Boilers & Heaters

Widest Range of Boilers & Fired HeatersWidest Range of Boilers & Fired Heaters

Boiler & Heater Group

01

Improving your businessis 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)

Thermax's Boiler & Heater Groupprovides equipment and completesolutions for generating steam forprocess and power needs throughcombustion of various solid, liquidand gaseous fuels, as well asthrough heat recovery fromturbine/engine exhaust and (waste)heat recovery from industrialprocesses. The Group also offersheaters for various applications inthe Chemical, Petrochemical andRefinery segments. Its services armoffers renovation and modernizationsolutions for old boilers and heaters.

The major industry segments servedby the Group in India and across theworld are Steel, Refinery,Petrochemical, Power, Cement,Sugar, Fertilizer, Paper, Chemical,Non-Ferrous Metal and Textile.

Thermax has always kept its primary focus on customer

satisfaction through constant upgradation of

technologies and an in-depth understanding of market

needs. In the process, we have acquired a reputation for

successfully delivering on challenging projects.

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Group turnover of over US$ 840 million

Six core businesses in energy and environment

Thermax Today

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Boilers and Heaters for Industry

Boilers for Power Utilities

Absorption Coolers

Water and Waste Treatment Solutions

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ISO 9000 and 9001 accredited

14001 certified plant

OHSAS 18001:1999 certified plants

Manufacturing plants spread over 250,000 sq. mtr. in Pune and

400,000 sq. mtr. in Baroda

Manufactures to international standards–ASME, EN, GOST, BS, DIN,

UDT, IBR, PED etc.

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Chemicals

Air Pollution Control

Power (Turnkey Projects)

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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 for distilleries,

for urban waste disposal,

and

for power

generation. The B&H Group is also working on a range of

products for the emerging market for

spent wash-fired boiler municipal solid

waste-fired boiler waste heat

recovery boiler for cement plants internal-

recirculation circulating fluidized bed boiler

solar energy based

heat recovery systems.

Our Green BusinessPhilosophy and Activities

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Ms Meher Pudumjee

Chairperson

“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."

1989Thermax Babcock &

Wilcox, a joint venture of

Thermax Pvt. Ltd. and

Babcock & Wilcox (USA)

is formed.

On February 15, 1995

Thermax goes public

with an issue (IPO) of

60,88,700

.

equity

shares

1995

1980Wanson India becomes

Thermax Pvt. Ltd.

“Conserving energy,

Preserving the

environment” adopted as

the corporate vision.

Mr. A.S. Bhathena, Mumbai

based entrepreneur

collaborates with Wanson, a

Belgian company, to start

Wanson India for

manufacturing small, coil

type packaged boilers

("Vaporax") in Pune.

1966

Corporate MilestonesCorporate Milestones

05

B&W

t he companya McDermott company

2004Thermax buys out

Babcock & Wilcox stake

in joint venture.

Corporate Milestones

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200

Forb

es

Asia

BillionBest

Under A

BestUnder A

Received the “Zero Lost

Time” safety award from

M/s Reliance Industries.

Thermax signs license

agreement with Babcock

& Wilcox for utility boilers

2008

2005Thermax among the 200

companies featured in the

Forbes Asia List of "Asia's

Best under a Billion"

companies.

2006Work begins on an additional

manufacturing facility at

Vadodara, Gujarat, to cater to

the growing business of the

Boiler & Heater Division.

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To be a globally respected high performance

organisation offering sustainable solutions in

energy and environment.

THERMAX VISION

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SOLID FUELS, AGRO-WASTES, BIOMASS

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Circulating Fluidized Bed Combustion Boiler (CFBC)

Atmospheric Fluidized Bed Combustion Boiler (AFBC)

Travelling Grate

FIRED HEATER

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Petrochemical

Upstream Oil & Gas

Refinery

WASTE HEAT RECOVERY BOILER (WHRB)�

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Sponge Iron

Coke Oven

Non Ferrous (Copper Smelter/Zinc Smelter etc)

Refinery and Petrochemical

Cement

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Chemical

Sulphur Recovery

Exhaust Gas Boiler

Hydrogen Plant

Glass Furnace

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Spent Wash/Spent Grain Fired Boiler

Municipal Solid Waste/Refuse Derived Fuel Fired Boiler

WASTE TO ENERGY

� Renovation and Modernisation

SERVICES

LEAN GAS FIRED BOILER

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Blast Furnace Gas, Coke Oven Gas, Corex Gas Fired Boiler

CO/H2 Gas Fired Boiler

OIL & GAS

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Bi-Drum Packaged/Site Erected Boiler (FM/HCFM/PFM)

Singe-Drum High-Capacity Boiler ("Radiant" Boiler)

Heat Recovery Steam Generator (HRSG)

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33

35

CFBC

Boiler

Major Clients

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Kanoria Chemical

Indian Rayon & Inds. Ltd.

Grasim Industries Ltd.

Ultratech Cement Ltd.

Grasim Cement Ltd.

Saurashtra Cement

GHCL Ltd.

Ballarpur Industries Ltd.

ACC Ltd.

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Circulating

Fluidised Bed

Combustion

Kanoria Chemicals Ltd.,

Renukoot - India

1 x 110 TPH, 65 kg/cm (g),

495 C Coal Fired CFBC Boiler

2

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Product Features�

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Compact, economical design and construction

Two stage separation for better bed inventory control

Impact separation with ‘U-beam' particle separators

Best-in-class compliance with environmental norms

Low auxiliary consumption

Minimum refractory

Bottom-ash cooler (wet and dry)

Operating Range

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Capacity : Upto 680 TPH

Design pressure : Upto 200 kg/cm2(g)

Steam temperature : Upto 560°C

Fuels : Coal, lignite, petroleum coke, sludge, oil pitches,

biomass, high - sulphur coal, petcoke, washery

rejects, mill rejects

Boiler-Turbine-Generator (BTG) package can be offered on

case-to-case basis.

