REVOMAX

LARGEST SELLING LITTLE STAR OF THERMAX

REVOMAX : FEATURES
 Once through (Water)
 Instant steam generator
 Reverse flue (flue gas)
 Coil type
 Non-IBR
 Automatic
 Packaged supply (skid mounted)
 ONCE THROUGH
STEAM GENERATOR
INSTANT STEAM GENERATED
Output=Dry Steam(x)+Water(100-x)

COIL HOLDING
CAPACITY :
5 GALLON STEAM IN 3 MINUTES
WATER FROM COLD START

NON IBR

MASS
MASSBALANCE
BALANCE
INPUT=OUTPUT Input Feed water = 100 kg/h
INPUT=OUTPUT
100=(100-x)+x
100=(100-x)+x
 Energy loss ENERGY BALANCE
Final Heat content
FLUE
Initial Heat Content+Heat Picked
GASES
up
TO STACK

PR - 9.5 kg/cm2
WET STEAM (80 %
dry)
R/C LOSSES
RXA 06 with
ECONOMISER
and Qw
FUEL WATER
OPTIMISER 600 kg/hr
T 30O C
Energy
Input
Initial Heat content
 IMPORTANT
Revomax is designed for :
80 % dry steam
rest water
Energy balance is satisfied with Dryness Fraction = 0.8
 All forced circulation boilers generate wet steam.
 Quantity of water pumped in = F&A 100oC. Rating, if dryness
is 80.48 %, at 9.5 kg/cm2 steam pressure.
 Thus, RXA-06 pumps in 600 l/hr water. If more is pumped,
dryness fraction drops and usable heat reduces.
If heat load is 200,000 Kcal/hr,offer RXA-06 and not RXA-05
since, Usable Heat (Hu) from Table :
RXA-05 : 193,957 Kcal/hr
RXA-06 : 232,748 Kcal/hr
 REVOMAX - A table for usable heat

Model Qw Qds Qm H-s H-m H-t H-u F&A

RXA 02 200 160.96 39.04 106797 7086 113883 77583 200
RXA 03 300 241.44 58.56 160195 10629 170824 116374 300
RXA 04 400 321.92 78.08 213594 14172 227765 155165 400
RXA 05 500 402.40 97.60 266992 17714 284707 193957 500
RXA 06 600 482.88 117.12 320391 21257 341648 232748 600

Qw Feed wated fed in, kg/hr.

Qds Dry steam quantity, kg/hr.
Qm Moisture quantity, kg/hr.
H-s Total heat content in dry steam,kcal/hr
H-m Total heat content in moisture, kcal/hr.
H-t Total heat content in steam at outlet, kcal/hr.
H-u Usable heat in process by condensation, kcal/hr.
F&A Steam output, kg/hr, from and at 100o C.
0.8048 Dryness Fraction
663.5 Enthalpy of dry steam, kcal/kg.
181.5 Enthalpy of water, kcal/kg.
REVOMAX:ONE STEP FURTHER
Higher output - 600 Kg/hr F&A
Large tube diameter 31.8 mm
Modular assembly, compact
Higher efficiency, 88% (NCV).
Higher aesthetic appeal

HOW IS IT POSSIBLE?
 REVERSE FLAME
 MEMBRANE WALL HEAT EXCHANGER.
 OPTIMUM SIZE ECONOMISER
 HEAT OPTIMISER
 INTEGRAL AIR PRE-HEATER & PROPER AIR SUPPLY
 REVERSE FLAME TECHNOLOGY
COMBUSTION CHARACTERISTICS

REVERSE FLUE STRAIGHT FLUE

Combustion air
Combustion air
O2
CO2 CO2
O2 O2
CO+ +
CO
C&
O2 O2
CO C&
CO
 REVERSE FLAME

What the user gets ....

Quality of Combustion - Consistent.
Assured rated steam output
Assured high efficiency
 MEMBRANE WALL DESIGN

FLAME

MEMBRANE WALL
W/O MEMBRANE WALL
 MEMBRANE WALL
 Fin and tubes fully welded.
 No gas leakage to 3rd pass.
 Large tube and wide fin.
 2nd pass turbulence high.
 Hence high heat absorption.

What Revomax offers....

Gas tight furnace - no gas bypass
Larger tube - high turbulence
What the user gets ....
Quality of Combustion - Consistent
Assured rate steam output
Assured high efficiency.
 Thermax
ECONOMISER
Competition

VENT
VENT
T2 T2
T1

T1

ECONOMISER WITH ECONOMISER WITH

OPTIMUM HEAT LARGE HEAT
TRANSFER AREA TRANSFER AREA
NO STEAMING IN ECONOMISER HEAT LOSS AS A RESULTS
STEAMING THRO’ VENT
 ECONOMISER
What REVOMAX offers :
Low flue gas pressure drop
Smoke tube design
Operates at Atmospheric pressure, hence Water
gets de-aerated (removes dissolved oxygen).
What the user gets :
Low blower power consumption
Easy to de-soot
Water gets deaerated, hence long life of coil - No
Oxygen pitting
 HEAT OPTIMISER
FROM FEED WATER TANK
30oC FROM ECONOMISER
OUTLET
TO
FEED
WATER
PUMP

70 - 75oC 85 - 90oC

45 - 50oC

TO ECONOMISER INLET
 HEAT OPTIMISER
WHAT REVOMAX OFFERS ....
Counter flow pattern -
pump inlet temperature under check
Pipe-in-pipe design, fully welded,
Hence no air leakage to pump suction

WHAT THE USER GETS ....

