We Design & Build High-Efficiency Boiler Economizers – Saving Waste Energy, Cutting Costs

We Design & Build High-Efficiency Boiler Economizers – Saving Waste Energy, Cutting Costs!

Boost Your Boiler’s Performance with Our Advanced Serrated Fin Economizer!

Why Our Economizers?

  •  Serrated Fins → 30% more heat transfer than smooth tubes.
     Custom Designs for high-pressure/high-temperature boilers (1–50 ton capacity).
     Proven ROI – Payback period as low as 6–18 months.
  • Wide Capacity Range  1 Ton to 50 Ton (Custom Solutions Available)
    ✅ Built for High Pressure & High Temperature Operations

 ✅ Key Benefits:

  • Maximize Fuel Savings (Lower Operating Costs)

  • Reduce Emissions (Eco-Friendly Compliance)

  • Extend Boiler Lifespan (Durable Construction)

***Technical Specifications 

  •        Pressure range- 4 bar to 100 Bar
  •        Materials- MS, SS and carbon Steel
  •        Fin types- Serrated Fin and Cylindrical Fin, Turbine Blade Fin and cross Fin
  •        Temperature range- 80 deg centigrade  to 150 Deg centigrade

How Boiler Economizers Cut Fuel Costs in Power Plants, Oil Mills & Textile Plants

Industrial boilers waste 20-30% of energy as hot exhaust gases. Economizers recover this waste heat, preheating feedwater and slashing fuel costs by 10-25%. Here’s how they work in key industries:

1. Power Plants: Fuel Savings = Massive ROI

  •      Problem: Gas/coal-fired boilers lose huge heat through flue gases.

  •      Solution: Economizers preheat feedwater before it enters the boiler, reducing fuel needed to reach             operating temperature.

  •      Result: A 15% drop in fuel use can save $500,000+ yearly for a mid-sized plant.

2.     Oil Mills (Seed Crushing, Palm, Edible, Coconut, etc.): Efficiency = Higher Margins

  •       Problem: Boilers run 24/7 for steam in sterilization, drying, and refining.

  •      Solution: Serrated fin economizers capture waste heat, cutting diesel or biomass fuel consumption.

  •      Result: One Malaysian palm oil mill reported 20% lower fuel costs after installation.

3.      Textile Plants: Steam Cost = Competitive Edge

  •        Problem: Dyeing, bleaching, and drying demand constant steam.

  •       Solution: Economizers reuse exhaust heat, reducing coal/gas use by 10-30%.

  •       Result: A Bangladesh textile factory saved $200,000/year with a 3-ton economizer.

 Get a FREE Quote Today!
 Call/WhatsApp: 01818-271791
 Email: selim@classicindustrialservice.com

 Visit: www.classicindustrialservice.com

#BoilerEconomizer #EnergySavings #IndustrialEfficiency #SteamSystems #ThermalEngineering #GreenManufacturing

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Use Biomass Boilers Reduced carbon Footprint

The term “ biomass boilers ” refers to all boilers and systems powered by fuels of organic origin, i.e. waste, residues and industrial and urban waste of vegetal or animal origin that can no longer be reused, but which can be transformed into electrical energy and heat.

As defined by the European Directive 2009/28/EC, biomass is “ the biodegradable fraction of products, waste and residues of biological origin from agriculture (including vegetal and animal substances), forestry and related industries, including fishing and aquaculture, as well as the biodegradable fraction of industrial and municipal waste ”.

Biomass and the fuels derived from it represent a renewable energy source, since the carbon dioxide they emit during the combustion process is more or less the same as that which plants absorb during their life and release once they die. The combustion of biomass does not therefore lead to an increase in carbon dioxide in the atmosphere, the main cause of the greenhouse effect, but rather constitutes a further advantage for the environment given the biodegradability of the substances that are burned.

Our boilers are designed to burn both biomasses now considered commonly used, such as wet wood chips and pellets, and biomasses derived from organic waste such as sawdust, briquettes, bark, chicken manure, mushroom beds, miscanthus, nutshells, peat, CDR, vine shoots, pomace, grape marc.
For specific fuels we require a chemical analysis, on the basis of which we can then design a customized system.
The disposal of industrial processing waste has a significant impact on company costs. Biomass systems allow waste to be transformed into a resource, obtaining electrical energy and heat from its combustion.
The biomass systems we design are suitable for any type of industrial process and comply with pollution regulations. The boilers can be built with “water jacket” technology, which allows for smaller dimensions and higher yields, but are also available with an adiabatic chamber. We supply complete systems, from the storage/feeding system, transport, combustion and fume filtering.
We follow and support our customers in every phase of the project, from the choice of the machine to the commissioning.
Usually the plant is divided into various sections of which the main ones are:

  1. Storage silo
  2. Power system
  3. Water heater
  4. Combustion grate
  5. Filtering
  6. Fireplace  

 

 

  1. Storage silo

The storage silo is the part of the plant where the biomass is stored, to then be moved and transported to the feeding system.
We can create different types of storage silos depending on the characteristics of the fuel and the customer’s needs.

