Industrial Boiler Product Range

B&W

Table of Contents

Oil & Gas fired boilers FM Packaged Boiler High Capacity FM (HCFM ) Boiler Power for Industry Boiler ( PFI ) Radiant Boiler ( RB ) Heat Recovery Steam Generator ( HRSG ) Solid fuel fired boilers Atmospheric fluid bed boiler - Underbed fuel feed design (AFBC - UB ) Atmospheric fluid bed boiler - Overbed fuel feed design (AFBC - OB ) Circulating fluid bed boiler ( CFBC ) Traveling grate fired boiler ( TG ) Dumping grate fired boiler ( DG ) Pinhole grate fired boiler ( PG ) Pulverised fuel boiler ( PF ) Accessory equipments Deaerator Renovation & Modernization After Sales Service

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Designs and information shown in this booklet are for purposes of illustration only. Equipment designed for specific applications may differ.

FM Packaged Boiler

Membrane Furnace Wall

Steam Drum

Outer Casing

Superheater

Burner

Convention Bank Water Drum

Wind Box

Capacity Range Pressure Temperature Fuel

: 5 TPH to 100 TPH : Upto 74 Kg/cm2g : Upto 4500C : All liquid and gaseous fuels, Waste Fuels, BFG, Tar, Bio-Gas.

Typical Efficiency : 93% ( on LHV ) Design features : Bi-Drum, bottom supported, forced draft, natural circulation boilers.l Special design of drum internals for high steam purity l Membrane / Studded wall water cooled furnace construction l Minimum foundation required l Can be installed outdoor l Fully drainable superheater l Suitable for firing of heavy fuels / lean gases l Fine combustion control & high turndown ratios l Preengineered economiser l Short / attractive delivery 2

High Capacity FM (HCFM/PFM) Boiler

Superheater

Saturated Steam Supply Pipes Steam Drum

Reach wll with header arrangement

Buck Stray

Wind Box Furnace Side Wall

Convention Bank Burner Furnace Wall Base Frame

Capacity Range Pressure Temperature Fuel Design features

: 80 TPH to 272 TPH : Upto 124 Kg/cm2g : Upto 4500C : All liquid and gaseous fuels, Waste Fuels, BFG, Tar, Bio-Gas. : High Capacity FM (HCFM/PFM) boiler completely pre-engineered with modular design for dock or field assembly l Multiple burners for increased capacity. l Special design of drum internals - High steam purity l Membrane / Studded wall water cooled furnace construction l Minimum foundation required l Can be installed outdoor l Fully drainable superheater l Firing of heavy fuels / lean gases possible l Fine combustion control & high turndown ratios l Short / attractive delivery l Over 5000 operating units. 3

Power for Industry Boiler ( PFI )

Capacity Range Pressure Temperature Fuel Design Features

: 45 TPH to 208 TPH : Upto 80 kg/cm2g : Upto 5100C : Liquid and /or gaseous fuels, blast furnace gas, CO gas and high ash liquid fuels : Bi-drum bottom supported, multiple gas pass unit designed specifically to burn liquid and / or gaseous fuels. l Membrane walled water cooled furnace l Combined hot air & gas ducts integral with rear wall casing l Fully drainable bottom supported superheater l Flat superheater temperature v/s load curve l Wash water drains

High Pressure Radiant Boiler ( RB )

Capacity Range Pressure Temperature Fuel

: 80 TPH to 500 TPH : Upto 140 Kg/cm2g : Upto 5400 C : All liquid and gaseous fuels

Design Features : Single Drum, bottom supported, forced draft, natural circulation, 2 pass type boilers. l Furnace & second pass made of totally water-cooled membrane walls l Front wall firing on wide range of liquid & gaseous fuels l Higher operational reliability l Steam drum outside the flue gas path, permitting quick start-up & load chasing l Fully welded construction l Fully drainable, horizontal, convective superheater l Steam cooled superheater support.