No cavitation -
pump & washers last long
Low pump maintenance cost, since pump is safe from high
water temp
 AIR SUPPLY SYSTEMS
Competition Revomax

CENTRAL
ENTRY TANGENTIAL
ENTRY
JACKET AIR FLOW PATTERNS

REVOMAX OTHERS
 AIR JACKET
WHAT REVOMAX OFFERS ....
Tangential air entry, Well-aligned assembly
Maximum Heat recovered, hence Low stack temp.
WHAT THE USER GETS .…
Operator safe from hot spots
Assured High efficiency, Consistent steam output
 SAFETIES
High steam temperature switch Coil safe from overheating
Blowdown valve limit switch Coil safe from burnout
Low/No water switch Coil & pump safe

Fuel low temperature interlock Prevents backfire and improper

combustion
Flame Monitor Flame failure safety
OPH relief valve Over pressure safety
OPH pressure switch Over pressure safety

Steam safety valve Coil safe from over-pressure

Feed water pump relief valve Pump safe from over-pressure
 PRODUCT LIMITATION
Not suitable for fluctuating steam demand. Accumulator required.
If dry steam needed, separator a must.
Boiler needs stoppage to drain coil.
Condensate from neither steam separator nor system can be used.
A separate main electrical isolating switch fuse unit needs to be
installed; Not supplied by Thermax.
Over load relays are provided for motor protection, no fuses.
Pressure beyond 125 kg/cm2g not available.
Some imported spares have to be stocked for emergencies.
Accessibility adequate / not comfortable
Optimum design.
Economiser needs weekly cleaning if furnace oil is used as a fuel.
 REVOMAX PLUS- RXD 06
SNo Improvements Problems Field trials-results.
sedCustomer U.S.No. 6,7,10,12,14
expectations
addressed
1 Increased furnace  Stack temperature  Consistent rated  100%
volume and heat  Consistent efficiency output  84% on GCV
transfer area  Controlled water  Consistent efficiency  CO2: 13.5% , SI: 2
temp. at inlet of WP  Maintenance cost  Stack: 230oC
2 New economiser design Proper gas venting Maintenance cost No WP cavitation
3 Improved burner rod  Leak proof  Plug and Play  No burner rod
with oil circulating tube (< 3 drops per stop)  Consistent Efficiency leakage
 Smokeless comb.  Product safety in  No back fire
Every ON/OFF operation  Smooth ON/OFF
4 New OPH design  Precise viscosity  Consistent Efficiency  Fuel temp. control
(Direct immersion control  Boiler price within  3o C
type)  Cheap & more  Maintenance cost  No oil cracking
reliable  Plug and Play
5 Provision for coil and Improved MTBF  Maintenance cost  No breakdown
inner shell expansion  Uninterupted running  No distortion
 REVOMAX PLUS - RXD 06
SrNo Improvements Problems addressed Customer Field trials-results.
expectations Unit S.No.
addressed 6,7,10,12,14
6 Tangential water entry Jacket sealing not Consistent rated Dismantling and
through chimney duct critical no sealing output reassembly time
(No jacket piercing) required Consistent Efficiency reduced by 2 man
Maintenance cost hours
7 Improved oil filter & Improved MTBF Uninterupted running No WP & FP
transperent water filter failures
8 Improved wegmann Improved MTBF Uninterupted running No Wegmann cone
cone shielding Maintenance cost over heating
9 Improved radiator Improved MTBF Uninterupted running No overheating of
design Maintenance cost inner shell
 Sealing gaskets
were in place
10 Improved pumping Better ergonomics Maintenance cost Water pump & fuel
module design pump could be
removed in 15 min.
 BOILERS (NON - IBR)
COMPARISON WITH COMPETITOR’S PRODUCTS

S.NO. SPECIFICATIONS THERMAX ELITE

1. SERIES OFFERED REVOMAX STEAMPACK

02/03/04/05/06 100/200/300/
400/600
2. TYPE OF PRODUCT :

A. NO. OF COILS ONE ONE

B. NO. OF PASSES THREE TWO

C. HORIZONTAL / VERTICAL VERTICAL VERTICAL

D. PRESSURE PART MEMBRANE COIL 2 START, ONE

BLANK COIL
 COMPARISON OF TUBE OD
A : REVOMAX B : ELITE
OD=31.8
OD=25.4
THK=3.3
THK=3.3
ID=25.2
AREA=498.8 MM2
A ID=18.8
AREA=277.6 MM2

Comparison of
B area :
A=1.79B
REMARKS :

 Due to single coil, inner diameter of tube is kept large (1”),

more than that of competitor’s product.
Thus, less chances of coil choking.

