A major automotive tire manufacturer needed to replace its water-tube steam generator with a more efficient, reliable, and high-performance solution.
The goal was to ensure steam production up to 26,000 kg/h at 26 bar, with a turnkey supply and uninterrupted production continuity.
The solution
ICI Powering Evolution conducted an on-site inspection and assessment of the existing system to design the most suitable technical solution.
The project included:
- Dismantling and removal of the existing water-tube boiler
- Construction of a new concrete and steel base, designed according to the Local Coordinate System (LCS), considering static, dynamic, seismic, and wind loads
- Supply and installation of a GX 12000 steam generator, with 20,000 kg/h output at 26 bar
The plant was equipped with:
- GSS 72H system for up to 72 hours of autonomous operation
- PED level probes, TDS control, and mud separator
- Modulating gas burner with O₂ control
- Flue gas recirculation (FGR) system
- ECXV 120-130 economizer for heat recovery
The executive design phase included drawings, diagrams, and technical specs, followed by on-site project management for full installation.
The project was completed with commissioning, certification by the notified body, and training of plant personnel.
Achieved results
Thanks to optimized efficiency devices and thorough design execution, the company was able to:
- Reduce energy consumption
- Increase system efficiency
- Lower emissions, meeting stringent environmental regulations
Key benefits
✅ Turnkey solution from design to commissioning
✅ Higher energy efficiency and lower operating costs
✅ Reduced emissions thanks to FGR and O₂ control
✅ Fully automated system, compliant with current regulations
✅ Full technical supervision in all project phases