Based on Internal Re-circulation Circulating Fluidised

Bed (IR-CFB) technology from M/s Babcock & Wilcox, U.S.A.

*Product is supported under technical collaboration agreement withBabcock & Wilcox, USA.

B&W


Major Clients

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Bhushan Ltd.

Nav Bharat Ferro Alloys Ltd.

Usha Martin, Jamshedpur

Shree Cement

Gujarat Ambuja

JK Cement

Madras Cement

Nestle

JSW Energy Ltd.

Grace Industries

West Coast Paper Mills Ltd.

Khanna Papers Mills Ltd.

ITC

DCW

Chemplast

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Design pressure : Upto 160 kg/cm (g)

Steam temperature : Upto 540 C

Fuels : Coal, lignite, rice husk, petcoke, spent

coffee ground, washery rejects, low ash

coal, paper sludge, roasted chaffs, DOB,

bagasse, pith woodchips, biomass

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Operating Range

Boiler-Turbine-Generator (BTG) package can be offered on

case-to-case basis.

Product Features�

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Multifuel firing

Optimum combustion with staged secondary air system

Machine welded membrane panel

Better steam purity

Bed evaporator design for better reliability

Pin studs welded on inbed surfaces

Overbed as well as underbed feed system offered

‘Hopper bottom’ design also available for specific applications


AFBC

Boiler

Atmospheric

Fluidized Bed

Combustion

Nav Bharat Ferro Alloys Ltd.,

Polancha, A.P, India

1 x 110 TPH, 93 kg/cm (g),

485 C Coal Fired AFBC Boiler

2

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B&W


FBC

Technology

A Case Study

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R .R. Energy Pvt. Ltd. has set up a 14 MW biomass-based power plant at Garh

Umaria / Darramuda, Raigarh district, Chhattisgarh. The unit started commercial

production of power from January 13, 2007. The generated power is sold to the grid

for a remunerative tariff.

R. R. Energy was promoted by the Raipur-based Hira Group, whose other group

companies include Hira Ferro Alloys Ltd. and Godawari Power & Ispat Ltd.

Among the other notable features of the project is the use of air-cooled condenser

instead of a cooling tower to help conserve water. Also, ash from hoppers and ESP is

conveyed to an ash silo and later transported to cement plants.

Special design aspects of boiler help ensure maximum availability and efficiency of

boiler.

Biomass

Fired

Boiler

Biomass Boiler Based on FBC TechnologyGreenEnergyProduct

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Operating Parameter�

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Capacity : 70 TPH

Design pressure : 66 kg/cm (g)

Steam temperature : 490 C

Type : AFBC Boiler with “Hopper Bottom”

Fuels : Rice husk, indian coal and char

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Product Features�

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Continuous ash discharge

Grate driven by hydraulic drives

Better steam purity

Bi-drum / single drum, natural circulation, top supported design

Installation suitable for outdoor duty

Three / two stage superheater with inter stage feed water spray

Even fuel distribution on grate

Modulating cyclo motor

Tall furnace for complete combustion

Pinhole grate or water cooled pusher grate is offered for specific

applications

Boiler-Turbine-Generator (BTG) package can be offered oncase-to-case basis.

Biomass

Fired

Boiler*

GreenEnergyProduct

Major Clients

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JGC for Rio Tuba Nickel HPP

Project, Philippines

Davangere Sugar Co. Ltd.

Bannari Amman Sugars Ltd.

Bajaj Hindustan

Mawana Sugars Ltd.

NCS Sugar Ltd.

Dhampur Sugars Ltd.

JHV Sugar Ltd.

A. B. Sugar Ltd.

Bharat Sugar Ltd.

Sri Chamundeshwari Sugars

India Cane Sugar Ltd.

Mufindi Paper Mills Ltd., Tanzania

Madhucon Sugar Ltd.

Travelling

Grate Boiler

Bannari Amman Sugar Ltd.,

Nanjungud, Karnataka, India

1 x 120 TPH, 67 kg/cm (g), 485 C

Bagasse, Biomass Fired

Travelling Grate Boiler

2°

Operating Range�

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Design pressure : Upto 135 kg/cm (g)

Steam temperature : Upto 540 C

Fuels : Biomass, lignite, rice husk, spent coffee

ground, washery rejects, low ash coal, paper

sludge, roasted chaffs, DOB, bagasse, pith

wood chips, coal

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B&W

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T L

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T L

T L

T L

T L

attemperator

T L

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Capacity : Upto

Pressure : Upto 110 kg/cm (g)

Temperature : Upto 538 C

Fuels : All liquid and gaseous fuels, waste fuels,tar, hydrogen, refinery gases

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Operating Range

Product Features�

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High Capacity Floor Mounted (HCFM/PFM) boiler completely pre-

engineered with packaged design to check for field assembly

Multiple burners for increased capacity

Special design of drum internals for high steam purity

Membrane/studded wall water-cooled furnace construction

Fully drainable convective superheater

Fine combustion control and high turndown ratios

Bi-Drum

Packaged /

Site Erected

Boiler


Major Clients

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Galaxy Project FZCO for Burrup