Heat Recovery Steam Generator ( HRSG )

Capacity Range Pressure Temperature

: Upto 100 MW : Upto 135 Kg/cm2g : Upto 5600 C

Design Features : Single drum / Bi-boilers with or without supplementary firing on Gas Turbine Exhaust l Supplementary fired / unfired mode l Fresh air firing option l Multiple Pressures (levels) l Natural Circulation l Single drum all welded construction l Low gas side pressure drop l Cold casing insulation l Fully drainable superheater finned tubes l Modular design l Integral Deaerator / makeup water heater option l Low power consumption l High tolerance to Turbine Exhaust Gas flow maldistribution l 99.99 % availability l Lower capital costs l Easy maintenance and accessibility

Atmospheric Fluid Bed Combustion Boiler ( Underbed feed system design )

Capacity Range Pressure Temperature Fuel Design Feature

: Upto 300 TPH : Upto 135 Kg/cm2g : Upto 5400 C : Coal / Lignite / Rice Husk / Pith / Petcoke / Washery Rajects / Char / Oil / Agricultural Waste etc. : Top or bottom supported, Single or Bi-drum design boilers suitable for firing low calorific value fuels. Suspension burning of fuel - higher combustion efficiency l Coal Size 6 mm l Bubbling Bed Ash Coolers l Stainless Steel Fluidizing Nozzles l Boiler bank without Baffles l High Steam Purity l Membrane walled furnace l Start-up by oil / charcoal.

Atmospheric Fluid Bed Combustion Boiler ( Over bed feed system design )

Capacity Range Pressure Temperature Fuel Design Feature

: Upto 300 TPH : Upto 135 Kg/cm2g : Upto 5400 C : Coal / Lignite / Rice Husk / Pith / Spent Coffee Ground / Spent Tea Ground / Washery Rejects / Char / Oil / Gas / Agricultural Waste / Sludge etc. : Top or bottom supported, Single or Bi-drum design boilers suitable for firing low calorific value fuels. Suspension burning of fuel - higher combustion efficiency l Coal Size upto 12 mm accepted l Bubbling Bed Ash Coolers l Stainless Steel Fluidizing Nozzles l Boiler bank without Baffles l High Steam Purity l Membrane walled furnace l Start-up by oil / charcoal.

Circulating Fluidized Bed Combustion Boiler ( CFBC )

Capacity range Fuel

: Upto 500 TPH : Coal, Lignite, Petroleum Coke.

Design Features : Top supported Internal Recirculation CFB with U-Beam Impact Separators available in Single or Bi-drum design Suitable for firing wide range of low calorfic, high ash fuels with less expensive fuel preparations l Lower emissions levels l High availability and lower maintenance l Reduced Boiler building volume l Wide load swings with high turn-down l Low power consumption l Low start up time l Two - stage solids collection for better performance

Travelling Grate Fired Boiler ( TG )

Capacity Range Pressure Temperature Fuel Design Feature

: Upto 140 TPH : Upto 106 Kg/cm2g : Upto 5150 C : Bagasse / Rice husk / Coal / Lignite, Other biomass : Travelling Grate stoker fired, Bi-drum, top or bottom supported, balanced draft, natural circulation boilers l Modulating secondary air system for even distribution of bagasse l Tall furnace for higher residence time l Continuous ash discharge l Compact low operating pressure hydraulic drive l Suspension burning for complete combustion & quick response to load variation l Special design of drum internals - High steam purity l No underground ducting l No air leakage l Flexibility in firing various fuels 10

Dumping Grate Fired Boiler ( DG )

Capacity Range Pressure Temperature Fuel Design Feature

: Upto 100 TPH : Upto 106 Kg/cm2g : Upto 5150 C : Bagasse / Other biomass / Other low ash fuel : Dumping Grate stoker fired, Bi-drum, top or bottom supported, balanced draft, natural circulation, water tube boilers l Modulating secondary air system for even distribution of bagasse on grate l Tall furnace for longer residence time l Suspension burning for complete combustion & quick response to load variation l Special design of drum internals - High steam purity l Flexibility in firing various low ash fuel.

