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Diesel generator set waste heat boiler

Design, manufacturing, and installation of waste-heat boilers for diesel generators

In the early 1990s, Guangdong experienced rapid economic growth, yet its power grid faced severe shortages. Consequently, a large number of internationally renowned, high‑capacity medium‑ and low‑speed diesel generator sets were imported. As these units all run on heavy diesel fuel, they required accompanying waste‑heat boilers to generate steam for preheating the fuel before operation. Located in Guangdong and specializing in boiler manufacturing, our company has supplied a substantial range of waste‑heat boilers for diesel generator sets of various sizes throughout the province, with capacities spanning from 500 kW to 65,000 kW. Our products have served well‑known international brands such as MAN, WARTSILA, SULZER, MSB, MARK, DEUTZ, MITSUI, and others. Additionally, we have provided waste‑heat boilers to leading domestic manufacturers, including Guangzhou Diesel Engine Factory, Zhenjiang Diesel Engine Factory, Shaanxi Diesel Engine Factory, Wuxi Diesel Engine Factory, Dalian Diesel Engine Factory, and many more.

Later, as technology continued to advance, the efficiency of the waste‑heat boilers we designed and manufactured steadily improved. When the steam generated by the exhaust from diesel‑generator sets is fully utilized, a substantial surplus remains beyond the plant’s own steam consumption. We capture this excess steam and route it to a steam turbine to generate additional electricity—commonly referred to as waste‑heat power generation—thereby creating a new driver of economic growth for the power plant. Typically, waste‑heat power generation can boost output by approximately 6% to 7% of the unit’s rated capacity; for example, a 100,000 kW diesel‑generator installation could produce an additional 6,000 to 7,000 kW of electricity through waste‑heat recovery. As a result, this approach has gained strong support from many diesel‑generator plants, increasing both the plant’s overall power output and the enterprises’ bottom line.
To date, our company has supplied nearly 700 waste-heat boilers for diesel generator sets both domestically and internationally, including approximately 120 units dedicated to waste-heat power generation.

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Product Overview

Design, manufacturing, and installation of waste-heat boilers for diesel generators

In the early 1990s, Guangdong experienced rapid economic growth, yet its power grid faced severe shortages. Consequently, a large number of internationally renowned, high‑capacity medium‑ and low‑speed diesel generator sets were imported. As these units all run on heavy diesel fuel, they required accompanying waste‑heat boilers to produce steam for preheating the fuel before operation. Located in Guangdong and specializing in boiler manufacturing, our company has supplied a substantial range of waste‑heat boilers for diesel generator sets of various sizes throughout the province, with capacities spanning from 500 kW to 65,000 kW. Our products have served leading international brands such as MAN, WARTSILA, SULZER, MSB, MARK, DEUTZ, MITSUI, and others. We have also provided waste‑heat boilers to prominent domestic manufacturers, including Guangzhou Diesel Engine Factory, Zhenjiang Diesel Engine Factory, Shaanxi Diesel Engine Factory, Wuxi Diesel Engine Factory, Dalian Diesel Engine Factory, and many more.

Later, as technology continued to advance, the efficiency of the waste‑heat boilers we designed and manufactured steadily improved. When the steam generated by the exhaust from diesel‑generator sets is fully utilized, a substantial surplus remains beyond the plant’s own steam consumption. We capture this excess steam and route it to a steam turbine to generate additional electricity—commonly referred to as waste‑heat power generation—thereby creating a new driver of economic growth for the power plant. Typically, waste‑heat power generation can boost overall output by approximately 6% to 7% of the unit’s rated capacity; for example, a 100,000 kW diesel‑generator installation could produce an additional 6,000 to 7,000 kW of electricity through waste‑heat recovery. As a result, this approach has won strong support from many diesel‑generator plants, increasing both the plant’s total power output and the enterprises’ bottom line.
To date, our company has supplied nearly 700 waste-heat boilers for diesel generator sets both domestically and internationally, including approximately 120 units dedicated to waste-heat power generation.

1. Introduction to Waste Heat Boiler Products

Schematic diagram of the waste heat boiler installation location:

(1) Classification of Waste Heat Boilers

(2) Flow Diagram of Natural Circulation and Forced Circulation Systems

(3) Flowchart of the Waste Heat Power Generation System

When the number of generating units is large and their power output is substantial, the steam produced by the waste‑heat boiler not only meets the steam requirements of the units themselves but can also be used to drive a steam turbine for power generation. The schematic flow diagram is shown below:

(4) System flow diagram for a waste-heat thermal oil furnace

In regions experiencing severe water shortages, an organic heat transfer fluid (commonly referred to as thermal oil) can be used in place of water as the heat-transfer medium, replacing steam while still enabling the heating of heavy oil and ensuring the normal operation of diesel generator sets.

(5) Common natural-circulation waste-heat boilers

① Vertical fire-tube natural-circulation boiler

② Horizontal fire-tube natural-circulation boiler

③ Water-tube natural circulation boiler

(6) Common types of forced-circulation waste-heat boilers

① Coaxial coil-type heating surface

② Stepwise opening-type heating surface

③U-tube heating surface

④ Heating surface of finned tubes

(7) Outline drawings of several forced-circulation waste-heat boilers

① Coil-type forced-circulation waste heat boiler body

② Fin-tube waste heat boiler body

③ Images of waste heat boiler projects for waste heat power generation

(8) Example images of a small gas turbine unit utilizing a waste heat boiler

Our waste heat boilers are not only used in diesel generator sets; they are also employed in gas turbine units ranging from 500 to 30,000 kW. Below are some on-site photos.

(9) Snapshots from some waste heat boiler installation sites

① Zhongshan Waste Heat Power Generation Project, China

②Bangladesh Waste Heat Power Generation Project

③ Gambia Waste Heat Power Generation Project

④ Medan Power Plant Project in Indonesia

⑤ Chile Copper Mine Power Plant Project

(10) Conclusion

Above, we have provided a brief overview of our company’s expertise in the design, manufacture, and installation of waste‑heat boilers for various types of diesel generator sets. If you would like more information or wish to place an order, please contact us for a custom design and quotation. Simply provide the unit’s exhaust flow rate and flue gas temperature, and we will develop a tailored waste‑heat boiler—covering selection, calculations, engineering, fabrication, and installation. With over thirty years of experience, we are confident that our solutions will meet your expectations.

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