Recovers Heat and Generates Steam for Chemical Processes

BORSIG Process Heat Exchanger GmbH provides sophisticated replacement waste heat boilers tailored for nitric acid, caprolactam, and formaldehyde production. These boilers utilize a forced circulation design, ensuring efficient heat recovery and steam generation by capturing released thermal energy from catalytic processes. Integrating easily into existing lines, they manage up to 500 °C steam temperatures at pressures between 40 and 80 bar. The design supports continuous operation, optimizing energy use, and ensuring sustainable production processes. Available in different material options for corrosion resistance, they offer seamless compliance with international standards. Featuring an integrated cooling system, these boilers maintain operational efficiency while facilitating easy maintenance with an available CIP system. Custom engineering support is offered to meet specific production requirements, enhancing plant efficiency and reliability.

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Maximizes Steam Generation Efficiency

The BORSIG steam superheater is engineered for demanding industrial applications requiring high-pressure steam, prominently utilized across chemical, petrochemical, and energy sectors. This sophisticated equipment features a vertically arranged U-tube system with a combined steam inlet/outlet chamber, facilitating effective steam superheating post waste heat recovery. The equipment is seamless in integrating with secondary reformers and reformers, making it ideal for reformed and synthesis gas processing.

With a steam capacity handling pressures up to 130 bar and temperatures up to 530°C, the superheater optimizes energy efficiency and enhances system resilience by incorporating a unique internal gas-side bypass for precise temperature regulation. Its design minimizes thermal stress through efficient radial temperature distribution across the tube sheet.

BORSIG ensures material durability by avoiding comprehensive refractory linings, focusing instead on selective insulation where necessary to prevent heat loss. Easy integration into existing systems and complementary service options further enhance operational continuity while meeting rigorous industry safety standards. BORSIG offers customization to accommodate unique process requirements, ensuring tailored solutions for efficient steam optimization and reliability in high-demand environments.

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Preheats and Efficiently Transfers Heat

The HP and LP Preheaters and Special Vessels from BORSIG Process Heat Exchanger GmbH offer a high-precision solution for chemical and power plant applications. Utilizing superheated steam extraction and efficient heat transfer, these preheaters increase the feed water temperature, optimizing the steam cycle and reducing boiler energy demands. This system is ideal for processing feed water in high-pressure zones before entering boilers, significantly enhancing thermal efficiency across operations. Ideal for applications in oil refineries, petrochemical, and chemical industries, this equipment supports the production of key end-products like gasoline, ethylene, and vinyl chloride. Built to handle continuous, high-speed operations, these preheaters are offered with material options that ensure corrosion resistance for long-lasting performance. Integration into existing systems is seamless, with customizable solutions tailored to specific process conditions.

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Cools and Recovers Heat from Synthesis Gas

The Synthesis Gas Cooler from BORSIG Process Heat Exchanger GmbH is designed to address the rigorous demands of high-temperature gas cooling and heat recovery in petrochemical and refining industries. This fire-tube boiler employs helically wound heating surfaces to effectively reduce synthesis gas temperatures from 1,400 °C to 300 °C, utilizing the recovered heat to generate and superheat steam at pressures up to 140 bar. Ideal for producing hydrogen, carbon monoxide, ammonia, and other industrial gases, this cooler integrates seamlessly into operations handling crude oil or natural gas derivatives.

The unit handles up to 200,000 Nm³/h of gas flow, facilitated by a design that ensures constant gas velocity for optimal self-cleaning. Reinforcement ribs and ceramic coatings provide superior erosion and corrosion resistance, making it suitable for harsh environments with particulate-laden emissions. Engineered for continuous, high-pressure, and high-temperature operations, the cooler’s inlet nozzles incorporate forced circulation to mitigate material stresses. The modular tube design allows for easy access and maintenance, ensuring operational efficiency and longevity.

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Recovers Heat and Generates Steam from Waste Gases

The Reformed Gas Waste Heat Boiler from BORSIG Process Heat Exchanger GmbH is designed to efficiently recover heat and generate high-pressure steam from synthesis gas processes. Utilizing a patented stiffened or flexible tube sheet design, it ensures optimal cooling and minimizes metal temperature, thus preventing crevice corrosion. With applications spanning synthesis gas processing, petrochemical refining, and hydrogen production, this boiler accommodates high gas inlet temperatures up to 1,200°C and steam pressures up to 160 bar. It features an internal gas-side bypass for precise outlet temperature control via a single valve adjustment, allowing seamless integration into refining and power generation lines. Constructed to handle continuous, high-pressure operations, it offers robust performance and longevity, and is suitable for a range of industries including chemical, petrochemical, and energy production. Options for customization and engineering support ensure tailored solutions for specific industrial requirements.