Fertilizers Pty. Ltd., Australia

Lurgi Aktiengesellschaft Ein

Unternehmen der for PDH AlfaseL,

Saudi Arabia

KBR for Chevron Energy, Nigeria

Sabic Petrokemya, Saudi Arabia

Uhde India A/c Egyptian Propylene

& Polypropylene Company

Cairn Energy India Pvt. Ltd. for

Northern Area Development

Managala And Rageshwari Fields,

Rajasthan

Trust Chemicals Industries LLC,

Egypt

Eastern Bechtel Ltd., UK for

Onshore Gas Development project

(OGD lll)

Eastern Bechtel Ltd., USA for Abu

Dhabi Gas Industries Company

(AGD ll)

Qatar Vinyl Company Ltd., Qatar

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FM/HCFM/

PFM

KBR for Chevron Energy, Nigeria

3 x 167 TPH, 63 kg/cm (g),

400 C Natural Gas/Tail Gas fired

HCFM Boiler

2

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B&W

OIL AND GAS

T L

300 TPH


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Fuels : Liquid fuels such as natural gas, purge gas, cokeoven gas, #2 oil, # 6 oil, heavy fuel oil, residue oil,HSD, naphtha, hydrogen gas, bio gas, waste gas.

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Operating Range

Product Features�

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Fully convective superheater thus resulting in longer life and reliability

Front wall firing for a variety of liquid and gaseous fuels (independently

or in combination)

No boiler bank hence reduced drum thickness, reduced capital cost,

construction, maintenance costs and higher operational reliability

Fully welded, bottom supported, membrane walled design provides a

leakproof construction on flue gas and water / steam side

Steam drum outside the flue gas path permits quick startup and load

chasing

Large furnace size and volume helps to reduce emissions. Furnace

dimensions designed to meet specific requirements

Fully drainable, horizontal and convective superheater for long life and

high reliability

Steam cooled superheater supports for increased reliability

Low refractory and thus reduced maintenance

Radiant Boiler

Major Clients

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Southern Petrochemicals Ind.

Corp.

Gujarat Narmada Valley

Fertilizer Co.

Arabian Petrochemical Co.

L&T for Tata Fertilizer

OEP for Oswal Chemical &

Fertilizer

Madras Fertilizers

Reliance Petroleum Ltd.

Toyo Engg. for Chambal

Chemicals & Fertilizers Ltd.

Hindustan Fertilizer Corporation

Ltd., Dibrugarh

Single-Drum

High

Capacity

Boiler

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Reliance Industries Ltd,

Jamnagar, India

2 x 125 TPH, 115 kg/cm (g)

510 C Oil Fired Radiant Boiler

2

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B&W

OIL AND GAS

Product Features�

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Proven design with more than 100 installations

Natural circulation design for higher reliability, availability andlower power consumption

Single drum construction for reduced thermal stresses during startupand shut down

Fully welded construction for quicker start-ups and shutdowns

Special drum internals which promote circulation and ensure high steampurity

Gas tight internally insulated ducting and casing for lower thermal loads

Safe location of welds–outside gas path for higher reliability and longerlife

Tolerant to economiser steaming for better ‘off design’ operation

Careful duct internal design for predictable performance and longer life

Fully drainable superheater for higher reliability

Strategic soot blowing for oil firing

Firing gases and #2 oil in the duct burner

Operating Range�

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Capacity : Gas turbine size of 320 MW



Fuels : Natural gas/ naphtha / HSD / kerosene /refinery fuel gas etc.

2

°

Boiler-Turbine-Generator (BTG) package can be offered oncase-to-case basis.

Major Clients

Heat

Recovery

Steam

Generator

(HRSG)*

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Aban Power Ltd, Tamil Nadu, India

1 x 168 TPH, 110 kg/cm (g),

542 C Frame 6 FA

Supplementary Fired HRSG Boiler

2

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Daelim for Numaligarh Refinery

Reliance Petrochemicals Ltd.

Tuma Turbomach SA for Sarabhai

Piramal Pharmaceutical Ltd.

Aban Power Ltd.

Reliance Utilities and Power Ltd.

EID Parry Ltd., Kakinada

Internusa A/c Bekasi Power,

Indonesia

Abener for Hassi R’mel project,

Algeria

Essar Power A/c Vadinar Power

Co. Ltd., Jamnagar, India

Jacobs Netherlands BV For

Schoonebeek Oilfield

Redevelopment Project,

Netherlands

Lanco Infratech Ltd, India,

Kondapalli, Andhra Pradesh B&W*Product is supported under technical collaboration agreement withBabcock & Wilcox, USA.

OIL AND GAS

Reliance Industries Ltd.- Jamnagar Refinery Expansion Project

HRSG Parameters: 408 TPH, 82 bar(g), 310 C

Gas Turbine Model: Frame-9E

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One HRSG with supplementary firing and fresh airfiring arrangement

First HRSG being exported to European market fromIndia for a Frame-9E application

NAM (Netherlands Aardolie Maatschappij) is the endcustomer while Shell and Exxon Mobil are importantstakeholders

HRSGs designed to generate 205 TPH in fresh airfiring mode

FGR fan is used to achieve the required NOx level

Jacobs Netherlands for Schoonebeek Oilfield Redevelopment Project

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HRSGs on

Frame-9E

Gas Turbine-

Selected

Case

Studies

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Boiler feedwater pumping station has 2.5 MW drivemotor with VFD control

