BIOMASS BOILERS
Improving your business is our business
Thermax offers products, systems and solutions in energy and environmental engineering to industrial and commercial establishments around the world. Its business expertise covers heating, cooling, waste heat recovery, captive power, water treatment and recycling, air pollution control and waste management and performance chemicals.
Thermax brings to customers extensive experience in industrial applications and expertise through technology partnerships and strategic alliances. Operating from its headquarters in Pune (Western India), Thermax has built an international sales and service network spread over South East Asia, Middle East, Africa, Russia, UK and the USA.
Boiler & Heater Group (B&H)
Thermaxs Boiler & Heater Group provides equipment and complete solutions for generating steam for process and power needs through combustion of various solid, liquid and gaseous fuels, as well as through heat recovery from turbine/engine exhaust and (waste) heat recovery from industrial processes. The Group also offers heaters for various applications in the Chemical, Petrochemical and Refinery segments. Its services arm offers renovation and modernization solutions for old boilers and heaters.
The major industry segments served by the Group in India and across the world are Steel, Refinery, Petrochemical, Power, Cement, Sugar, Fertilizer, Paper, Chemical, Non Ferrous Metal and Textile.
Thermax as an organisation is committed to sustainable development. Sustainability for us is not only a criterion applied to the energy and environment related solutions that we provide, but in fact pervades day-to-day activities, informs key decisions and guides new initiatives. In pursuit of achieving the Thermax vision of sustainable development for society, the Boiler & Heater Group has in the recent past delivered several breakthrough innovations through a combination of in-house R&D and global sourcing of the best available technologies. Among these are spent wash-fired boiler for distilleries, municipal solid waste-fired boiler for urban waste disposal, waste heat recovery boiler for cement plants and internal-recirculation circulating fluidised bed boiler for power generation. The B&H Group is also working on a range of products for the emerging market for solar energy based heat recovery systems.
Our Green Business Philosophy & Activities
When business organisations consider moving to decisions that are sustainable -- like saving electricity, recycling water, using renewable energy or putting up green buildings -- the big investments required upfront would certainly impact the balance sheet here and now. But, if we were to think of a longer time-frame, all these decisions would make a lot of sense when we consider the concept of life-cycle cost -- a higher capital cost, but with far lower operating costs such that it pays for itself over the life of the product. Long-term sustainability also goes hand in hand with the kind of decisions we make, processes we follow, policies we adopt and the values we propagate. Companies passionate about the cause of Sustainable Development will constantly come up with innovative solutions which, over time, will definitely add to the bottom line. If we were to redefine success of an organisation as achieving the triple bottom line -- economic, environmental and social -- it would be a sustainable model and we would be a far happier and healthier species on earth! So what can each one of us do? What can we do as an organisation to achieve this triple bottom line? These are questions we need to ask ourselves and act as quickly as possible since time is running out.
Ms. Meher Pudumjee
Chairperson
Kakatiya Cement Sugar & Industries, Hyderabad, Andhra Pradesh, India
1 unit of 90 TPH, 86 Kg/cm2(g), 5155C, coal / bagasse fired travelling grate boiler
Thermax has always been responsive to the energy needs of industry and to the ever-changing economic and environmental factors governing those needs. Current trends and future outlook highlight the need for utilising the vast untapped energy potential of agrowastes and biomass.
The Thermax biomass boiler is the very equipment required to improve profitability through maximum utilisation of solid agrowastes generated in your plant or available in nearby areas. Over 300 plants in India and abroad meet their process steam and electric power requirements through biomass fired boilers supplied by Thermax .
Biomass Boiler
Flexible design - a variety of options
Capacity upto 300 TPH, Pressure upto 160 kg/cm2(g) and temperature upto 560C
Travelling Grate, Dumping Grate, Pinhole Grate, Pusher Grate or Hopper Bottom (fluid bed)
Membrane wall / tube and tile construction
Indoor and outdoor installation
Auto controls or remote - manual control option
Multifuel firing capability - Includes bagasse, husk, straw, coffee grounds, cane tops, coconut shells, lignite, coal, pith, wood chips, oil, gas etc.
