Heat Recovery Systems
OTSG & HRSG Modules for High-Efficiency Energy Utilization
Overview
Heat Recovery Systems are critical process units designed to capture and reuse waste heat from gas turbines, engines, furnaces, and high-temperature process streams. Mechasol designs and supplies Once-Through Steam Generators (OTSG) and Heat Recovery Steam Generator (HRSG) modules that convert otherwise wasted thermal energy into usable steam or hot water, significantly improving overall plant efficiency and reducing fuel consumption.
These systems are engineered as integrated thermal modules, fully compatible with upstream and downstream process units and compliant with international design codes.
Engineering Philosophy & Design Basis
Mechasol heat recovery systems are designed based on a process-driven and performance-oriented engineering approach, considering:
Exhaust gas temperature and mass flow
Required steam or hot water duty
Pressure and temperature class
Integration with existing boilers or utility systems
Transient operation and load variations
Space and modularization constraints
Each system is optimized to maximize thermal efficiency, reliability, and lifecycle performance.
OTSG – Once Through Steam Generator Systems
Concept & Operating Principle
OTSG systems generate steam in a single-pass configuration, where feedwater enters the system and exits as steam without steam drums or recirculation. This design offers fast start-up, compact layout, and high operational flexibility.
Key Advantages
Rapid start-up and shutdown
Compact and lightweight design
Reduced footprint compared to conventional HRSGs
Excellent performance under variable load conditions
Typical Applications
Gas turbine exhaust heat recovery
Engine-based power plants
Oil & gas facilities requiring fast steam availability
Modular and containerized energy systems
OTSG modules are particularly suitable where space limitations and operational flexibility are critical.
HRSG – Heat Recovery Steam Generator Systems
Concept & System Architecture
HRSG systems recover heat from exhaust gases using multi-pressure steam generation sections, typically including economizer, evaporator, and superheater modules. Mechasol HRSG systems are engineered for maximum heat extraction and stable steam generation.
Design Configurations
Horizontal or vertical gas flow
Single-pressure, dual-pressure, or triple-pressure designs
Natural or forced circulation
Supplementary firing (duct burners) if required
Typical Applications
Combined Cycle Power Plants (CCPP)
Large industrial gas turbines
Refineries and petrochemical complexes
HRSG systems are preferred where large and continuous steam demand exists.
Key System Components
A complete Mechasol Heat Recovery System typically includes:
Heat recovery boiler modules
Economizers and superheaters
Expansion joints and bypass dampers
Stack and ducting systems
Safety valves and instrumentation
Control and automation panels
Optional supplementary firing systems
All components are designed and supplied as part of a fully integrated package.
Automation, Control & Safety
Mechasol OTSG and HRSG systems are equipped with advanced automation systems providing:
Continuous temperature and pressure monitoring
Steam flow and quality control
Turbine and process interlocks
Emergency shutdown and safety logic
Remote monitoring and diagnostics
Systems comply with ASME, EN, PED, and relevant international standards.
Advantages of Mechasol Heat Recovery Solutions
High overall plant efficiency improvement
Reduced fuel consumption and operating costs
Lower CO₂ and NOx emissions
Modular and skid-mounted design options
Seamless integration with existing utility systems
EPC and turnkey project capability
Typical Industries & Applications
Mechasol Heat Recovery Systems are widely used in:
Power generation and combined cycle plants
Oil & gas processing facilities
Refineries and petrochemical plants
Industrial furnaces and heaters
Energy-intensive manufacturing industries
EPC & Modular Delivery Capability
Mechasol delivers heat recovery projects as:
Standalone equipment modules
Skid-mounted or containerized units
Fully engineered EPC turnkey solutions
Scope includes engineering, manufacturing, installation, commissioning, and operator training.
Summary
Mechasol OTSG and HRSG Heat Recovery Systems transform waste heat into valuable energy, delivering higher efficiency, lower emissions, and improved operational economics. With strong engineering capability and modular design expertise, Mechasol provides reliable heat recovery solutions tailored to modern industrial and energy applications.