HRSG to be supplied in compliance with CE, PED andAtex codes

HRSG to be shipped in modular form (pressure partsmodule)

Scope: Superheater + HRSG Block + Economiser +Main Stack + FD and FGR Fans + BFW Pump +Dampers + Stack Silencer + Field Instrumentation +PLC-based BMS + Supervision of Erection &Commissioning

HRSG Parameters: 315 TPH, 49 kg/cm (g), 396 C

Gas Turbine Model: GE Frame-9E

2°

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Six HRSGs with supplementary firing arrangementwith Natural Gas + Naphtha + SKO + HSD + Ref. Gas(In all 16 fuels)

Bechtel was the client’s consultant

HRSGs designed to generate 315 TPH at 60% of gasturbine load

Superheat control range is from 60-100% of gasturbine load in unfired mode

Firing temperature of 800 C

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Pyroblocks used in transition ducts

Scope: HRSG Block + Economiser + WPH RCC Stack +Field Instrumentation + PLC-based BMS + LV MCC +Water Re-circulation

System + Erection and Commissioning

Order won against stiff global competition

Package includes four nos. oil & gas-fired industrialboilers rated at 275 TPH @ 49kg/cm (g) and 396 Cand five nos. waste heat recovery boilers

In all 3,400 TPH of steam generating capacity suppliedto the new Reliance refinery expansion project

2°

Reliance Industries Ltd.,

Jamnagar, India

Refinery Expansion Project

315 TPH, 49 kg/cm (g), 396 C

Gas Turbine Model: GE Frame-9E

2°

OIL AND GAS

GreenEnergyProduct

Major Clients�

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Tata Steel, Jamshedpur

Jindal Vijaynagar Steels Ltd.,

Bellary

Kalyani Steels Ltd., Hospet

Nagpur Alloys and Castings Ltd.,

Raipur

Kirloskar Ferrous Industries Ltd.,

Hospet

Steel Authority of India Ltd.,

Bramhani Industries Ltd., Bellary

Blast

Furnace

Gas / Lean

Gas Fired

Boilers

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Fuels : Blast furnace gas, coke oven gas, corex gas,LD gas & other lean gases.

2

°

Operating Range

Salient Features�

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Highest reliability in spite of slow burning, low calorific value and low

combustibles nature of gas

Tolerance to variations in pressure, flow and calorific value of BFG

Change over to oil firing in case of interruption in BFG gas supply

Safe operation of boiler under varying load conditions

Low volumetric heat release rate with larger boiler furnace

Furnace refractory lining for stable combustion of BFG

Scroll burner for high mixing energy of air and BFG for efficient

combustion

Safety interlocks to ensure proper burning of BFG without support fuel

Zero oil/gas support within 70-100% MCR

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More than two dozen lean gas fired boilers supplied to Indian

Steel Industry

More than 50 installations of B&W worldwide

Burners manufactured indigenously based on proprietary Babcock &

Wilcox design, ensuring perfect match and integration with furnace

geometry

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JSW Steel Ltd., Bellary, India

1 x 80 TPH, 62 ata

485 C, BFG / COREX

gas fired boiler

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T L

T L

Rourkela

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Waste

Gas

Fired Boiler

(CO/H )2

Major Clients

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Hi-Tech Carbon Ltd.

Philips Carbon Black Ltd.

Continental Carbon

Cabot Corporation

Thai Carbon Black

Birla Carbon

BA Energy, Canada

Salient Features

Operating Range

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Natural circulation design

Fire tube or water tube boilers

Special refractory lined combustor for burning lean gas

Adequately sized combustor for proper residence time to ensure

complete burning of gas

Membrane wall water tube construction to minimize refractory and

increase radiant heat transfer

Control systems to ensure complete combustion of lean gas

Waste gas fired boilers are designed to burn waste gas/tail gases to

generate steam for process or power. Typical systems include:

Carbon Black Plants (CO Gas)

Ferro Alloy Plants (CO Gas)

Caustic Soda Plants (H Gas)

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GreenEnergyProduct

Thai Carbon Black Company

Pvt. Ltd.,Thailand

100 TPH, 45 kg/cm (g),

420 C CO Fired

Waste Gas Fired Boiler

2

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� Capacity : Upto 70 MMKcal/hr (Single unit)

Operating Range

The Fired Heaters in the Chemical and Petrochemical plants are for:

Two types of designs can be offered depending on the application

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Heating process fluids

Thermal cracking

Vertical cylindrical

Box type furnace

Major Clients�

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Reliance Industries Ltd.

Indian Oil Corporation Ltd.

Hindustan Petroleum

Corporation Ltd.

Shell

Finolex Industries Ltd.

Bharat Petroleum

Corporation Ltd.

UHDE GmbH

Qatar Petroleum

Gas Authority of India Ltd.

Fired Heater

in Petro-

chemical

Plant

LIQUID phase heaters for

VAPOUR phase heaters for

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Mineral oils / Synthetic oils

Molten salt heaters

Synthetic oil / Mineral oilvaporisers

Hydrocarbon vaporisers

PROCESS industry heaters

CRACKERS

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Steam superheaters

Charge heaters

Start up heaters

Ethylene di chloride cracker

Acetic acid cracker

Gas cracker

Application


Hazira, India

5 x 10 MMKcal/hr

Dowtherm Vaporisers

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FIRED HEATER

� From 2 MMKcals/hr upto 30 MMKcals /hr capacity

Operating Range

Product Features�

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Cracker can be designed with Radiant wall burners for liquid or gaseous

fuel firing

Efficiency as high as 90%

Efficiency of the unit can be enhanced through a forced circulation waste

heat boiler mounted on top of convective section

Multi tier layout of burners

Coil metallurgy can be SS 347H and Incoloy

HK 40 bends in the radiant section

Extended surface coils in the convection section

Major Clients

� Finolex Industries Ltd.