Membrane panelled furnace design
Machine welded membrane wall furnace forms a gas tight enclosure preventing ingress of unwanted excess air
Requires no refractory in furnace walls and eliminates associated maintenance
Results in quicker boiler commissioning due to reduced site welding, simplified handling / erection
Higher overall efficiency
Optimum design & selection of auxiliary equipment to ensure the highest operational efficiency and availability of the plant
High efficiency steam separators ensure steam purity
Variable speed fuel feeder allows fine control of feed
Modulating cyclomotor to ensure even distribution of fuel
Tall furnace for complete combustion
Tall furnace increases residence time of flue gases, allowing fuel to burn completely before the gases enter the superheater zone
High pressure, deep penetration secondary air jets are strategically located at multiple levels on furnace walls, ensuring proper turbulance and good mixing of volatiles with air and complete combustion
Indian Cane Sugar Ltd., Bagalkot, Karnataka, India
1 unit of 125 TPH, 87 Kg/cm2(g), 515C, bagasse & coal fired travelling grate boiler
Travelling GrateSalient Features
Travelling Grate ensures uninterrupted combustion
Continuous ash discharge system avoids dependence on operators judgement
Grate speed can be varied continuously in range 0-12 m/hr.(0-45ft / hr)
Overlapping grate design prevents air leakages
Maintenance of grate can be carried out without shutting down the boiler
An overfire air system provides turbulence and thorough mixing of the volatile gases, thus assuring complete combustion
All other advantages of suspension burning are ensured
Dumping Grate can be offered in place of travelling grate on request
Proven Design & Rugged Construction for Reliable Continuous Operation
Catenary design provides for automatic take-up or tensioning of grate chains to prevent jamming. Effective catenary is maintained by gravity, thus making external shaft adjustments unnecessary.
Grate surface consists of a series of grates specifically designed for spreader stoker firing. The grates are constructed of best quality heavy duty heat-resisting cast iron alloy and
are made in short sections (230 mm to 300 mm long) which can be individually replaced, thus reducing grate maintenance costs.
Grate curvature design keeps the grate closed without the aid of auxiliary weights when making the turn around the sprockets.
Grate removal is easily achieved through a grate access door. On removal of one bolt, any grate section can be replaced while the stoker is in operation. Grate support within the furnace is provided by a series of skids and skidrails, each constructed of hardened cast iron for maximum life.
Front and rear grate shafts carry the grate chains on hardened sprockets.
The air pressure chamber, completely sealed at both front and rear to prevent air leakage, directs and distributes combustion air through the active grate surface.
Three front undergrate air seals prevent air by-passing to the ash discharge end.
The rear seal is designed to allow rear water wall expansion while maintaining tightness.
Indian Cane Sugar Ltd., Bagalkot, Karnataka, India
1 unit of 125 TPH, 87 Kg/cm2(g), 515C, bagasse & coal fired travelling grate boiler
Travelling Grate front and rear air seals automatically keep excess air to a minimum within the furnace. These front and rear seals are ruggedly constructed for long service and are automatically self-adjusting to maintain continuous close sealing contact.
The curvature design of the grates keeps the grates closed without the aid of auxiliary weights, when making the turn around the sprockets. No gaps appear between the grates, thereby directing all foreign materials into the ash pit and not into the drive shaft mechanism.
Design is such that any grate section can be replaced without taking the stoker out of service. Simply remove a single bolt, nut & washer and slide the grate off the carrier bar.
To reduce maintenance costs, grate surface is made in short sections (230 mm to 300 mm long) of best quality, heavy duty, heat-resisting cast iron alloy with uniformly spaced, tapered, self-cleaning air-metering openings, and with close fitting overlapping edges to prevent air leakage at the joints.
The hydraulic grate drive is a self-contained unit in a single housing with no external piping. Hydraulic pump and control regulate the flow and pressure through linkage in a ratchet gear which drives the main shaft. The hydraulic drive and main shaft are connected by a heavy-duty flange coupling. The hydraulic unit is equipped with a factory-set relief valve to protect the grates should the need arise. To compensate for variation of the ash content in the fuel, the drive can be infinitely regulated to control the grate speed from 0 to approximately 15 meters per hour.
Technical Features
Bajaj Hindustan, Gola, Uttar Pradesh, India
1 unit of 100 TPH, 45 Kg/cm2(g), 425C,bagasse fired pinhole grate boiler
Pinhole GrateSalient Features
Stationary inclined water cooled grate design with no moving parts for avoiding any mechanical failures and reducing maintenance in the furnace
Steam nozzles for simplified on-line ash removal from the grate without drop in boiler pressure. Also agitation of fuel occurs which results in reduction in unburnt carbon loss
An economical and viable option for high capacity boilers
Combustor can accept air of temperature upto 250C thus resulting in smooth combustion of fuel
Inherently capable of burning high-moisture bagasse
An overfire air system provides turbulence and thorough mixing of the volatile gases, thus assuring complete combustion
Adequate number of feeders for uniform fuel distribution
All other advantages of suspension burning are ensured
Jocil Limited, Dokiparru, A.P.
