective Evaporator & Superheater<\/h3>\n

Bundled bare or finned tubes raise steam quality to saturation or superheat. An optional attemperator trims steam temperature to process tolerance.<\/p>\n<\/div>\n

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STEP 04<\/div>\n

Economiser & Gas Outlet<\/h3>\n

Boiler feed water is preheated against the coolest flue gas zone. Stack temperature is normally held above acid dew point to protect downstream ducting.<\/p>\n<\/div>\n

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STEP 05<\/div>\n

Soot Blowing & Cleaning<\/h3>\n

Steam or sonic soot blowers maintain heat transfer. Automatic shot cleaning is available where flue gas is heavily laden with sticky particulates.<\/p>\n<\/div>\n<\/div>\n

<\/p>\n

Key Features & Engineering Advantages<\/h2>\n
\n
\n

Skid-Mounted Modular Build<\/h3>\n

Pre-assembled modules arrive hydro-tested and wired. Bolt-up erection cuts site welding by up to 70% and removes critical-path risk on brownfield jobs.<\/p>\n<\/div>\n

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Flexible Circulation Logic<\/h3>\n

Natural-circulation evaporators for stable base-load; forced-circulation for compact footprints or rapid load swings \u2014 selected to match your duty curve.<\/p>\n<\/div>\n

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Acid & Chloride Resistant Tubes<\/h3>\n

Inconel cladding, Alloy 625 overlay and SA213 T22\/T91 tube options tuned to flue gas chemistry, extending life well beyond generic carbon-steel bundles.<\/p>\n<\/div>\n

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Tangential Soot Blowers<\/h3>\n

PLC-scheduled retractable soot blowers clean heat transfer surfaces without operator intervention and hold thermal efficiency within \u00b11%.<\/p>\n<\/div>\n

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Full Instrument Package<\/h3>\n

Steam drum level, trim control, feedwater safety, O\u2082\/CO analysers, and stack CEMS \u2014 all pre-wired to a marshalling cabinet, not left to site teams.<\/p>\n<\/div>\n

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AS\/NZS 3788 Ready<\/h3>\n

Pressure parts stamped to ASME Section I with full AS\/NZS 3788 inspection data \u2014 a drop-in replacement of legacy European HRSG<\/em> in most Australian sites.<\/p>\n<\/div>\n<\/div>\n

<\/p>\n

Technical Specifications<\/h2>\n

Standard capacity bands are shown below. Custom HRSGs matched to specific flue-gas envelopes, dust loadings and downstream steam users are available \u2014 the engineering team builds each unit against your actual heat balance rather than a catalogue curve.<\/p>\n

\n\n\n\n\n\n\n\n\n\n
Model<\/th>\nSteam Output (t\/h)<\/th>\nSteam Pressure (MPa)<\/th>\nSteam Temp. (\u00b0C)<\/th>\nGas Flow (Nm\u00b3\/h)<\/th>\nHeat Efficiency<\/th>\n<\/tr>\n<\/thead>\n
EP-MW-2<\/strong><\/td>\n2<\/td>\n0.8 \/ 1.6<\/td>\nSaturated<\/td>\n8,000<\/td>\n\u2265 88%<\/td>\n<\/tr>\n
EP-MW-6<\/strong><\/td>\n6<\/td>\n1.6 \/ 2.5<\/td>\nSat \/ 350<\/td>\n24,000<\/td>\n\u2265 90%<\/td>\n<\/tr>\n
EP-MW-15<\/strong><\/td>\n15<\/td>\n2.5 \/ 3.82<\/td>\n350 \/ 450<\/td>\n60,000<\/td>\n\u2265 91%<\/td>\n<\/tr>\n
EP-MW-35<\/strong><\/td>\n35<\/td>\n3.82 \/ 5.3<\/td>\n450 \/ 485<\/td>\n140,000<\/td>\n\u2265 92%<\/td>\n<\/tr>\n
EP-MW-80<\/strong><\/td>\n80<\/td>\n5.3 \/ 9.8<\/td>\n485 \/ 540<\/td>\n320,000<\/td>\n\u2265 92%<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Design Basis & Compliance<\/h3>\n
\n\n\n\n\n\n\n\n\n\n\n
Parameter<\/th>\nEver-power Value<\/th>\nReference Standard<\/th>\n<\/tr>\n<\/thead>\n
Pressure Part Code<\/td>\nASME Section I + U-stamp<\/td>\nAS\/NZS 3788<\/td>\n<\/tr>\n
Material (radiant section)<\/td>\nSA210 C \/ SA213 T22 \/ T91<\/td>\nASTM \/ EN 10216-2<\/td>\n<\/tr>\n
Tube Corrosion Margin<\/td>\n2.0\u20133.5 mm (duty-based)<\/td>\nEN 12952-3<\/td>\n<\/tr>\n
Stack Temp. (min.)<\/td>\n\u2265 180 \u00b0C (acid-safe)<\/td>\nAS 3814<\/td>\n<\/tr>\n
Insulation Surface Temp.<\/td>\n\u2264 60 \u00b0C at 25 \u00b0C ambient<\/td>\nISO 12241<\/td>\n<\/tr>\n
Noise Level<\/td>\n\u2264 85 dB(A) at 1 m<\/td>\nAS 1055<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

