Global Boiler Industry Achieves Major Milestones As Advanced Ultra-Supercritical Technology Matures

Global Boiler Industry Achieves Major Milestones as Advanced Ultra-Supercritical Technology Matures

The global boiler industry continues its rapid evolution, driven by the dual imperatives of decarbonization and energy security. According to Global Market Insights, the worldwide boiler market is projected to grow from $122.4 billion in 2026 to $220.9 billion by 2035, representing a compound annual growth rate of 6.8%. The industrial boilers segment alone is expected to expand from $12.8 billion in 2026 to $20.7 billion by 2035, at a CAGR of 5.4%. This sustained growth reflects rising industrial demand, manufacturing expansion, and the accelerating replacement of aging infrastructure worldwide.

World's First 630°C Ultra-Supercritical Coal-Fired Power Project Reaches Full Capacity

A landmark achievement in global power generation was reached on July 28, 2026, when the world's first 630°C ultra-supercritical secondary reheat coal-fired power project achieved full-capacity commercial operation-22. The project, comprising two 1,000 MW units, set four world records: the highest reheat steam temperature (631°C), the highest main steam pressure (35.5 MPa), the highest thermal efficiency (exceeding 50%), and the lowest coal consumption rate (245.74 grams per kilowatt-hour)-22. These figures represent the absolute upper limits of current coal-fired power technology.

The boiler, the powerhouse of the unit, pushed pressure-bearing, temperature-resistance, and energy-efficiency metrics to industry extremes. To achieve precise control of wall temperature deviation across all operating conditions, the development team pioneered a multi-dimensional temperature deviation "flattening" technology, ensuring stable main steam temperature of 616°C and two-stage reheat steam temperature of 631°C-22. The project also marked the world's first engineering application of domestically developed G115 advanced martensitic heat-resistant steel, breaking the long-standing foreign monopoly on high-temperature alloy materials-22. Upon full operation, the project saves 208,000 tons of standard coal annually and reduces carbon dioxide emissions by approximately 540,000 tons per year-22. The successful operation of both units marks the full maturity of domestically developed 630°C ultra-supercritical thermal power complete technology, new materials, and equipment supply chains, providing a complete engineering template for batch construction of similar units domestically and for exporting high-efficiency thermal power technology to global markets.

Breakthrough in Boiler Retrofit Technology Cuts Downtime by More Than Half

In a significant development for the boiler retrofit segment, the first domestic ultra-supercritical boiler vertical water wall retrofit project was completed and put into operation in July 2026. The project, undertaken at a 600 MW ultra-supercritical unit, converted the original vertical tube water wall to a spiral water wall configuration. The retrofit was completed in just 115 days-a dramatic reduction from the industry standard of 6 to 8 months for similar projects. The compressed schedule substantially reduced plant downtime and associated revenue losses, effectively solving a long-standing industry bottleneck.

The upgraded "spiral tube section + upper vertical tube section" composite water wall design, combined with a new burner system, delivered significant performance improvements. Temperature differences between adjacent tubes at the same position were stabilized within 4°C, while the overall furnace maximum temperature differential under normal operation did not exceed 28°C. These improvements effectively eliminated equipment risks such as water wall deformation and fin tearing caused by excessive thermal stress, substantially enhancing unit stability. The successful project has established a standardized technical retrofit process covering equipment flushing, multi-round defect inspection, and ignition commissioning, providing a complete upgrade solution for similar ultra-supercritical units nationwide.

Major Coal-Fired Power Projects Reach Key Milestones

Multiple large-scale coal-fired power projects have reached critical construction milestones in recent weeks. On July 26, 2026, a 2×1,000 MW peak-shaving coal power project achieved first-time successful ignition of its No. 1 boiler. The project, with a total investment of 8.034 billion yuan, is equipped with two domestically manufactured ultra-supercritical indirect air-cooled coal-fired generating units and is designed to generate 9 billion kilowatt-hours annually. As a key peaking support power source ensuring the stable operation of a major ultra-high voltage direct current transmission corridor, the project features exceptional deep peak-shaving capability, effectively compensating for the intermittent and fluctuating nature of wind and solar power generation. The first unit is scheduled to commence commercial operation on September 30, 2026.

On June 29, 2026, the No. 1 boiler of another 2×660 MW ultra-supercritical coal-fired project achieved first-time successful ignition-6. The project adopts energy-efficient, ultra-low emission, and intelligent control technologies. Upon completion, it will supplement regional power supply in eastern Zhejiang, improve the regional power grid architecture, and serve local industrial development.

Policy Framework Accelerates Boiler Energy Efficiency Upgrades

In June 2026, China's National Development and Reform Commission and four other ministries jointly issued a three-year action plan for energy-saving and carbon-reduction retrofits targeting nine key industries. For the coal-fired power sector, the plan requires promoting technologies including high-efficiency combustion, cold-end optimization, waste heat utilization, and intelligent control, while accelerating the upgrade of boilers, turbines, transformers, and other energy-consuming equipment. Retrofitted units are expected to achieve a reduction in coal consumption of at least 5 grams of standard coal per kilowatt-hour. The plan also calls for deep peak-shaving and wide-load regulation retrofits, encouraging the integration of coal power with new energy sources. Additionally, a national policy document mandates the complete phase-out of coal-fired boilers of 10 tons of steam per hour and below, with a phased replacement of medium and small coal-fired boilers across various industries.

Against this backdrop of rapid technological advancement and policy-driven modernization, the demand for high-quality pressure vessels, heat exchangers, cryogenic storage tanks, and custom-engineered process equipment continues to grow across the energy, chemical, metallurgical, food processing, and healthcare sectors.