Cooling & Heating

Bi - drum, water tube, high efficiency boiler

POWERMAXTM

TMPOWERMAX - the ideal boilerfor continuous operations andsuperheated steam

Improving your business

is our business

Thermax offers products, systems

and solutions in energy and

environment engineering to

i ndus t r i a l and commerc i a l

establishments around the world.

Its business expertise covers

heating, cooling, waste heat

recovery, captive power, water

treatment & recycling, air pollution

control & waste management and

performance chemicals. Thermax

brings to customers extensive

e x p e r i e n c e i n i n d u s t r i a l

applications, and expertise through

technology partnerships and

strategic alliances.

Operating from its headquarters in

Pune (Western India), Thermax has

built an international sales & service

network spread over South East

Asia, Middle East, Africa, Russia, UK

and the US. It has a full fledged

manufacturing set up that is

certified for ISO 9001:2000, ISO

14001 and safety management

according to OSHAS (ISO 18000).

In process heat, Thermax offers a

wide range of steam boilers, thermal

o i l hea te rs and hot water

generators. It has expertise in a wide

range of fuels - oil, gas, solid and

agro-waste/ biomass. Supporting a

broad array of industries in

generating, transferring and

conserving heat across a host of

applications, Thermax process heat

products and systems are exported

to North and South America, South

East Asia, Middle East, Africa,

Europe, CIS, Australia, Antarctica

and SAARC.

Sand Bed

FluidisingAir Nozzles

Fuel FeedingNozzles

Fuel FeedingVenturi Fuel

FeedingCross

PlenumChamber

PneumaticSpreader

Dumping

Grate

Air Supply

Rotary FuelFeeder

Fluidised BedSutable for

n Indian Coal

n Imported Coal

n Kutch Lignite

n Rice Husk

n Castor DOC

n Other select multi-fuel options

Firing technique

n Under Bed, Over Bed and Combi-feed

Dumping GrateSuitable for biomass fuels like

¡ Bagasse

¡ Wood Chips

Firing technique

¡ Pneumatic spreading

Customised options available for

Rotary FuelFeeder

Mechanical& PneumaticSpreader

Hydraulic Drive

Ash CollectingHopper

CombustionAir

TravellingGrate

Traveling GrateSuitable for

n Bagasse

n Indian Coal

n Imported Coal

n Wood Chips

n Palm Kernel Shell

n Julia Flora

Firing technique

n Pneumatic spreading

n Mechanical spreading

Presenting the versatile two drum, water tube design, solid fuel fired boiler, popularly known as the Bi-Drum, that is custom made for your application.

TMPowermax comes with several major advantages: n High pressure steam due to its water tube designn Uninterrupted operations n High degree of Superheat due to large super heater n The combustor can be adapted any type of fuel firing - Fluidized Bed Combustion, Travelling Grate, Reciprocating Grate or Dumping Grate - making the boiler suitable for burning any kind of solid fuel

Reciprocating GrateSuitable for

n

n Rice Husk

n Wood Chips

n Palm Kernel Shell

n Palm Fibres

n Other sized Biomass

n High Moisture Biomass

n Process Wastes

n Jungle Waste

n And many more...

Biomass Briquette and Pellete

Combustiontechnologyfrom Germany

Variable Pitch Feeding Screw

Reciprocating Grate

Hydraulic Drive

AshCollectingHopper

Dosing Bin

Sumerged AshHandling system

Ash ScrapingMechanism

RiadiativeSuperheater

ConvectiveSuperheater

Primary air supplyfor zone wisecombustion -Precisely controlledby electricallyactuated damper

Inbed Heat ExchangerInbed heat exchanger is required only in fluidised bed

combustor, where the heat exchanger is immersed in a

bubbling sand bed, to help take away the heat from the

bed. This helps in maintaining combustor temperature

below the ash melting point using minimal excess air,

which also results in higher efficiency.

Since sand is continuously rubbing against the inbed

tubes during operation, special studding is provided on

inbed tubes to avoid erosion.

EconomiserThe Economiser, made of bare tubes, aids in heat recovery

and improving efficiency. Coming after the boiler bank, it

uses the heat of the flue gases coming out from the boiler to

preheat water going into the steam drum.

Air PreheaterThe air preheater is also heat

recovery equipment situated

last in the flue gas path. It is a

cross flow gas-to-gas heat

exchanger, which provides hot

air for combustion.

SuperheaterTMPowermax comes with a superheater located at the top of

the furnace. This superheater is a heat exchanger, which converts saturated steam into superheated steam.

The superheater is constructed in two halves - radiation and convective zones - connected to each other by an attemperator.

The convective zone of the superheater is shielded from radiation by a nose wall, which also guides the flue gases to cover the entire convective superheater area.

The attemperator is a water injecting device that ensures temperature of the outlet steam is controlled within specified limits.

Water out

Water in

Flue gas out

Flue gas in

Flue gas in

Flue gas out

Air in

Air out

Left SideMembrane Wall

Nose/ RearMembraneWallFront Side

Membrane Wall

Right Side

Membrane Wall

Baffle Plate

Flue gastoeconomiser

Ash collection hopper

Ash collectionat flue gasreversal

Flue gasfrom

superheater

Membrane Water FurnaceWall TMThe furnace of the Powermax is made of membrane walls. This is an arrangement

in tube and fin construction, which provides the advantage of a gas tight chamber,

preventing the influx of air which, in turn, results in higher efficiency.