<\/p>\n

Applications Across Australian Industry<\/h2>\n
\n
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Waste-to-Energy Plants<\/h3>\n

MSW moving-grate boilers, refuse-derived fuel lines and C&I waste sorting facilities across metropolitan councils.<\/p>\n<\/div>\n

\n

Licensed Hazardous Waste Centres<\/h3>\n

Rotary-kiln incinerators serving third-party collectors, medical waste aggregators and chemical-industry clients.<\/p>\n<\/div>\n

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Chemical & Petrochemical<\/h3>\n

RTO \/ thermal oxidiser back-ends, sulfur recovery units, spent caustic oxidiser exhaust.<\/p>\n<\/div>\n

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Cement & Lime<\/h3>\n

Pre-heater tower exhaust, AFR (alternative fuel & raw material) co-processing flue gas, clinker cooler vent air.<\/p>\n<\/div>\n

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Metals & Mining<\/h3>\n

Smelter off-gas, roaster exhaust, sponge iron kiln post-combustion gas at 900\u2013950 \u00b0C.<\/p>\n<\/div>\n

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Biogas & Landfill Flare Recovery<\/h3>\n

Enclosed flare retrofit adding a small modular HRSG to monetise a flare that was previously burning off destruction-only.<\/p>\n<\/div>\n<\/div>\n

<\/p>\n

Why Choose Ever-power<\/h2>\n

A modular waste heat boiler is only as good as the heat-balance behind it. Oversized units choke on low-calorific gas; undersized units never meet steam contract. The Ever-power engineering approach is built on six practical commitments \u2014 the kind a replacement of imported HRSG<\/em> rarely carries through to commissioning.<\/p>\n

\n
\n
600+<\/div>\n
waste heat boilers delivered across refining, hazardous waste and WTE \u2014 reference list available on NDA request.<\/div>\n<\/div>\n
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40%<\/div>\n
shorter erection time than stick-built HRSG, proven across four brownfield shutdowns within 2-week windows.<\/div>\n<\/div>\n
\n
CFD<\/div>\n
gas-side computational fluid dynamics on every project above 10 t\/h \u2014 dead-zones and erosion hotspots resolved at design stage.<\/div>\n<\/div>\n
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10-yr<\/div>\n
pressure-part design life with documented residual-life assessment methodology for Australian WorkSafe audits.<\/div>\n<\/div>\n
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DCS<\/div>\n
Siemens \/ Rockwell \/ Emerson logic supplied pre-programmed and simulated \u2014 commissioning engineers land ready to start, not rewrite.<\/div>\n<\/div>\n
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24\/7<\/div>\n
remote-diagnostics VPN with regional spares pool; critical wear parts dispatched inside 48 hours across Australian ports.<\/div>\n<\/div>\n<\/div>\n

See how our engineering team supports waste liquid incinerator and HRSG retrofits on the Ever-power company page<\/a>, or browse the full boiler line-up on our home page<\/a>.<\/p>\n

<\/p>\n

Australian Project Case Studies<\/h2>\n
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CASE STUDY 01 \u2022 WESTERN AUSTRALIA<\/div>\n

Hazardous Waste Treatment Centre \u2014 Kwinana<\/h3>\n

A Category C and D licensed waste centre was operating a 1990s-era incinerator without a heat recovery section. Flue gas at 1,050 \u00b0C was being quenched straight to the scrubber, wasting roughly 9 MW of thermal energy per operating hour.<\/p>\n

\n

Ever-power solution:<\/strong> EP-MW-15 skid-mounted HRSG with bypass duct for incinerator start-up, 15 t\/h saturated steam at 2.5 MPa.<\/p>\n

