Header-Type Water-Tube Rotary-Grate Steam Boiler
The header-type water-tube rotary grate steam boiler is an industrial solution that meets high-capacity and continuous steam demands in the most economical way using solid fuel. Thanks to rotary grate technology, coal and biomass are fed automatically, ash is discharged automatically, and a continuous, balanced combustion process is ensured. The four-pass flame circulation system delivers high efficiency and rapid steam production, while firebrick and rock wool insulation minimize heat loss. The fully automatic control system ensures minimal operator intervention and low operating costs.
Header-Type Water-Tube Rotary Grate Steam Boiler
Header-type water-tube rotary grate steam boilers are systems used in industry to meet high-capacity, continuous steam demands in the most economical way using solid fuel. They combine the high efficiency of the header-type water-tube boiler design with the automatic combustion advantages of the rotary (moving) grate technology.
The boiler consists of tubes arranged in rows between two parallel plate boxes; these tubes are connected within the header, ensuring a completely leak-tight seal with the body. Thanks to the maintenance hatches on the header surface, the tubes can be easily installed and replaced. Between the front and rear headers, double-walled 45-degree deflector plates allow the flame to pass through four times; as a result, the boiler’s efficiency is significantly higher than that of Scotch-type boilers, and steam demand is met more quickly.
A distinctive feature of the system is the rotary grate mechanism located at the bottom of the combustion chamber. The moving grate ensures that solid fuels, such as coal and biomass, are fed into the furnace in a regulated manner, are advanced throughout the combustion process, and that ash is automatically discharged at the end of combustion. This design ensures continuous and balanced combustion, minimizing operator intervention, saving fuel, and eliminating the need for manual feeding and cleaning.
The pipes are installed at a 6-degree angle to the floor, creating a dynamic steam flow; this flow allows the steam to collect in the steam drum from the bottom up. The combustion chamber walls are vertically oriented; their outer surfaces are lined with firebrick and covered with rock wool, providing excellent thermal insulation. Firebrick both retains the boiler’s heat and increases the heat transfer surface area, thereby meeting the need for rapid steam production.
Advantages
• By combining a header-type boiler design with a rotary grate combustion system, the goal is to achieve the highest efficiency and lowest fuel cost among steam boilers.
• Thanks to the rotating (movable) grate, solid fuels such as coal and biomass are automatically fed, ash is automatically discharged, and continuous, balanced combustion is ensured.
• It operates with a fully automated system; the need for user intervention and qualified personnel is minimized.
• Thanks to its water-tube design, the evaporation rate per unit area is very high; it provides very rapid steam supply during sudden increases in steam demand and during startup.
• The boiler is a four-pass design and is highly efficient due to the long flame path.
• It retains heat for 24 hours, making it suitable for restarting directly with solid fuel; it is ideal for stop-start operations and applications with variable steam demand.
• High-quality steam is produced at high dryness.
• The exterior insulation is lined with firebrick and rock wool; thermal insulation is excellent.
• It automatically starts and stops based on pressure and temperature; steam production costs are lower compared to other systems.
• It is easy to operate, maintain, and repair; it is the longest-lasting boiler type under suitable water conditions.
Technical Specifications
- Four-pass design with header-type water tubes
- Solid fuel (coal/biomass) combustion system with a rotary grate
- Automatic fuel feeding and automatic ash removal
- High-efficiency heat transfer surfaces
- Excellent thermal insulation with firebrick and rock wool
- High-quality steam production with a high degree of dryness
- Rapid steam supply and high responsiveness to sudden steam demands
- Fully automatic control and safety systems
- Low fuel consumption and low operating costs
- Various capacity and operating pressure options
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Optional Equipment:
- Economizer or Recuperator (flue gas heat recovery)
- Automatic water supply and level control system
- Safety valves (EN ISO 4126-1 compliant)
- Steam collector and blowdown system
- Fuel storage bunker and screw feeder
- A header-type water-tube steam boiler that automatically feeds coal and biomass using rotary grate technology, automatically discharges ash, and ensures continuous and stable combustion. Thanks to its four-pass flame circulation, it offers high efficiency, rapid steam production, and low fuel costs.
Food and Beverages
Milk and dairy products, canned goods, tomato paste, oil refining, sugar, and beverage production—high demand for steam in pasteurization, sterilization, and cooking processes.
Textiles and Dyeing
Continuous, high-pressure steam for fabric dyeing, finishing, drying, and printing processes.
Chemicals and Pharmaceuticals
Reaction heating, distillation, and process heat; production lines requiring sterilization.
Paper and Pulp
High-capacity steam for paper drying cylinders and pulp processing.
Lumber, Wood, and Particleboard
Drying ovens, pressing, and steam treatment processes—particularly offering economic advantages when using biomass (wood chips, wood waste) as fuel.
Feed, Fertilizer, and Agricultural Processing
Feed pelletizing, drying, and processing facilities.
Hotels, Hospitals, and Institutional Facilities
Steam requirements for laundry, kitchen, and central heating.
Rubber, Plastics, and Tires
Process steam for vulcanization and molding processes.
Solid fuel systems with rotary grates offer significant fuel cost advantages over natural gas, particularly in facilities where coal and biomass are inexpensive and readily available and where steam consumption is high and continuous—which is why the food, textile, paper, and wood industries stand out.
Companies we have delivered this boiler to
- Akova Süt ÜrünleriKonya · 2 × 25 t/h, 25 bar
- Özmiroğlu YağHatay · 20 t/h, 12 bar + 12 t/h, 12 bar + 25 t/h, 12 bar
- Yonca GıdaManisa · 2 × 15 t/h, 12 bar
- Verde Yağİzmir · 12 t/h, 12 bar + 3 × 23 t/h, 17 bar + 12 t/h, 17 bar
- Halmer TekstilDenizli · 10 t/h, 8 bar
- Orkide YağKemalpaşa / İzmir · 6 t/h, 12 bar
- Defne Tarımİzmir · 6 t/h, 8 bar
- Altınköy GıdaAydın · 6 t/h, 6 bar
- Uğuray SütAksaray · 2 × 20 t/h, 25 bar
- Cici SütManisa · 18 t/h, 20 bar
- İtimat Süt ÜrünleriBursa · 10 t/h, 8 bar + 6 t/h, 8 bar
- Seven Foodsİzmir · 10 t/h, 8 bar
Frequently Asked Questions
A header-type boiler is a water-tube boiler in which the tubes are arranged in rows between two parallel plates (header box), and their ends are expanded inside the header and connected in a leak-proof manner.
It operates automatically with a rotary grate combustion system using coal and biomass fuels such as sawdust, olive pomace and shells.
It provides high efficiency thanks to its four-pass flame circulation and insulated body; our boilers operate with a thermal efficiency ranging from 85% to 95%, depending on the boiler type, fuel, and operating conditions.
A header-type water-tube boiler is suitable for high capacity, solid fuel, and continuous steam production; a Scotch boiler is suitable for natural gas and small to medium capacities. Water-tube Boiler Guide
Header-Type Water-Tube Rotary-Grate Steam Boiler — let’s size it together
Our engineers plan capacity, pressure and fuel choice for your needs.