Syngas-fired steam boiler

Syngas-fired steam boilers use synthesis gas to produce process steam for industrial applications. This lets you tap into energy that is already present in your processes while reducing your dependence on conventional fuels.

As syngas can vary widely in composition, a thorough analysis and a tailored burner design are indispensable. The Callens Group experts have the expertise to safely integrate these complex energy streams into your production environment.

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When is a syngas-fired steam boiler worthwhile?

Syngas, or synthesis gas, is a combustible mixture of hydrogen and carbon monoxide, among other components and is produced during the gasification of biomass or waste streams, or as a by-product stream in your process.

If you have access to such a gas stream, it may be worth your while to use it to produce process steam instead of flaring it off. By making the most of the energy value of the syngas, the need for natural gas or other fossil fuels drops.

5 situations where syngas is eligible for steam production

You have an existing syngas stream.
You produce syngas through the gasification of biomass or waste streams.
You want to make the most of the energy value of process gases.
You want to reduce your natural gas consumption.
You want to make your energy supply less dependent on external energy suppliers.

Output	up to 40 MW
Capacity	25 to 55,000 kg/h steam
Design pressure	0.5 to 30 barg
Efficiency	up to 95 %

Technical specifications of syngas-fired steam boilers

No two syngas streams are identical. The calorific value, the hydrogen content, the CO content and any contaminants all help determine how we design the installation.

That is why we start every project with a thorough analysis of the available gas stream. Based on that information, our engineers determine the most suitable burner technology, safety systems and control strategy.

By fully tailoring the steam installation to the properties of the syngas, we create a reliable, high-performance heat supply.

advantages

Advantages of a syngas-fired steam boiler

Companies that produce syngas during their operations can put the energy from this waste stream to good use by generating steam. This valorization offers a host of benefits.

Fewer fossil fuels

Using syngas as a fuel reduces the consumption of natural gas or other conventional fuels.

Higher energy efficiency

By reusing the syngas produced on site for steam production, less energy is lost and the installation’s overall efficiency increases.

Fewer waste streams

Gaseous by-product streams get a useful application within the production process.

More energy independence

Companies become less dependent on external energy suppliers and fluctuating energy prices.

Perfectly combinable

Syngas-fired steam boilers can be integrated into hybrid energy systems together with natural-gas-fired boilers, CHP units, e-boilers or heat recovery systems.

Lower impact on the surroundings

By putting syngas to good use for steam production, there is less need for visible flaring, which limits the impact on the surroundings.

How do you integrate syngas into your existing steam plant?

Integrating syngas starts with an analysis of the composition of your syngas, its flow rate and its availability.

A dual-fuel configuration with natural gas, where the installation automatically switches from one energy source to the other, is a popular choice. This keeps steam production assured, even when syngas production is temporarily lower.

The Callens Group specialist analyze the full energy balance of your site and develop a configuration that prioritizes reliability, efficiency and flexibility.

Maintenance of your syngas-fired steam boiler 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.

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

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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

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.

Syngas, or synthesis gas, is a combustible gas mixture that mainly consists of hydrogen, carbon monoxide and other gas components. It is produced during the gasification of biomass, waste streams or as a by-product stream within certain industrial processes. Instead of letting this energy stream go to waste, syngas can be used to produce process steam. This makes the most of the gas’s energy value, reduces fossil fuel consumption and increases the site’s energy efficiency. Want to know whether the gas streams at your site are suitable for steam production? The Callens Group specialists will be happy to explore the possibilities with you.

Natural gas is a fossil fuel that mainly consists of methane (CH₄). It has a relatively constant composition and calorific value, which makes it a predictable fuel for industrial steam production. Syngas, or synthesis gas, on the other hand, consists of a mixture of hydrogen (H₂), carbon monoxide (CO), methane (CH₄), carbon dioxide (CO₂), nitrogen (N₂) and other gas components. The exact composition will depend on the production process and the raw materials used. As a result, the energy value of syngas can vary widely. Precisely because no two syngas streams are the same, using syngas requires tailored burner and control technology. That is why the Callens Group specialists always analyze the composition of the available gas to guarantee safe, stable and efficient steam production.

Syngas is available in companies that work with gasification installations, biomass processes, waste processing, chemical processes, steel production or other industrial applications that release combustible process gases. In these operations, syngas can be a valuable energy source for steam production.

In certain cases, yes. Technical feasibility will depend on the composition of the syngas, the existing burner technology and the required safety systems. Modifications to the burner and the controls will often be required. Want to know whether your existing installation is suitable for syngas? The Callens Group specialists will gladly carry out a technical analysis.

The calorific value and composition of syngas can vary widely from project to project. That is why every system is specifically tailored to the properties of the available gas. This guarantees stable combustion, high efficiency and safe operation.

When syngas replaces an existing energy stream that would otherwise go to waste, you can lower your fossil fuel consumption, thereby reducing your site’s total CO₂ emissions. The exact impact will depend on the origin of the syngas and the reference situation.

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 syngas-fired steam boiler. You can find out more about the various steps in our workflow here.

Yes, provided it is design correctly and the right safety systems are in place. Because the composition of syngas can vary, burners, piping, detection systems and controls are specifically tailored to the properties of the gas.

Cost-effectiveness is mainly determined by the quantities of syngas available, the number of operating hours and the amount of natural gas it can replace. Companies that already have a stable syngas stream can often achieve significant energy savings. Curious what economic added value syngas could offer your site? Our experts will be glad to look at your situation.

At the Imerys site in Willebroek, Callens helped deliver an energy recovery installation that converts a waste stream of syngas (rich in H₂, CO and sulfur compounds) into steam at 100 t/h and 68 barg, which is used to generate electricity via a steam turbine. The installation delivers 29 MWe — enough to power the entire site, and any surpluses are uploaded to the public grid. By valorizing previously flared residual gases, the project reduces CO₂ emissions by around 25,000 tons a year and contributes to a more sustainable industrial production process.

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