Result:<\/strong> Site replaced natural-gas-fired auxiliary boiler. Annual gas saving A$1.8M, full payback in 21 months, zero unplanned outage in first 18 months.<\/p>\n<\/div>\n<\/div>\n

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CASE STUDY 02 \u2022 NEW SOUTH WALES<\/div>\n

Waste-to-Energy Plant \u2014 Western Sydney<\/h3>\n

A green-field MSW WTE project needed a 35 t\/h HRSG for two moving-grate lines. Local EPC wanted a supplier who could deliver modules in 10 containers and erect them inside a 90-day civil-to-first-fire window.<\/p>\n

\n

Ever-power solution:<\/strong> EP-MW-35 units with Alloy 625 overlay on first-bank tubes (high chloride MSW), dual Inconel soot blowers, ASME U-stamp + AS\/NZS 3788 documentation.<\/p>\n

Result:<\/strong> Site erection completed in 82 days, first steam on spec, performance guarantee met at 92.4% heat efficiency on acceptance test.<\/p>\n<\/div>\n<\/div>\n<\/div>\n

<\/p>\n

Frequently Asked Questions<\/h2>\n
\n
\n

How is a modular waste heat boiler different from a stick-built HRSG?<\/h3>\n

A modular unit is pre-assembled in the fabrication shop and shipped in transportable skids. Pressure parts, drums, economiser coils, steel structure and piping are hydro-tested before despatch. On site, erection becomes bolt-up work instead of full welding \u2014 cutting labour, scaffolding and NDE volume by around 40%.<\/p>\n<\/div>\n

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Can the boiler handle dusty or corrosive flue gas from an incinerator?<\/h3>\n

Yes. For dusty service (rotary kiln, sponge iron, MSW) we specify low gas velocity across tube bundles, sacrificial erosion shields on leading edges, and retractable soot blowers. For corrosive service (high Cl, high S) we use Alloy 625 or Inconel 825 overlay on the first radiant bank and keep stack temperature above acid dew point.<\/p>\n<\/div>\n

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What is the typical payback period in Australia?<\/h3>\n

For sites above 6,000 operating hours per year that would otherwise buy natural-gas steam at current Australian tariffs, payback typically sits between 18 and 30 months. Waste-to-energy and hazardous waste sites with no existing steam user usually pair the HRSG with a small condensing turbine for faster payback via electricity sales.<\/p>\n<\/div>\n

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Do you supply the full HRSG island or only the pressure parts?<\/h3>\n

Both scopes are available. A typical Ever-power package covers pressure parts, steel structure, refractory inlet duct, soot blowers, valves and safety valves, instrumentation, feedwater pumps, deaerator, and a pre-programmed control panel. An EPC wrap including piling, erection and commissioning is offered where the customer prefers a single responsibility.<\/p>\n<\/div>\n

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How is capacity selected when my flue gas flow varies across the year?<\/h3>\n

We design around two heat-balance cases \u2014 “normal” and “worst day” \u2014 plus a turn-down case if batch operation is expected. The evaporator and economiser are sized on worst day; the steam drum and feedwater system are sized with margin on turn-down. This prevents the common failure mode of HRSGs that perform at nameplate but stall at 40% load.<\/p>\n<\/div>\n

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Can it be integrated with an existing waste liquid incinerator?<\/h3>\n

Yes. Retrofit is the most common Ever-power scope in Australia. We carry out a site survey, tie-in sketch and heat-balance study, then engineer the HRSG to match the incinerator’s existing secondary combustion chamber outlet duct. Shutdown windows are usually kept under 21 days.<\/p>\n<\/div>\n

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What warranty and long-term support do you offer?<\/h3>\n

Standard pressure-part warranty is 24 months from commissioning or 30 months from shipment, whichever expires first. Performance guarantees on steam output and heat efficiency are backed by acceptance testing at site. Optional 3-, 5- and 10-year condition-monitoring service agreements are available for Australian clients through our partner network.<\/p>\n<\/div>\n<\/div>\n

<\/p>\n

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Need a Tailored Heat Balance?<\/h3>\n

Send your upstream process data, flue gas composition and steam demand to sales@rtooxidizer.com<\/a> or reach our engineering team through the contact page<\/a>. A full heat-balance, GA drawing and budget price will be returned within 10 working days \u2014 free of charge.<\/p>\n<\/div>\n


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