  1. Power system

From the storage silo the biomass is transported to the boiler and poured onto the combustion grate through the feeding system. The latter is generally made up of one or more augers or a chain conveyor (or both), designed to ensure the necessary supply of fuel to the boiler.
The system is designed in compliance with safety and fire prevention regulations.

  1. Water heater

Biomass boilers consist of a combustion chamber and a heat exchanger.
The combustion chamber is equipped with fans for air supply and probes for combustion parameter control. The chamber can be adiabatic or wet chamber. Combustion, which can take place on a fixed or mobile grate, produces hot fumes that go into the heat exchanger, and ash as waste. The ash can be collected either with automated systems or manually.
The heat exchanger uses the energy of the fumes to produce hot water, superheated water, steam, etc., depending on the type of system selected. All safety accessories and the system for automatic exchanger cleaning are generally included in the supply.
Our boilers are built in compliance with the latest regulations and can be certified according to ASME, PED, etc.

  1. Combustion grate

The grill or brazier is the area where the material for combustion is poured. There are 3 types of grills:

  • Fixed flat
  • Flat furniture
  • Inclined mobile

The flat fixed grate is the simplest; it is an economical system that requires regular manual cleaning of the ash.
The mobile grates are used for medium-large sized systems and are equipped with systems for automatic ash expulsion. This type of grate allows control over the progress of combustion, thus ensuring greater efficiency.

  1. Filtering

The fumes at the exchanger outlet must be “cleaned” and, generally, two systems are used for this purpose (separately or together):

  1. Cyclone (or multi-cyclone) filters for initial filtering that complies with the main pollution regulations;

  2. Bag or electrostatic filters for superior filtration

  1. Fireplace

After filtering, the fumes are pushed by the tail fan through the chimney and expelled into the atmosphere.
Other components may be present in a biomass plant depending on the characteristics of the fuel and the customer’s requests; correct initial design is essential to prevent possible future inconveniences.

BIOMASS PLANTS

The use of biomass has ancient origins, wood has always been burned for heating and cooking. Today, individual consumption has developed on a large scale, adapting to the most varied industrial applications.
Modern power plants are able to exploit the energy contained in biomass to produce hot water, superheated water, steam and electricity, reducing the environmental impact to a minimum compared to non-renewable energy sources.

Hot water

For water temperatures below 110/115°C, hot water boilers are used. The most common uses are in the central heating sector of hospitals, greenhouses, industrial warehouses, etc. Thanks to the simplicity of the system and the undemanding management, hot water systems are preferred to others within the limits described above.

Superheated water

For water temperatures above 110/115°C, superheated water boilers are used. The most common uses are in the district heating sector and specific industrial applications (food, manufacturing, etc.). This type of system is also used in cogeneration plants.

Steam

Our range of biomass boilers includes biomass steam generators (saturated or superheated). Applications range from industrial (food, pharmaceutical, etc.) to electricity generation with steam turbines.

Cogeneration and trigeneration

The term “cogeneration plants” refers to those systems that allow the combined production of electricity and heat. When we talk about trigeneration, we are referring to systems that can produce three distinct forms of energy: electricity, heat and cooling.
We can provide turnkey cogeneration and trigeneration plants.

Boilers

Model Typology Minimum potential Maximum potential
GPT – AC Smoke pipes, 3 turns, hot water production 900 kW 9000 kW
GPT – AS Smoke pipes, 3 turns, superheated water production 900 kW 9000 kW
GPT – CP Smoke pipes, 3 turns, steam production 1000 kg/h 12000 kg/h
GPT – HA Smoke pipes, 3 turns, hot air production 400 kW 1500 kW
GPT – PW Cogeneration 50 kWe 5000 kWe
Standard boiler data Design pressure Boiler room dimensions (mm) Potential Maximum weight with water (kg)
GrillGF-P GrillGF-M30 GrillGM-M30 Grill