The fuel characteristics determine critical parameters like height and footprint of a

furnace, which ensure complete combustion.

In superheated boilers, the furnace is provided with a ‘nose’ wall. This provides

radiation shielding to the convective zone of the superheater and prevents any

overheating of the convective zone of the superheater tubes. The nose wall guides

the flue gases to cover the entire convective superheater area.

The membrane wall furnace also ensures that flue gases are cool enough to enter the

boiler bank, and that no fouling takes place.

Boiler BankThe boiler bank is a tube nest connecting the water and steam drums, where water is converted into steam.

Downcomer portion of boiler bank, take the water to the water drum, and then a mixture of steam and water rises through, the riser portion of boiler bank tube to the steam drum. Water and steam are separated in the steam drum, and while the steam goes out, water gets re-circulated.

The flue gases turn around in the bottom drum against the baffle wall and rise towards the steam drum.

Ash separation takes place during reversal, and ash is collected in the hopper below the water drum.

Electrostatic Precipitators¡

Electrostatic Precipitators (ESP) is an

arrangement of electrically charged

electrodes. When dust laden gases

enter the ESP through the inlet nozzle,

dust particles get electrically charged

by the emitting electrode. Due to the

influence of this electrical field, these

charged dust particles migrate to the

grounded collecting electrode. The

accumulated dust particles on the

collecting plate are dislodged into the

hopper due to periodic mechanical

rapping. Clean gas then flows out

through the outlet nozzle of the ESP. For boiler applications, the ESP enables

achieving emissions as low as 50 mg/3Nm .

Pollution control equipment

Complete Condensing¡

Power generation through condensing turbine is normally done with power generation as the prime objective.

Here steam demand is controlled according to the requirement of power generation, and the power is normally consumed in an ‘islanding’ mode.

Extraction cum Condensing¡

When power and process are both critical, and need to be catered to equally, Extraction-cum-Condensing Turbines are used.

Steam generation is controlled according to the combined need for process steam and power. This power is consumed either by using a ‘grid parallel’ or ‘islanding’ system.

High PressureSteam from Boiler

Steam to Condense

High PressureSteam from Boiler

Low pressuresteam to process atconstant pressure

Water fromcooling tower

Water tocooling tower

Power generationTMPowermax can support any of your power needs, be it extraction, condensing or a combination

Back Pressure¡

Power generation using back pressure turbine is quite beneficial to many process industries. Normally, steam generation is controlled according to process demand and the power generated is incidental.

The power generated may or may not be sufficient for the complete power requirement of the process house.

The generated power is normally consumed parallel to the grid power or suitable alternative arrangements.

High PressureSteam from Boiler

Low pressuresteam to process atconstant pressure

Steam to Condense

Cyclomax¡

The Cyclomax is an arrangement of multi-cyclones. When dust laden gas enter the cyclone tangentially, the centrifugal force that develops due to the cyclonic action makes the dust particles move outward radially, they finally strike the wall and drop out of the gas stream into the hopper. Clean gas then flows out through the exit tube.

For boiler applications, Cyclomax enables achieving emissions as

3low as 300 to 350 mg/Nm .

Bag Filter¡

Bag filter is an arrangement of filtration material in the form of bags. When dust laden gases pass through the fabric, the dust is retained while clean air passes through. This dust, deposited on the outer surface of the bags, is removed by high pressure compressed air, operating in a pre-determined cycle. This air flow is led into the bags through a pulse-solenoid valve combination which is energized by a solid state sequential controller. Thermax bag filters come with features like casing entry, with perforated sheets that facilitates better gas distribution and pre-separation of coarser dust; bags with snap rings that ensure low outlet emissions; leakproof inlet-cum-bypass-damper and outlet damper for automatic system isolation under high/ low temperature situations for safety.

For boiler applications, bag filters enable achieving emissions 3as low as 100 mg/nm .

Water fromcooling tower

Water tocooling tower

High Pressure steam

In view of our constant endeavor to improve the quality of our products, we reserve the right to alter or change specifications without prior notice. All photographs shown in this publication are representative in purpose and are to be used for reference purpose only. Whilst this information is given in good faith, no warranty or representation is given concerning such information which must not be taken for establishing any contractual or other commitment binding on Thermax Ltd. For actual details and specifications, please refer the Thermax offer document.

Registered Office

D-13, MIDC Industrial Area,R. D. Aga Road Chinchwad, Pune - 411019, IndiaTel.: +91 - 20 - 66122999, 66155000Fax: +91 - 20 - 27472049

enquiry@thermaxglobal.com

www.thermaxglobal.com

Thermax Business Portfolio

Heating

Cooling

Power Generation

Air Pollution Control

Chemicals

Water & Wastewater Solutions

Solar

Specialised Services

Roofing ShedLoading Zone

VibroFeeder

R.P.Gate

Crusher

VibratingScreen

RecycleBucketElevator

ProductBucketElevator

Roof TrusswithSheeting

Boiler bankhopper

Ecomomisher/ Airpre-heater hopper

Polluction controlequipment hopper

Air line

Fly Ash Silo

PneumaticGate ValveDistancePieceAshConditioner

Support

Airout

Airin

A typical layout

A typical ash handling plant

A typical coal handling plant