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Pinhole Grate Fired Boiler ( PG )

Capacity Range Pressure Temperature Fuel Design Feature

: Upto 300 TPH : Upto 106 Kg/cm2g : Upto 5150 C : Bagasse / Other biomass / Other low ash fuel : Pinhole Grate Stoker fired, Bi-drum, top or bottom supported, balanced draft, natural circulation boilers. l Modulating secondary air system for even distribution of bagasse on grate l Tall furnace for longer residence time l Stationary water cooled grate design with no moving parts, avoiding mechanical failures l Steam nozzles for simplified on line ash removal l Suspension burning for complete combustion & quick response to load variation l Special design of drum internals - High steam purity l No underground ducting 12

Pulverised Fuel Boiler ( PF )

Capacity Range Pressure Temperature Fuel

: 150 TPH to 500 TPH : Upto 152 kg/cm2g : Upto 5400C : Coal / Lignite

Design Features : Top-supported, Single or Bi-drum, single gas pass unit l Membrane wall construction l Furnace nose arch, and economizer and / or air heater for economical heat recovery l Higher operational reliability l Steam cooled superheater support

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Deaerator

Capacity Range Pressure Temperature Design Feature

: 10 TPH to 300 TPH : 0.35 to 7 Kg/cm2g : 105 to 1500 C : Spray & Tray type Deaerators l Fixed spray nozzle - assured performance & fine spray l Multiple levels of perforated trays l Large manhole access for deaerator tower internal inspection l Canopied steam inlet l External vent condenser for ease of maintenance & repair l Special deaerator internals promote intense mixing of water & steam & ensure high oxygen removal.

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Renovation & Modernization

Babcock & Wilcox, (B&W) USA, has been the pioneer in the field of Industrial, Utility and Supercritical boilers since 1867. B&W has a rich experience in evolving and implementing Engineering solutions to steam generator problems. Thermax Babcock & Wilcox shares this knowledge base on a two-way basis with B&W. The Renovation & Modernization (R&M) Division of TBW implements Remaining Life Assessment Study programs, Plant Improvement Project (PIP) and Replacements-in-Kind (RIK) Solutions to existing boilers. Scores of Industrial and Utility boilers have benefited from TBW's R&M programs. Life Extension Studies l Condition Assessment, Remaining Life Analysis and Life Extension studies for Steam Generators. l Boiler Performance Reviews and System Analysis. Capacity & Efficiency Upgrades Retrofitting modern fuel firing systems and pressure part upgrades to increase capacity of the existing steam generators. l Restoring original capacity of derated boilers. l Enhance steam-generating capacity above original rating. l Improvement in thermal efficiency.

Engineering Studies l Design and performance analysis of operating boilers irrespective of make, age, design or fuel. l Evolution of techno-economic solutions for further implementation. Pressure Part Upgrades Modification of pressure parts by redesigning heat transfer surfaces such as Furnace water walls, Superheaters, Reheaters, Economizers, etc.

Fuel Flexibility Upgrades l Fuel conversion from / to liquid, gaseous or solids in solo or multiple firing mode. l Conversion to fluidized bed combustion. l Conversion from coal to lignite and to biomass firing, such as husk, bagasse, pith etc.

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After Sales Service

Services on call l Prompt response to any customer call/complaint and deputation of engineer as required Preventive /Predictive Service l Annual Service Contract package comprising of site visits for performance monitoring & optimization, annual shutdown and emergencies Condition Assessment & Remaining Life -Analysis Studies l Review & survey using special testing equipment & patented methods l In-situ examination & analysis of pressure parts for present condition & remaining life l In accordance with Central Boiler Board IBR regulation 391A Boiler Performance Optimization l Studies & engineering solutions to bring back the unit to optimum performance l Fuel conversions, capacity enhancement and technology upgrades Test facilities l In-house test facilities encompass proven NDT & metallurgical testing

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B&W

Thermax Babcock & Wilcox Limited

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