GM-M50

1200 GPT/AC 6 bars
10 bars
8000×5000 H.4200 9000×6000 H.4500 9000×6000 H.4500 9000×6000 H.5000 1200 kW 18,800
GPT/AS 8000×5000 H.4350 9000×6000 H.4650 9000×6000 H.4650 9000×6000 H.5150 1200 kW 18,800
GPT/CP 8500×6000 H.5880 8500×6000 H.5880 9000X6500 H.5960 9000X6500 H.6520 1860 kg/h 23,800
1650 GPT/AC 6 bars
10 bars
8500×6000 H.4200 8500×6000 H.4500 9500×7700 H.4500 9500×7700 H.4800 1650 kW 26.100
GPT/AS 8500×6000 H.4350 8500×6000 H.4650 9500×7700 H.4650 9500×7700 H.4950 1650 kW 26.100
GPT/CP 9500×7000 H.6420 9500×7000 H.6420 9500×8000 H.6500 9500×8000 H.7100 2560 kg/h 30.800
2100 GPT/AC 6 bars
10 bars
10000×7500 H.4600 10000×7500 H.4900 9500×8500 H.6000 9500×8500 H.5700 2100 kW 35.800
GPT/AS 10000×7500 H.4750 10000×7500 H.5050 9500×8500 H.6150 9500×8500 H.5850 2100 kW 35.800
GPT/CP 9500×8000 H.7145 9500×8000 H.7145 9500×9000 H.8270 9500×9000 H.8270 3255 kg/h 43.300
3000 GPT/AC 6 bars
10 bars
11000×8500 H.5500 11000×8500 H.5800 11000×8500 H.5800 10500×8500 H.6947 3000 kW 50.800
GPT/AS 11000×8500 H.5650 11000×8500 H.5950 11000×8500 H.5950 10500×8500 H.7097 3000 kW 50.800
GPT/CP 11000×9000 H.8200 10500×9000 H.9450 10500×9000 H.9530 10500×9000 H.9450 4650 kg/h 60,000
The following special models are also available:
• 7000 with potential 7000 kW 10850 kg/h
• 9000 with potential 9000 kW 12000 kg/h

Standard design pressures from 6 bar to 25 bar – Higher design pressures available on request. .

For any requests for special models and applications and/or different from those in the catalogue, a feasibility analysis must be carried out.

Grids

Model Typology Minimum potential Maximum potential
GF – P Fixed pellet grill 900 kW 3000 kW
GF-M30 Fixed grid for wood chips maximum humidity 30% 900 kW 3000 kW
GM – M30 Mobile grate for wood chips maximum humidity 30% 900 kW 9000 kW
GM – M50 Mobile grate for wood chips maximum humidity 50% 900 kW 9000 kW
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Cogeneration plants and Save Energy

Cogeneration plants and Save Energy

We support companies in creating cogeneration plants with simultaneous production of electricity and heat. Garioni Naval today produces industrial boilers , naval boilers and biomass boilers for all needs. We propose ourselves both as suppliers of components, especially boilers, and as builders of the entire turnkey plant. Our solutions are based on traditional fuels, biomass or heat recovery. All generators belonging to cogeneration plants are designed, tested, built according to the latest regulations and can be certified according to PED, ASME, naval authorities or other regulations depending on the country of installation. The management and control system is built in compliance with the most up-to-date standards and can include innovative features such as remote control or remote connection via the Internet for more convenient and safe use.

HEAT RECOVERY UNITS

Among industrial boilers, we design and manufacture heat recovery units (recovery steam generators and heat recovery boilers) tailored for various types of industrial and naval applications. Our recovery units use exhaust fumes from engines, electric generators, ovens, incinerators and other industrial processes and transfer the heat to a secondary fluid, which can be steam, water, diathermic oil or even air. Each
individual recovery unit is specifically designed for its specific purpose, based on the quantities, temperature and chemical/physical characteristics of the fumes, as well as taking into account the performance requirements and any dimensional or environmental constraints.
Different construction types can be made: single or multi-pass smoke tubes, coils, or through batteries of smooth or finned tubes. Large water tube steam generators with natural or forced circulation are also produced. The orientation can be either horizontal or vertical. The recovery units are highly customizable, not only in terms of size and performance but also in terms of equipment, control system and management.
All recovery steam generators are designed, tested, built according to the latest regulations and can be certified according to PED, ASME, naval entities or other regulations depending on the country of installation.
The installation of a heat recovery unit guarantees significant energy savings and helps reduce emissions of harmful and greenhouse gases into the atmosphere.

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