Membrane coil provides additional heat transfer area.

Revomax is designed as a vertical unit - advantages :

 Lesser floor area

 Coil removal is easy
 Coil draining is easy
S.NO. SPECIFICATIONS THERMAX ELITE

3. PRODUCT DETAILS

A. DESIGNED PRESS 10.54 KG/CM2 G 15 KG/CM2 G

RANGE OFFERED 15 KG/CM2 G & 0-30 KG/CM2 G
ON REQUEST

B. HYD.TEST PRESS 28 KG/CM2 G 55 KG/CM2 G

FOR COIL ON TUBES

C. REVERSE FLUE TECH PRESENT ABSENT

D. EFFICIENCY CLAIMED 88 +/- 2% 93 +/- 2%

ON NCV
REMARKS :

In Revomax, hydro-test pressure of tubes : 70 kg/cm2

Coil is tested at : 28 kg/cm2

Reverse Flue technology has the following advantages :

Higher heat flux

Higher heat transfer co-efficient in radiant zone
Even distribution of heat along the coil surface
Better conditions for combustion - Time, Temperature,
Turbulence.
S.NO. SPECIFICATIONS THERMAX ELITE

4. COMPONENTS

A ECONOMISER SMOKE TUBE ECONOMISER SMOKE TUBE

CONNECTED IN BETWEEN ECONOMISER
FLUE GAS OUTLET AND WITH TWO
OPTIMISER, FEED WATER COMPARTMENTS.
CIRCUIT FLUE GAS FLOW
THROUGH
ECONOMISER
IS CALLED
THIRD AND
FOURTH PASSES.
FEED WATER
CIRCULATES
BETWEEN TANK
& ECONOMISER
THROUGH AN
INSULATED
PIPE LINE.
 OPTIMUM HEAT ABSORBED LARGER AMOUNT OF HEAT
NO STEAMING IN ECONOMISER STEAMING RESULTS
VENT LOSS OF HEAT TO VENT
VENT
T2 T2
T1

T1

ECONOMISER WITH ECONOMISER WITH

OPTIMUM HEAT LARGE HEAT
TRANSFER AREA TRANSFER AREA
REMARKS :

Revomax Economiser is smaller than competitors’. However, boiling

does not take place here.

In Elite, economiser is large; Also, no system provided to ensure

that feed water temp. does not exceed 70oC.
S.NO. SPECIFICATIONS THERMAX ELITE

4B. OPTIMISER OPTIMISER IS USED TO NO OPTIMISER

REDUCE TEMPERATURE
OF WATER COMING OUT
OF ECONOMISER (90oC)
TO 70oC SO THAT IT CAN
BE FED TO FEED WATER
PUMP.

REMARKS :

BY PROVIDING OPTIMISER , FEED WATER TEMPERATURE IS KEPT BELOW 70 oC.

HENCE , WATER PUMP CAVITATION IS AVOIDED.
S.NO. SPECIFICATIONS THERMAX ELITE

4C BURNER PRESSURE JET BURNER PRESSURE JET

WITH OIL CIRCULATION BURNER WITHOUT
FACILITY, SOLENOID CIRCULATION
VALVE IS INTEGRAL WITH FACILITY.
BURNER SOLENOID
VALVE IS
SEPARATELY
MOUNTED

REMARKS :

OIL CIRCULATION IS PROVIDED WHICH HELPS IN BETTER FUEL ATOMISATION.

IN ON -OFF OPERATION , OIL FLOW IS STOPPED AT THE NOZZLE HENCE THERE
IS NO OIL DRIPPAGE PROBLEM, WHEREAS IN CASE OF EXTERNAL SOLENOID
VALVE, OIL AFTER THE SOLENOID VALVE TENDS TO DRIP.

4
S.NO. SPECIFICATIONS THERMAX ELITE

4D FUEL OIL PUMP SUNTEC - FRENCH MAKE PRAKASH MAKE,

INDIAN

4E BLOWER THERMAX - WITH SEPARATE COMMON

MOTOR FOR UNITS RXA-03 MOTOR
ONWARDS FOR BLOWER
AND FUEL
PUMP
5 INSTRUMENTS :

A. TEMPERATURE VERMA - TRAFAG MINI

INDICATOR CUM ELECTRONICS
SWITCH

B. BURNER SEQ. CONTROLLER NO SEQ.

PROGRAMMER PETERCEM MA 810 CONTROLLER
S.NO. SPECIFICATIONS THERMAX ELITE

C. IGNITION 14.5 KV 14.5 KV

D. HOOTER INSIDE CONTROL PANEL OUTSIDE PANEL

E. PHOTOCELL PETERCEM MAKE LOCAL MAKE

MODEL 8209 (200 MW) (350 MW)

6. SAFETIES :

A. FLAME FAILURE PHOTOCELL PHOTOCELL

DETECTION

B. STEAM TEMP. HIGH TEMP. SWITCH TEMP. SWITCH

C. FUEL OIL TEMP. TEMP. SWITCH TEMP. SWITCH

(HIGH / LOW)