Machinery works are measured in hectares of covered floor: foundry and forge bays, assembly halls, paint lines, test rigs, clean rooms and amenity blocks, all fed from one heat source. The duties are very different from one another, from background warmth in a 30 m high hall to steam held to a fixed pressure on an engine test bench, and the plant has to serve them at the same time.
Three heat duties on one site
Almost every plant in this complex needs the same three things in different proportions: warmth in very large volumes, steam for process operations, and air at a controlled temperature. How the load is split between water and air sets both the capital cost and the time it takes to warm the building on a Monday morning.
- Space heating
- Production bays, assembly halls, warehouses and amenity blocks, with hot water for showers and sanitary zones.
- Process steam
- Test benches, autoclaves, steaming chambers, degreasing and washing lines, and humidity control where the process needs it.
- Process air
- Paint booth supply air, drying air and clean room supply air, delivered at a set temperature rather than through radiators.
- Recovered heat
- Cupolas, heating and heat treatment furnaces give off a stream that a recovery boiler can turn back into shop heating.
Equipment and why it is chosen
Hot water for buildings and infrastructure
CORE, SLIM and BASE fit small works and reconstructed boiler houses where the room cannot grow. CORE DUO gives two independent chambers where a stoppage is unacceptable, and TRINITY and MEGA carry the load of a full plant. QUANT, QUANTUM, EON and MEGA X supply superheated water where a site network needs a higher temperature head.
Steam for process work
PILLAR and RAPID come up to working parameters in minutes, which suits test rigs and intermittent users that would otherwise hold a large boiler on standby. TOR, HERO and TRIPASS cover continuous demand, and PULSE supplies saturated steam with close temperature control where the process will not tolerate drift.
Air heating, outdoor and recovery plant
Air heating needs no pipework, cannot freeze and warms a hall far faster than a water system, which is why ZEPHYR, KENO, LUMO, ROCK, MODUL and GUST often suit high bays, greenhouses and gate curtains. ROOK and WARD place the boiler house outdoors when floor space is scarce, and PHOENIX and ECHO recover heat from furnace exhaust.
Parameters and operating ranges
- Hot water
- From 3000 kW with BASE to 20 MW with TRINITY and 50 MW with MEGA, at up to 16 bar and 115 °C; efficiency of 94–96% across the range.
- Superheated water
- Up to 20 MW at 15 bar and 180 °C with QUANTUM and EON, and up to 209 MW with MEGA X for large works and district networks.
- Steam
- From 600 kW with RAPID through 5000 kg/h at 15 bar with HERO to 25–220 t/h with MIRA X; PULSE holds saturated steam to 12 bar and 180 °C.
- Hot air and thermal oil
- Air heaters from 50 kW to 1500 kW with direct or indirect firing; MAGMA and CRUX heat oil circuits to 300 °C for test rigs and drying without pressure in the system.
Reliability and day-to-day operation
Multi-fuel capability is the first practical safeguard: gas, diesel, fuel oil, pellets and wood chips are all available depending on where you are, and a boiler that can switch keeps producing when a supply contract changes. The second is water quality, so we supply DEGAS for deaeration, DRY and BUFFER for blowdown and condensate, and BOOST or ECO to recover the last heat from the flue gas.
CONTROL holds the set point without the swings that damage coatings and tooling, and keeps burner and pump group behaviour quiet enough for sensitive areas. The Digital Twin telemetry system logs the running record continuously, so maintenance follows real operating hours and the lifetime warranty on the heat exchanger and main load-bearing elements is supported by data.
How a project runs
We start from your figures: heated volumes and building heights, process duties and their schedule, available fuels, water analysis and the control system already installed. From there we calculate the thermal and hydraulic design against the real load graph, agree the layout and control philosophy with your engineers, and only then start manufacture.
Pressure equipment is built to EN 12952 and EN 12953 under PED 2014/68/EU, with ASME practice where a project calls for it, inside an ISO 9001 quality system; marine duties are documented to the classification practice your yard works to. Welds are checked by radiography and ultrasonic testing, every unit is hydraulically tested above working pressure, and witnessed inspection by a notified body such as TÜV can be arranged. Installation supervision, commissioning, operator training and scheduled service complete the work.