1 unit of 30 TPH, 66 Kg/cm2(g), 485C, rice husk and coal fired
Hopper Bottom (Fluidised Bed Combustion) boiler
Hopper Bottom (Fluidised Bed Combustion)*Salient Features
FBC combustor does not have any moving parts thus reducing maintenance in the furnace
Uniform temperature distribution in the bed and agitating characteristic of fluidised bed ensures optimum combustion
Low excess air requirement resulting in higher efficiency
Lower NOx and CO emissions
Low temperature operation greatly helps in minimising the biomass fuel ash agglomeration and fouling tendency
Continuous slow draining of bed ash is possible which helps in: ` Easy settling and disposal of large sized particles which hamper fluidisation
` Maintaining alkali concentration at minimum level
` Avoiding accumulation of fuel over slumped bed
` Under bed / over fuel feeding for proper distribution of fuel
*Product is supported under technical collaboration agreement with Babcock & Wilcox, USA.
CLIENT CITY NOS. TPH KG/CM2G DEG.C FUEL YEAR
Dumping Grate
Bannari Amman Sugars Coimbatore 2 32 42 410 Bagasse 1990
Seksaria Sugar Mills UP 1 50 32 390 Bagasse 1990
Phoenix Pulp & Paper Thailand 1 80 65.3 480 Bark/Oil 1991
Lampang Sugars Thailand 1 50 16 265 Bagasse 1992
Pinhole Grate
Bajaj Hindusthan Lakhimpur Kheri, UP 1 80 45 4205 Bagasse 2000
Bajaj Hindusthan Gola 1 100 45 425 Bagasse 2003
Hopper Bottom (Fluidised Bed Combustion)
Shree Cements Ltd. Beawar, Rajasthan 2 80 65 4955 Imported Coal, Petcoke, Lignite
2001
Nestle Philippines Inc. Philippines 1 24.95 18 Saturated Spent Coffee Grounds, green coffee residue, roasted chaffs & HFO
2004
Bhushan Limited Orissa 1 165 88 5205 Washery rejects, char 2004
Holcim Group - Ambuja Cements
Chhattisgarh 1 80 67 4955 Coal/Rice husk/coal/biomass/pet coke
2006
Usha Martin Ltd. Ghamaria, Jamshedpur
1 140 69 4905 washery rejects, char fired Hopper bottom
2006
ITC Limited Bhadrachalam 1 90 65 480 F Grade coal / biomass 2008
Sabah Forest Industries Sdn Bhd. Sabah, Malaysia 1 75 65 480 Wood, Bark & Sludge 2010
Travelling Grate
Kakatiya Cement Sugar & Industries
Hyderabad 1 90 86 5155 Coal/Bagasse 2000
Tamilnadu Newsprint & Papers Ltd.
Appakudal 2 85 87 515 Bagasse/Imported coal/pith/lignite
2001
Balrampur Chini Mills Ltd. U.P. 1 80 87 515 Bagasse/Rice Husk 2001
Rio Tuba Nickel HPP project through JGC
Philippines 1 105 49 400 Indonesian coal 2002
Bannari Amman Sugars Ltd. Nanjangud 1 120 67 485 Bagasse/biomass 2002
Davangere Sugar Co. Ltd. Kukkuwada 1 90 87 515 Bagasse,coal / biomass 2002
Mawana Sugars Ltd Nagalamal 1 120 87 515 Bagasse, Rice husk & Indian coal
2005
Dhampur Sugars Ltd. Dhampur, UP 2 170 105 540 Rice husk & coal 2005
Bharat Sugars Ltd. Hulliatti Karnataka 1 120 108 540 Bagasse & coal 2006
Sri Chamundeshwari Sugars Bangalore 1 135 108 540 Bagasse & coal 2006
Indian Cane Sugar Ltd. Bagalkot 1 125 87 515 Bagasse & coal 2006
Madhucon Sugar Ltd. Khammam 1 120 108 540 Bagasse 2006
Nava Bharat Ventures Ltd. Hyderabad 1 100 87 5155 Bagasse 2006
Yashwantrao Mohite Krishna Sahakari Sakhar Karkhana Ltd.