Application� EDC cracking

Ethylene di

Chloride (EDC)

Cracker

Fired Heater

in Petro-

chemical

Plant

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Finolex Industries Ltd.,

Ratnagiri, India

1 x 11.56 MMKcal/hr, EDC Craker

FIRED HEATER

The Fired Heaters in Oil & Gas industry for the Upstream Segment are for:


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Thermal cracking


Box type furnace

Operating Range


Fired Heater

in

Oil & Gas

Industry

for the

Upstream

Segment

Application�

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Crude pumping stations

Tank farm heating

Hot oil heaters on gas turbine exhaust or incinerator exhaust

Water glycol heaters

Steam flood boilers

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Kakinada, India

3 x 21.5 MMKcal/hr

Hot Oil Heater

Major Clients�

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Hindustan Petroleum

Corporation Ltd.


Bharat Petroleum Corporation Ltd.

UHDE GmbH, Germany

Qatar Petroleum

Bharat Oman Refinery Ltd.

Shell Inc., Gabon (West Africa)�

FIRED HEATER

The Fired Heaters in Oil & Gas Industry for the DownstreamSegment are for :


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Thermal cracking


Box type furnace

Fired Heater

in

Oil & Gas

Industry

for

Refinery


Operating Range

Application�

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Crude distillation unit

Vacuum distillation unit

Delayed coker unit

Fluid catalytic cracker unit (FCCU)

Diesel hydro desulfurization treatment (DHDT) plants

Naphtha vaporizers in hydrogen

Motor spirits quality (MSQ) heaters

Naphtha splitter unit (NSU)

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Indian Oil Corporation Ltd,

Barauni, India

1 x 20.08 MMKcal/hr Combined Feed

Heater for DHDT Unit

Major Clients�

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Hindustan Petroleum

Corporation Ltd.


Bharat Petroleum Corporation Ltd.

UHDE GmbH, Germany

Qatar Petroleum

Bharat Oman Refinery Ltd.

Shell Inc., Gabon (West Africa)�

FIRED HEATER

GreenEnergyProduct

WHRB

in Sponge

Iron Plant

Major Clients�

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Jindal Steel & Power Ltd.

Bhushan Power & Steel Ltd.

Bhushan Steel & Strips Ltd.

Tata Sponge Iron Ltd.

BMM Ispat

Ispat Godavari Ltd.

Shree Metallics Ltd.

Singhal Enterprises

Janaki Corporation Ltd.

Salient Features

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Natural circulation water tube design

Gas tight side wall of water wall construction

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Pioneer in waste heat recovery in sponge iron plant

More than 100 installations

Design takes into account high dust in gases

Horizontal design on 100 TPD DRI kiln for greater operational comfort

Vertical design for 350 TPD, 500 TPD, 650 TPD and also for 100 TPD

Operating Range

WHRB on 100 TPD, 350 TPD, 500 TPD, 650 TPD

Pressure : From 44 kg/cm (g) upto 115 kg/cm (g)


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23

Jindal Steel & Power Ltd., India

4 x 57 TPH, 66 kg/cm (g), 490 C

in Sponge Iron Plant

2°

WASTE HEAT RECOVERY BOILER

WHRB in

Coke Oven/

Coke Dry

Quenching

Plant

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Pioneer in waste heat recovery in coke oven plant

Water wall panel construction in 1st /2nd pass

Site/port assembly with modularized construction

Horizontal/vertical design

Optional blast furnace firing capability

Forced circulation design for coke dry quenching plant

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Non recovery coke oven plant

Recovery type coke dry quenching plant

Recovery type coke by-product plant

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Application

Operating Range

Major Clients�

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Hooghly Metcoke & Iron Ltd.

(Tata Power)


Bhushan Power & Steel Ltd.

Konark Metcoke Ltd.

(Neelanchal Ispat Ltd.)

Electrosteel Casting Ltd.

24

GreenEnergyProduct

Jindal Steel & Power Ltd.,

Raigarh, India

8 x 33.5 TPH, 72 kg/cm (g),

490 C WHRB in Coke Oven Plant

(Non Recovery Type)

2

°


GreenEnergyProduct

Major Clients

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Birla Copper

Cominco Binani Zinc Ltd.

Hindustan Copper Ltd.

Pyrites Phosphates &

Chemicals Ltd.

WHRB in

Non-Ferrous

Industry

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Waste heat boiler on

Waste heat boiler on

Waste heat boiler on the

In non-ferrous industry it is common practice to have a boiler operating at

high pressure but without superheat. This facilitates the operation of the

boiler well above the dew point of the gases.

zinc pyrite roasters

copper smelters

copper convertors

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Capacity : 10 TPH to 100 TPH

Pressure : 45 -60 kg/cm (g)


2

°

Operating Range

Salient Features�

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Forced circulation water tube design

Gas tight side wall of water wall design

Wide pitched in-line geometry to prevent choking

On-line hammering system

Baffles to prevent channeling of gases

Provision of cavity followed by variable pitch convection coils

25

Birla Copper, Bharuch, India

WHRB for 300 TPD Copper Convertor

Unit to produce 21 TPH of steam

at 45 kg/cm (g) at

saturation temperature

2


Major Clients

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Indian Oil Corp.Ltd., (IOCL)

