Yes, waste heat recovery systems can often be integrated with existing boilers, provided the system is properly engineered to match the facility’s operating conditions. In many cases, an economizer or waste heat boiler is installed in the flue gas stream to capture excess heat that would otherwise exit through the stack. The recovered heat is then used to preheat boiler feedwater or combustion air, reducing the amount of fuel required to generate steam.

Successful integration depends on factors such as exhaust temperature, flow rate, available space, and the boiler’s pressure and capacity limits. Engineers must evaluate whether the existing boiler can accommodate lower flue gas temperatures without causing condensation or corrosion issues. Controls also need to be synchronized so that heat recovery operates efficiently without disrupting normal boiler performance.

When properly designed, waste heat recovery systems improve overall boiler efficiency, stabilize steam production, and lower fuel consumption. This not only reduces operating costs but also decreases emissions and enhances overall plant energy performance, making integration a practical solution for many industrial facilities seeking greater efficiency.