Revitalization of Waste Heat Boiler

Customer: Nickelhütte Aue, Germany

At Nickelhütte Aue, our experienced service team successfully avoided the costly replacement of a decades-old waste heat boiler. Through precise diagnostics, we determined that more than half of the boiler was in near-new condition. Revitalization proved to be a significantly more economical and time-saving solution. The result: maximum efficiency, minimal downtime and long-term cost savings.

With TÜV-certified structural integrity and upgraded components, the boiler is now fully prepared for reliable operation, a result achieved in just six weeks rather than the full year required for a total replacement.

That’s how we helped Nickelhütte Aue get ahead

As part of the waste heat boiler revitalization, the front wall, left and right-side walls, partition wall, and tube-bundle wall were dismantled and reinstalled.

Key Benefits:

Extended boiler service life through renewal of heavily stressed components
Increased operational safety by replacing worn parts
Improved heat transfer, resulting in enhanced energy efficiency
Reduced downtime through preventive maintenance
Significant cost savings compared to purchasing a new unit

Why DIEFFENBACHER Energy Service?

Project delivered on time and on budget despite extremely challenging timeline
In-house engineering that enabled quick reaction to unexpected challenges
Coordination of several suppliers on site: DIEFFENBACHER Energy Service acted as a single point of contact

Technical Data

Electrical Output	2 MW
Steam flow (MCR)	8 t/h
Steam pressure	40 bar (a)
Steam temperature	350 °C
Country	Germany