Hindustan Petroleum

Corporation Limited

Foster Wheeler A/c Samref,

Saudi Arabia

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Capacity : Upto 200 TPH Superheated Steam



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°

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Waste heat recovery boiler downstream of FCCU

One of the world’s largest WHRB designed and supplied to Reliance

Industries Ltd. India

Experience in handling very large volume of flue gases e.g. normal

operating conditions of 515,000 Nm3/hr at 731 C containing catalytic

dust

Two different technologies are available

Directly downstream of FCCU

‘CO’ gas boiler downstream of FCCU

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Designed to take care of carry-over catalytic dust

Complete membrane panel construction to take care of sulphur dew point

Soot blowers at suitable locations to take care of dust laden gases

Vibration arrestors provided to prevent tube vibration and consequent

failures

Natural circulation design

Fully drainable design of superheater

Co current and drainable economizer

Operating Range

Salient Features

WHRB in

Refinery &

Petro-

chemical

Plant

GreenEnergyProduct

Fluid Catalytic Cracking Unit (FCCU)

Supplied 2 units of

boilers on UOP Technology to

Reliance Industries Ltd, India

each producing 145 TPH to

391 C at 42 kg/cm (g) pressure°

2

26


GreenEnergyProduct

WHRB in

Cement

Plant

Product Features

a. Waste heat recovery boiler for pre-heater and calciner

b. Waste heat recovery boiler for clinker cooler (with and without center tap off)

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Horizontal boiler with tubes located vertically for uniform dust disposal and gasdistribution

Proven technology to handle high dust laden gases of pre-heater and calciner

Inline/Staggered heat transfer area

Cross flow gas direction offering efficient heat transfer

Fully field proven de-dusting hammering mechanism

Higher water holds-up capacity to cater to any steam fluctuations

Better accessibility

Vertical boiler with horizontal tubes

Cross flow gas direction offering efficient heat transfer

Proven design for highly abrasive AQC gases

Available in both forced/natural circulation design unlike other designs

Less floor space offering flexibility in layout

Special finned design for better heat transfer

Cement manufacturing is a highly energy-intensive process. Given thefragile and dynamic nature of the fuel and power situation faced by cementplants today, it makes sense for them to adopt waste heat recovery basedsolution for the following reasons:

Greater energy security (helps meet upto 35% of power requirement)

Improved competitive positioning

Regulatory push (Policies mandating use of minimum 5-10%renewable/WHR energy are already in place in several states)

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Major Clients� J.K. Cements, Nimbahera

27

J.K. Cements,

Nimbahera, India,

generating 72 TPH at

17 kg/cm (g), 325 C2°

Thermax along with technical assistance from M/s Taiheiyo EngineeringCorp. (Japan) offers this world-class solution for cement industry.


WHRB in

Chemical

Plant

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Can be offered as fire tube / water tube construction

Experience in offering flexible / fixed tube sheet design for fire tubeboilers

Experience in handling high gas side operating pressures upto 5000mmWC (special construction of economizer and superheater is provided)

Cast iron gill ring economiser to prevent sulphur corrosion

Equipment (boiler, superheater, economiser) is scattered aroundconverter

Gas outlet temperature control at every equipment is requiredfor efficient conversion of acid gas

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Nitric Acid Plants are either low pressure or high-pressure systems

The type of boiler used is either

Natural circulation fire tube

Forced circulation water tube

The NH3 burner is normally included as a part of the unit

Gas tight construction with stainless steel material

Heating coils to prevent dew point corrosion

Wall cooling coils to protect the shell

Lamont nozzles for uniform distribution of water in the coils

Major Clients�

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Hitachi Zosen

Mitsui Engg. & Shipbuilding Co.

Sterlite Industries Ltd.

Bagfas Fertilizer Co., Turkey

Birla Copper

Gujarat State Fertiliser

Indian Explosives Ltd.

Sulphuric Acid Plant

Nitric Acid / Caprolactum Plants

Operating Range

� Capacity : 20 TPD to 4500 TPD sulfuric acid production

28

Heat Recovery for

1800 TPD Sulphuric Acid Plant at

Bagfas Fertilisers, Turkey

generating 89 TPH capacity


GreenEnergyProduct

GreenEnergyProduct

Major Clients

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Reliance Petroleum Ltd.

Cochin Refineries Ltd.


Hindustan Petroleum Ltd.

Bharat Petroleum Corp. Ltd.

Bahrain Petroleum Co.

Dolphin Energy Ltd., Qatar

WHRB

in Sulphur

Recovery

Plant

Main Reaction Furnace�

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WHB downstream of Main Reaction Furnace

Fire tube boiler

Experience in designing and supply of boiler where gas inlet

temperature is around 1300 C

Multipass arrangement in same shell of boiler or separate shell with

common steam drum

Steam heated sulphur drains at outlet / intermediate gas chambers

Experience in design and supply of flexible / fixed tube sheet

Supplied six trains on 650 TPD plant (three in 1998 and three more in

2007) to Reliance Industries Ltd. Jamnagar

°

Tail Gas Incinerator�

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WHB downstream of tail gas incinerator

Water tube / fire tube design

Modularised construction

Experience in supplying superheater made of T22, T91, Incoloy

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Reliance Petroleum Ltd.,

Jamnagar, India

3 x 45 TPH at 38 kg/cm (g) in

Sulphur Recovery Unit

2


GreenEnergyProduct

Exhaust

Gas Boiler

(EGB)

