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Abstract
The research is talking about the waste heat recovery systems in general, its purpose and its effect on efficiency and economy of power plants, also abou various types of equipments used in waste heat recovery systems, development of waste heat recovery systems to relocate future. The research is taking a view about ammonia industry, illustrating in details the ammonia synthesis loop in ammonia plants as it is considered as a type of waste heat recovery systems found in the plant also different designs of waste heat boilers used in ammonia plants. The research is taking about boilers problems, poor water treatment and its bad effect on boiler performance and life time of tubes, accordingly the reliability of the boiler. The research is including known types of boiler tube failure, its symptoms and possible causes that can be used as hand book for boiler engineers. The research includes several case studies about waste heat boilers of same internal design of our case study suffered from failure in various ammonia plants inside Egypt. The research include case studies of waste heat boilers suffered from leakage problems outside Egypt, they are of different internal design but they are found in the ammonia-synthesis loop in the ammonia plants.
In the last part of the research we are taking a case study about the failure happened to waste heat boiler of ABU-QIR Fertilizers Company, the case study includes boiler description, internal design features, history of problems, inspection done for it, results of inspection, analysis of possible logic causes for failure, some calculations related to analysis then fmally the results and recommendations for preventing these failures after that.