Syngas-fired thermal oil boiler

Many industrial processes release synthesis gas, a stream that doesn’t necessarily have to be discharged but can be put to good use. A syngas-fired thermal oil boiler converts this residual stream into process heat. The result: the site’s energy efficiency goes up while the need for primary fuels goes down.

Because the composition of syngas can vary widely from project to project, this technology calls for a thorough technical analysis and a tailored combustion installation. The Callens Group specialists have the expertise to integrate these complex energy streams into industrial steam plants, safely and efficiently.

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When is a syngas-fired thermal oil boiler the right choice?

Syngas, or synthesis gas, is produced, inter alia, during gasification, thermal processes, waste processing and certain chemical applications. Its composition varies from process to process, but it usually contains combustible components such as hydrogen, carbon monoxide and methane.

Companies can use this syngas directly to generate process heat. In this way, a residual stream becomes a full-fledged energy source.

Reasons to consider a syngas-fired thermal oil boiler:

  • You have a syngas stream within your production process.
  • You want to make the most of the energy value of process gases.
  • You want to limit the consumption of natural gas or other primary fuels.
  • You need high process temperatures.
  • You are looking for an efficient way to valorize residual streams.
Callens TO Syng 2
Outputup to 60 MW
Capacity100,000 kcal/h to 12,500,000 kcal/h
Process temperatureup to 300 °C
Operating pressure0.5 to 30 barg
Efficiency95%

Technical specifications of syngas-fired steam boilers

The design of a syngas-fired thermal oil boiler is largely determined by the composition of the available syngas. Factors such as calorific value, pressure, temperature and composition influence the choice of burner, control technology and installation configuration.

Our engineers analyze these parameters and develop a solution that makes optimal use of the available energy while guaranteeing a stable heat supply.

BENEFITS

Syngas-fired thermal oil boiler

By using syngas as a fuel, a residual stream is turned into a valuable energy source, offering both economic and environmental benefits.

Fewer primary fuels

The consumption of natural gas or other external energy sources can be significantly reduced.

energy efficiency

By putting syngas to good use, the overall energy efficiency of your site increases.

waste streams

Gaseous by-product streams are put to good use within the production process.

emissions

By valorizing residual streams, less energy is lost and the need for additional fuels decreases.

Precise temperature control

Thermal oil ensures stable heat transfer and a controlled process temperature.

Higher process temperatures

Temperatures of up to approximately 300 °C are possible without high system pressures.

How do you integrate syngas into your existing heat plant?

Integration starts with an analysis of the available syngas stream and the heat demand of your production process. Next, we look at how to connect the thermal oil boiler to your existing consumers, pipework and energy supplies.

Depending on the situation, the installation can run entirely on syngas or be combined with other fuels to increase operational reliability.

The Callens Group specialists advise you on the configuration that best suits your process and energy objectives.

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Maintenance of your syngas-fired thermal oil boiler and 24/7 service

The Callens Group’s maintenance and service team makes sure your installation keeps performing at its best long 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.

On top of that, you can count on fast support whenever an unexpected breakdown occurs. Thanks to our 24/7 standby service, an extensive range of spare parts and the expertise of our service technicians, interventions can be carried out quickly and effectively.

After all, even the best maintained installation can malfunction or shut down unexpectedly. That is why the Callens Group offers a range of service packages, tailored to the response time and support you need. So even in unforeseen situations, you are assured of the right support and maximum operational reliability.

More information about our service packages
PARTNERSHIP

Why work with the Callens Group?

60 years of experience in EPCS projects
Independent integrator focused on customer needs
Flexible customer and project approach
Short decision-making lines and a personal approach
Unique service and maintenance support
Always close to customers with 13 locations

“Maximizing energy efficiency doesn’t start with choosing a technology, but with mapping out your specific situation.”

FAQ

Questions? We have the answers.

Syngas is produced by companies that work with gasification installations, biomass processes, waste processing, chemical processes, steel production or other industrial applications that release combustible process gases. In situations such as these, syngas can be a valuable energy source for generating industrial process heat.

That will depend on the quantity, composition and availability of the syngas. In some applications, syngas is sufficient as the only fuel, while in other situations a combination with a second fuel is preferable.

As an EPCS integrator, the Callens Group takes care 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 lifetime of your syngas-fired thermal oil boiler. You can find out more about the different steps in our workflow here.

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.

Discuss your challenge or project with our experts

Would you like to explore which solution is suitable for your specific project?

Our engineers are happy to think along with you, from initial exploration to concrete engineering.

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