An exhaust gas boiler recovers heat from the flue gases of genset to

produce steam, hot water or thermic fluid for various heating / cooling

applications. Key features of our offering:

Enhance system efficiency in genset based power plants upto 20%

depending on the system design

Available in configurations of water tube and smoke tube type

Expertise to integrate with all makes of engines

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Auxiliary oil heating, tank farm heating, line tracing

Process heating

Combined cycle

Steam / hot water for industrial chilling

Salient Features

Applications

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EGB installed on 0.5 MW to 50 MW genset installations

2 stroke and 4 stroke engines

Light oil, heavy oil and gas fired engines

Operating Range

Major Clients�

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GMR Vasavi- 200 mw IPP, India

PPC, Greece-KOS, Paros &

Chios Power Plant-75 MW

Moser Baer, India-60 MW

Sandakam, Malaysia 32 MW IPP

Nestle, Philippines, Srilanka &

India

Alok Industries, India 28MW

Gas CPP

Mangalore Chemical & Fertilizer

Ltd., India-48 MW

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Alok Industries Ltd.,

Vapi, Gujarat, India

6 Nos. x 6 MW Wartsila Engine

6 x 3.4 TPH at 10.5 kg/cm (g)2

GreenEnergyProduct

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Water tube / fire tube type design

Designed to handle heating of different liquids

Capacity to design and manufacture high capacity boilers

� Capacity : 30 TPD to 5000 TPD Hydrogen Production

Flue Gas Boiler / Convection Sectionof Hydrogen Reformer

Operating Range

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Fire tube boiler configuration

Flexible / Fixed tube sheet design

Alloy steel tubes to overcome metal dusting (such as T11, T22, etc.)

Internal bypass provided with liner to control the gas outlet temperature

Incoloy ferrules anchored in the inlet tube sheet refractory

Separate steam drum connected by risers and downcomers

Heat sensitive paint on the inlet box

High gas side operating pressures (around 30 Kg/cm g)

Gas rich in H2 / CO / CH4

Common steam drum for reformed gas boiler and flue gas boiler

2

Reformed Gas / Process Gas Boiler

WHRB in

Hydrogen

Plant

Major Clients�

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Hindustan Petroleum Corp. Ltd.

National Peroxides Ltd.

31

WHRB in Hydrogen Reformer at

HPCL Mumbai


GreenEnergyProduct

WHRB on

Glass

Furnace

Waste gases leaving glass-melting furnaces are at high temperatures of 1200to 1400 C (or float glass furnace at temperatures ranging from 450 C to550 C) and contain a high carryover of silicates and alkalis besides residuesfrom heavy oil firing. These waste gases have a high potential for heatrecovery.

° °

°

Salient Features�

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Compact single/ bidrum natural

circulation design

Optimum tube sizes and pitch to

avoid choking

Low gas velocities to avoid

erosion of tubes

Special cleaning mechanism to

maintain surface cleanliness

(e.g. hammering device, shot

ball cleaning)

Optimum design factor consider

corrosive and errosive nature of

Saturated/superheated steam for

process / chilling / power

solution

Major Clients

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Alembic Chemicals Ltd.

Ceat Ltd.

NATURAL CIRCULATION

2-DRUM WATER TUBE BOILER

CHEVRON

SEPARATOR

STEAM OUTLET

STEAM

DRUM

TUBE

BANK

WATER

DRUM

32

Steam Outlet

Steam Drum

Tube Bank

Water Drum

Hopper


Major Clients�

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Bannari Amman Sugars Ltd.

Sovereign Distilleries Ltd.

EID Parry India Ltd.

Mohan Breveries Distilleries Ltd.

Spent

Wash-Fired

Boiler

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Effective on-line cleaning system

Specially designed spent wash handling system

Adequate residence time to ensure complete combustion

System designed for maximum heat recovery

Backed by a sustained R&D initiative

Designed and Engineered for Excellence

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Helps meet zero liquid effluent discharge norm

Effective solution for power and process steam requirements of

distillery

Uses concentrated spent wash (or spent grain) as main fuel

Based on a patented technology developed indigenously by Thermax;

extensive R&D trials successfully conducted

Breakthrough Technology forthe Distillery Sector

Four units under execution; first unit planned for commissioning shortly.

33

Bannari Amman Sugars Ltd.,

Nanjangud, Karnataka, India.

1 x 23.4 TPH, 32 kg/cm (g), 350 C2°

WASTE TO ENERGY

MSW/RDF

Fired Boiler

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Successful in-house trials conducted while firing 100 % MSW/RDF

Based on Thermax's rich experience in firing various biomass, spent

wash, paper sludge and other industrial wastes

Specially designed furnace to ensure complete combustion

Hydraulic ram feeder provided considering fuel size variation

Specially designed automated soot removal system

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Can handle wide variation in fuel type, moisture and particle size

Complete combustion due to tumbling action enforced on fuel;

reduced suspension burning due to silent combustion

Positive movement of fuel over the grate minimizes clinkering and

blockages

Ram feeding system ensures uniform distribution of fuel on to the grate

Special grate and air plenum sections provided to ensure better

distribution / control

Carefully chosen grate area ensures consistency in combustion for

varying fuel characteristics

Low power requirement with simple control on hydraulically operated

system

No rotating parts, hence enhanced life and robust construction

Low maintenance requirements and high operating reliability

Designed and Engineered for Excellence

Specially Designed Pusher Grate

34

Pusher grate technology to

convert waste to energy

(MSW/RDF)

