Case Study on Waste Heat Recovery from Boiler Steam
Release Date:
2026-02-26
The square all-welded heat exchanger combines the advantages of plate heat exchangers and shell-and-tube heat exchangers, inheriting the high efficiency, compact design, high-temperature resistance, excellent sealing, and reliable safety of conventional plate heat exchangers. By implementing a square all-welded heat exchanger, residual steam is effectively recovered, converting waste heat generated during steel production into a valuable source of thermal energy for both industrial processes and domestic use, thereby significantly enhancing energy utilization efficiency. This technology not only delivers economic benefits to enterprises but also yields substantial environmental advantages.
Recently, a steel plant in Northeast China approached us, expressing interest in utilizing the substantial surplus steam generated during the steelmaking process with steam boilers. The plant plans to convert this excess steam into hot water for reuse in production and for heating within the facility. The collected parameters are as follows:
| Hot medium name |
Steam | Name of the cold medium | Tap water |
| Traffic | 1.4 m³/h |
Traffic | 10t/h |
| Inlet temperature | 180℃ | Inlet temperature | 5℃ |
| Outlet temperature | None | Outlet temperature | 70℃ |
Through discussions with the customer, we learned that they primarily use heat exchangers during the winter months. Having previously used plate heat exchangers, they found them cumbersome to clean and prone to scaling, and they are seeking a more suitable heat‑exchange solution.
The main challenge of this project was to heat a portion of the water to 70°C for industrial use, while another portion needed to be heated to 40°C for indoor heating. Based on the customer’s specific requirements, we developed several design options, incorporating multiple heat exchangers and integrating flow meters. Following detailed discussions, we adopted a solution that splits the outlet stream from the heat exchanger: a separate pipeline equipped with valves is used to inject cold water into the 70°C hot‑water line destined for heating, a configuration that earned high praise from the client. Given that the customer’s heat medium is high‑temperature steam—a clean heat source—and to prevent leaks, we specified a square‑type all‑welded heat exchanger. The heat‑exchanger design for this project is as follows:
| Heat transfer area |
10m² |
| Design temperature | 200℃ |
| Design pressure |
1.0MPA |
| Heat load | 754KW |
| Heat transfer coefficient |
862 W/(m²·K) |
Summary:
The square all-welded heat exchanger combines the advantages of plate heat exchangers and shell-and-tube heat exchangers, inheriting the high efficiency, compact design, high-temperature resistance, excellent sealing, and reliable safety of conventional plate heat exchangers. By adopting this square all-welded heat exchanger, residual steam is effectively recovered, converting waste heat generated during steel production into a valuable source of thermal energy for both industrial processes and domestic use, thereby significantly enhancing energy utilization efficiency. This technology not only delivers economic benefits to enterprises but also yields substantial environmental advantages.
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