Steam boiler running on liquid waste streams

Many industrial processes generate liquid waste streams with a high energy value. Instead of discharging these streams or processing them as waste, you can use them as fuel to produce process steam.

The Callens Group specialists design and integrate steam installations that valorize these waste streams safely and efficiently. This allows you to capitalize on your own process, to lower your fossil fuel consumption and to increase your site’s energy efficiency.

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When is a steam boiler running on liquid waste streams worthwhile?

If you continuously have energy-rich liquids available, you can use them as fuel for a steam boiler. That way, the liquids are no longer waste, but a useful heat source.

A steam boiler that runs on liquid waste streams increases energy efficiency and lowers energy costs.

4 reasons to use liquid waste streams for steam production:

You have liquid waste streams with an energy value.
You want to reduce the cost of disposing of your waste streams.
You want to consume fewer fossil fuels.
You’re looking for additional ways to lower your CO₂ emissions.

Output	up to 100 MW
Capacity	25 kg/h to 150 t/h steam
Design pressure	0.5 to 100 barg
Efficiency	up to 99 %

Technical specifications of steam boilers running on liquid waste streams

A first decisive factor in whether a liquid waste stream can serve as fuel is its calorific value. But there is more to it. Viscosity, moisture content and composition also affect combustion and the sizing of the installation.

That is why we start every project with a thorough analysis of the available waste stream. Based on that information, our engineers develop an installation that is optimally matched to both the fuel and the desired steam production.

advantages

Advantages of a steam boiler running on liquid waste streams

A steam boiler that runs on liquid waste streams helps companies increase their energy efficiency, lower energy costs and become less dependent on fossil fuels. What’s more, this approach ties in perfectly with the principles of the circular economy, where existing raw materials and energy streams are valorized to the maximum.

Valorization of waste streams

Liquid by-product streams gain a useful application within the production process instead of forming a costly waste stream.

Fewer fossil fuels

Using waste streams as fuel reduces the need for natural gas or other conventional energy sources.

Higher energy efficiency

More energy remains available within the production process, increasing the site’s overall efficiency.

Lower energy costs

By valorizing waste streams from your own processes, less energy has to be purchased externally.

Fewer waste streams

By using the energy content of waste streams, disposal and processing costs often drop as well.

Stable operation

even with varying waste streams. By carrying out a thorough analysis in advance and tailoring the installation accordingly, combustion remains stable and safe, even if the composition of the waste stream fluctuates.

Which liquid waste streams can be used for steam production?

Whether a waste stream can be used will depend on its energy value and composition. The following are certainly eligible:

contaminated solvents
organic residual products
process residues
waste oils

But other by-product streams from industrial processes are an option too.

Because no two waste streams are identical, our specialists analyze the composition, calorific value and availability of the fuel before developing a solution.

Based on that information, we determine which combustion and flue gas treatment technology will guarantee safe, reliable steam production.

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Maintenance of your steam boiler running on liquid waste streams and 24/7 service

The Callens Group’s maintenance and service team makes sure your installation keeps performing at its best, even after commissioning. With an in-house team of more than 120 service and maintenance technicians, we schedule preventive maintenance in line with the legal and technical requirements of your installation.

You can also count on fast support whenever an unexpected breakdown occurs. Thanks to our 24/7 on-call service, an extensive range of spare parts and the expertise of our service technicians, we carry out interventions quickly and effectively.

Even the best-maintained installation can malfunction or shut down unexpectedly. That is why the Callens Group offers various service packages, tailored to the response time and support you need. So even in unforeseen situations, you can count on our expertise.

More about our service contracts

partnership

Why partner with Callens Group?

60 years of experience in EPCS projects

An independent integrator focused on your specific needs

Flexible project execution

Short decision-making lines and a personal approach

Unique service & maintenance support

With 13 locations, always close by

“Maximizing energy efficiency doesn’t start with choosing a technology, but with mapping out your environment and goals.”

What is your challenge?

We’ll find a solution. With more than 400 experts in-house, no question goes unanswered.

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Questions? We have the answers.

Als EPCS-integrator neemt Callens Group het volledige traject op zich: van on-site analyse en engineering tot installatie en service. Meer info over de verschillende stappen in onze workflow vindt u hier.

That will depend on the energy value and composition of the waste stream. Examples include waste oils, contaminated solvents, organic process residues, distillation residues and other liquid by-product streams released during industrial processes. Each waste stream is analyzed in advance to determine whether it is technically and economically suitable as a fuel for steam production.

The key parameters are calorific value, moisture content, viscosity, composition and the available quantities. The higher the energy value and the more constant the supply, the more attractive the waste stream will generally be as a fuel. The Callens Group specialists carry out an analysis in advance to map the energy potential of the waste stream.

The composition of liquid waste streams can vary depending on the production process. That is why parameters such as calorific value, viscosity, moisture content and any contaminants are checked regularly. These analyses form the basis for stable combustion, high efficiency and safe operation of the installation.

By valorizing liquid waste streams for their energy, fossil fuel consumption can drop significantly. It can also reduce the site’s CO₂ emissions. The actual emission reduction will depend on the origin of the waste stream, the reference situation and the amount of fossil fuel being replaced. Curious what impact this could have on your energy consumption and emissions? The Callens Group specialists will be delighted to explore that with you.

That will depend on the nature of your waste stream, your installation and on local regulations. In many cases, there are specific environmental requirements for combustion, emissions and flue gas treatment. At the Callens Group, we support customers with the technical preparation and help gather the information needed for permit purposes.

This technology is mainly used in sectors where liquid process residues are released, such as the chemical industry, food industry, pharmaceutical sector, waste processing and certain process industries. For companies that continuously have access to energy-rich waste streams, this can be an attractive way to increase their energy efficiency.

As an EPCS integrator, the Callens Group takes charge of the entire process: from on-site analysis and engineering to installation and service. This gives you a single point of contact throughout the full service life of your steam boiler running on liquid waste streams. You can find out more about the various steps in our workflow here.

That will depend on the composition of the fuel and the applicable emission standards. Depending on the application, additional techniques may be needed to remove particulates, acidic components or other emissions. The most suitable solution is always determined based on an analysis of the waste stream and the local environmental requirements.

Cost-effectiveness is mainly determined by the amount of the available waste stream, its energy value and the amount of natural gas or other fuels it can replace. For companies currently incurring significant costs to process or dispose of waste streams, energy valorization can offer a particularly attractive business case. Want to know how much you could save at your site? Our experts will be happy to discuss your situation.

For an industrial customer, Callens carried out the start-up of two identical water-tube boilers of 14 tons of steam per hour each at 80 barg. Both boiler lines were commissioned in sync, quickly providing the required steam capacity for initial commercial production. The installation stands out for its very low emissions, with NOx, CO and NH₃ well within the strictest standards. This project shows how efficient, reliable steam generation can be combined with minimal environmental impact — a key starting point for future applications involving liquid waste streams.

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