WASTE TO ENERGY

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The boiler is the heart of any industrial plant, and even the smallest

problem with it can have an adverse impact on your profits

The Renovation and Modernization group (an SBU of Thermax Ltd) has

successfully implemented R&M solutions for larger boilers and heaters

since early 90s

The five-pronged R&M approach, that tailors technology and

experience based solutions for boiler users, has benefitted over 150

customers around the world

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Patented non-destructive techniques

Life Extension Programmes

Boiler performance reviews and system improvement analysis

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From gaseous to liquid fuels and vice-versa

From liquid/gas to solid fuels and vice-versa

Conversion to fluidized bed combustion for firing coal, lignite or

biomass fuels

Upgrade from flat fluidized bed to hopper bottom design

Fuel feeding system upgrades

Condition Assessment and RemainingLife Analysis and Engineering Studies

Renovation

&

Modernization

(R & M)

Major Clients

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Petronas Gas Bhd



Indian Navy

Fertilizers & Chemicals

Travancore

Deepak Fertilizers &

Petrochemicals Corporation

National Thermal Power

Corporation


IFFCO

Takreer Abu Dhabi Refinery

Zuari Industries Limited

Rashtriya Chemicals &

Fertilizers (RCF)

Fuel Conversion and Firing System Upgrade

35

SERVICES

Renovation

&

Modernization

(R & M)

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Steaming capacity enhancement

Efficiency improvement

Pollution abatement solutions

Instrumentation and controls upgrade

Troubleshooting and de-bottlenecking

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Enhancing pressure parts by redesigning heat transfer surfaces like

furnace water walls, superheaters, reheaters, economizers etc.

Replacement of pressure parts for life extension

Performance Enhancement Solutions

Pressure Part Replacements and Upgrades

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Remaining life analysis and life extension studies

Selective pressure part replacement/ upgrades

Re-engineering of fuel firing system

Performance enhancement solutions

Emission control solutions

Utility Boiler Revamps

36

Major Clients

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Tenaga Nasional Berhad,

Malaysia

Tata Steel Ltd., India

Ruwais Fertiliser Industries

(FERTIL), UAE

Nestle, Philippines

Nestle, Russia

IRPC, Thailand

(Thai Petrochemical)

Bharat Petroleum Corporation

Limited

Chennai Petroleum Corporation

Limited

Finolex Industries Limited

Gulf Petrochemical Industries

Company, Saudi Arabia

What can you expect froma 30 year old boiler?

...another 30 years

SERVICES

49

U.S.A

U.K.

Brazil

Germa

Nigeria

Afric

Algeria

Canada

Colombia

Mexico

Netherlands

Za

Ireland

Installations in over 75 countries

50

Timashevsk, Russia

Malaysia

Indonesia

Thailand

Kenya

ny

Bangladesh

Cambodia

Philippines

IndiaAbu Dhabi

aAustralia

Bahrain

EgyptJiddah,

Saudi Arabia

Kazakhstan

Kuwait

New Zealand

Oman

Qatar

Sri Lanka

Tanzania

TurkeyTurkmenistan

UAE

Uzbekistan

mbia

Vietnam

Jordan

Global Footprint of


For more details visit www.thermaxindia.com or

Write to [email protected]


Pune Admin Office & Works

Baroda Office & Works

REGIONAL OFFICES

Mumbai

New Delhi

Chennai

Kolkata

Hyderabad

OVERSEAS OFFICES

D-1, MIDC, R. D. Aga Road, Chinchwad, Pune 411 019.Tel.: +91-20-66126464, Fax: +91-20-27479200, 27479050

Plot No. 21/1,2,3, GIDC, Manjusar (Savli), Taluka Savli,Dist - Vadodara, Gujarat 391775.Tel: +91-2667-264727, Telefax: +91-2667-264728

Dhanraj Mahal 2nd floor, Chhatrapati Shivaji Maharaj Marg,Near Gateway of India, Mumbai 400 039, India.Tel: +91-22-22045391, 22045324, Fax: +91-22-22040859Email: [email protected]

9, Community Centre, Basant Lok, Near Priya Cinema,New Delhi 110 057, India.Tel: +91-11-26145326, 26145319, Fax: +91-11-26145311Email: [email protected]

Fatima Akthar Court, 3rd floor, 312, Teynampet,Chennai 600 018, India.Tel: +91-44-24353831/4, Fax: +91-44-24353841Email: [email protected]

Azimganj House, 5th Floor, 7 Camac Street,Kolkata 700 016, India.Tel: +91-33-22826711/13, Fax: +91-33-22826796Email: [email protected]

6-3-649, Behind Medinova, Nalanda Complex, 2nd Floor,Somaji Gujda, Hyderabad 500 082, India.Tel: +91-40-23310254/23312013, Fax: +91-40-23312335Email: [email protected]

Email:

SOUTH EAST ASIA

MIDDLE EAST

Thermax Limited3rd Floor, South Wing, Bangunan Getah Asli,148 Jalan Ampang, Kuala Lumpur - 50450, MalaysiaTel: +603 2166 98 01/03/04, Fax: +603 2161 2685Email: [email protected],

[email protected], Cell: +60 172454569

Thermax Babcock & Wilcox (A Division of Thermax Ltd.)C/o. Gulf Power International (Dabbagh Group),P.O. Box: 74426, Al-Khobar 31952, KSATel: +966 3 887 4557, Fax: +966 3 882 3041Email: [email protected],

Cell: +60 122056623

Cell: +966 553 915 403

www.thermaxindia.com

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