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Separates Ethylene from Purge Gases

The BORSIG Ethylene Recovery Unit for EO/EG Production efficiently captures ethylene from cycle gas purge streams, improving resource recovery in petrochemical and chemical operations. This unit employs a hydrocarbon-selective membrane stage, separating ethylene from argon and nitrogen. With its compact package unit design, it offers quick installation and seamless integration into existing systems. Common applications include the production of ethylene oxide, ethylene glycol, and other monomers. The unit ensures safe operation, high reliability, and low maintenance requirements, making it ideal for continuous, automated high-speed operations. With reference installations across various licensors, it promises a quick return on investment by optimizing process efficiency and reducing waste.

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Recovers Ethylene from Purge Gas Streams

The BORSIG Ethylene Recovery Unit is an engineered solution specifically designed for the petrochemical and chemical industries, offering an efficient method to recover ethylene from purge gas streams. Utilizing hydrocarbon-selective membranes, this unit simplifies the separation and recycling process by directing the ethylene-rich permeate back to the compression stage. Ideal for polyethylene production, it integrates seamlessly into existing installations or new projects with minimal additional equipment required. Its compact design allows for easy installation and retrofitting, while maintaining low maintenance and delivering reliable operation. The unit operates continuously, ensuring safe and sustainable performance in high-demand environments. Designed to meet specific customer codes and specifications, the Ethylene Recovery Unit contributes to reduced operational costs and improved process efficiency.

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Recovers and Purifies Hydrocarbons from Polyethylene Processes

The BORSIG Hydrocarbon Recovery Unit is an expertly engineered solution tailored for petrochemical and polymer industries. By combining membrane separation with absorption, condensation, and extraction processes, it efficiently recovers and purifies hydrocarbons like butane, pentane, and hexane. This modular unit is adaptable for polyethylene and gas processing, handling applications from polymer degassing to vent gas purification. Designed for energy efficiency, it operates at moderate pressures and temperatures, ensuring high recovery rates and product purities while maintaining low maintenance needs. Integrating smoothly into existing systems, it supports continuous operation and rapid installation, while offering retrofit options for existing plant infrastructure. Engineered with safe operation in mind, the unit is available in corrosion-resistant materials and can be configured to meet specific plant conditions and local regulations.

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Recovers and Purifies Monomers from Hydrocarbons and Nitrogen

The BORSIG Monomer Recovery Unit leverages the cutting-edge capabilities of BORSIG Membrane Technology GmbH to streamline and enhance the separation of hydrocarbons and nitrogen in various industrial applications. This specialized system efficiently recovers monomers like ethylene and propylene, vital for manufacturing polyethylene and polypropylene, through a process combining membrane separation with compression, condensation, and heating stages. Ideal for sectors such as petrochemical and industrial gas production, the unit’s modular design allows easy integration into existing plants and offers flexibility for handling multiple component streams.

Operating at moderate pressures and temperatures, the system ensures safe, reliable, and low-maintenance performance. Its package unit design enables quick installation and seamless adaptation to specific plant conditions and local regulations. The membrane technology optimizes nitrogen purification, while the hydrocarbon-enriched permeate stream supports further processing or improved condensation. The BORSIG Monomer Recovery Unit is a robust solution for industries seeking to enhance recovery rates and achieve high product purities, contributing to more sustainable and efficient production processes.

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Recovers and Purifies Propylene and Nitrogen

The BORSIG Propylene and Nitrogen Recovery Unit is a sophisticated solution designed for petrochemical producers and industrial gas processors seeking efficient separation and purification processes. Utilizing a strategic combination of compression, condensation, and membrane separation, this unit excels in recovering propylene and high-purity nitrogen from process streams. Applications range across polypropylene production, gas processing, and chemical manufacturing, delivering end-products like polypropylene resin and liquid nitrogen.

This unit operates continuously and is engineered for high reliability and quick installation. Its modular package unit design allows easy integration into existing facilities, supporting retrofit deployments. By using hydrocarbon-selective membranes alongside optional hydrogen-selective stages, you benefit from recovery rates exceeding 95% for propylene and nitrogen purity over 99 mol%. The system reduces energy consumption and minimizes emissions, aligning with environmental and economic objectives.

Available in various materials to resist corrosion, BORSIG’s Recovery Unit ensures compatibility with demanding industrial conditions. It is supported by comprehensive membrane services and complies with industry standards, offering an innovative edge in energy and environmental solutions within the chemical and energy sectors.

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