Satara, Maharashtra 1 90 87 5155 Bagasse 2008
Samarth Sahakari Sakhar Karkhana Ltd.
Jalna, Maharashtra 1 95 87 510 Bagasse 2008
Saha Cogen Lamphun A/c Jurong Engg
Thailand 1 65 53 412 Wood Chip 2009
Mitr Kalasin Bio Energy Company
Thailand 1 170 105 520 Bagasse, wood chips, rice husk
2010
Lokmangal Sugar Ethanol & Co-Generation Company Ltd.
Solapur 1 90 67 505 Bagasse, imported coal 2010
Dan Chang Bio-Energy Co.,Ltd. Thailand 1 170 105 520 Bagasse, wood chips, rice husk
2010
Lakshmi Sugar Mills Company Ltd.
Uttarakhand 1 110 110 540 Bagasse 2010
Kamadhenu Ventures (Cambodia) Ltd.
Cambodia 1 135 110 540 Bagasse 2010
Jamkhandi Sugars Ltd. Bagalkot 1 120 110 540 Bagasse 2010
Major Installations
Canada
U.S.A
Mexico
Colombia
Brazil
Algeria
U.K.
Ireland
REGIONAL OFFICES
Baroda oFFIce & WorkS
Plot No. 21/1,2,3, GIDC, Manjusar (Savli), Taluka Savli, Dist - Vadodara, Gujarat 391775
Phone: +91-2667-264727 Fax: +91-2667-264728
MuMBaI
Dhanraj Mahal 2nd floor, Chhatrapati Shivaji Maharaj Marg, Near Gateway of India, Mumbai 400 039
Phone: +91-22-22045391, 22045324 Fax: +91-22-22040859
NeW delHI
9, Community Centre, Basant Lok, Near Priya Cinema, New Delhi 110 057
Phone: +91-11-26145326, 26145319 Fax: +91-11-26145311
cHeNNaI
Fatima Akthar Court, 3rd floor, 312, Teynampet, Chennai 600 018
Phone: +91-44-24353831 / 4 Fax: +91-44-24353841
kolkaTa
Azimganj House, 5th Floor, 7 Camac Street, Kolkata 700 016
Phone: +91-33-22826711 / 13 Fax: +91-33-22826796
HyderaBad
6-3-649, Behind Medinova, Nalanda Complex, 2nd Floor, Somaji Guda, Hyderabad 500 082
Phone: +91-40-23310254 / 23312013 Fax: +91-40-23312335
OVERSEAS OFFICES
SouTH eaST aSIa
Thermax Limited
3rd Floor, South Wing, Bangunan Getah Asli, 148 Jalan Ampang, Kuala Lumpur - 50450, Malaysia
Phone: +603 2166 98 01 / 03 / 04 Fax: +603 2161 2685
Email: [email protected] Cell: +60 122056623
Email: [email protected] Cell: +60 172454569
MIddle eaST
Thermax Limited
C/o. Gulf Power International (Dabbagh Group), P. O. Box: 74426, Al-Khobar 31952, KSA
Phone: +966 3 887 4557 Fax: +966 3 882 3041
Email: [email protected] Cell: +966 553 915 403
euroPe
Thermax Ltd,
Avenue Charles Thielemans 109
B - 1150 , Brussels, Belgium
Phone: 32(0) - 27369244 / 473450186
Email: [email protected]
New Zealand
South Africa
Zambia
Tanzania
Sri Lanka
Indonesia
Australia
PhilippinesMalaysia
Netherlands Kazakhstan
Russia
Germany
Kenya
India
VietnamThailand
Bangladesh
Oman
Cambodia
Abu DhabiQatarBahrain
Jordan
Turkey
Kuwait
Uzbekistan
Turkmenistan
UAE
Nigeria
Algeria
U.K.
Egypt
Saudi Arabia
Yemen
Installations in 75 countriesGlobal Footprint of Boiler & Heater Group
For more details visit www.thermaxindia.com orWrite to [email protected]
The information contained herein is provided for general information purposes only and is not intended or to be construed as a warranty, an offer, or any representation of contractual or other legal responsibility. 2011 Thermax Ltd. All rights reserved.
Thermax limited,Boiler & Heater Group
Energy House, D-II Block, Plot No 38 & 39,
MIDC, Chinchwad, Pune 411 019
Phone: +91-20-661 2 6464 | Fax: +91-20-6612 6612 / 6612 6476
Email: [email protected] www.thermaxindia.com
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