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.
Our Green Business
Philosophy & Activities
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.

Boiler & Heater Group (B&H)

Thermax’s 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.
“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), 515±5°C, coal / bagasse ired travelling grate boiler
Biomass 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 .

Flexible design - a variety of options

ƒ Capacity upto 300 TPH, Pressure upto 160 kg/cm2(g) and temperature upto 560°C
ƒ Travelling Grate, Dumping Grate, Pinhole Grate, Pusher Grate or Hopper Bottom
(luid bed)
ƒ Membrane wall / tube and tile construction
ƒ Indoor and outdoor installation
ƒ Auto controls or remote - manual control option
ƒ Multifuel iring capability - Includes bagasse, husk, straw, coffee grounds, cane
tops, coconut shells, lignite, coal, pith, wood chips, oil, gas etc.

Membrane panelled furnace design

ƒ Machine welded membrane wall furnace forms a gas tight enclosure preventing
ingress of unwanted excess air
ƒ Requires no refractory in furnace walls and eliminates associated maintenance
ƒ Results in quicker boiler commissioning due to reduced site welding, simpliied
handling / erection

Higher overall efficiency

ƒ Optimum design & selection of auxiliary equipment to ensure the highest
operational eficiency and availability of the plant
ƒ High eficiency steam separators ensure steam purity
ƒ Variable speed fuel feeder allows ine control of feed
ƒ Modulating cyclomotor to ensure even distribution of fuel

Tall furnace for complete combustion

ƒ Tall furnace increases residence time of lue gases, allowing fuel to burn completely
before the gases enter the superheater zone
ƒ 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), 515°C, bagasse & coal ired travelling grate boiler
Travelling Grate
Salient Features
Travelling Grate ensures uninterrupted combustion
ƒ Continuous ash discharge system avoids dependence on operator’s judgement
ƒ Grate speed can be varied continuously in range 0-12 m/hr.(0-45ft / hr)
ƒ Overlapping grate design prevents air leakages
ƒ Maintenance of grate can be carried out without shutting down the boiler
ƒ An overire air system provides turbulence and thorough mixing of the volatile
gases, thus assuring complete combustion
ƒ All other advantages of suspension burning are ensured
ƒ Dumping Grate can be offered in place of travelling grate on request
 Proven Design & Rugged
Construction for
Reliable Continuous
Operation

ƒ Catenary design provides for automatic take- are made in short sections (230 mm to 300
up or tensioning of grate chains to prevent mm long) which can be individually replaced,
jamming. Effective catenary is maintained thus reducing grate maintenance costs.
ƒ Grate curvature design keeps the grate
by gravity, thus making external shaft
adjustments unnecessary.
closed without the aid of auxiliary weights
ƒ Grate surface consists of a series of grates when making the turn around the sprockets.
speciically designed for spreader stoker iring.
The grates are constructed of best quality
heavy duty heat-resisting cast iron alloy and
Indian Cane Sugar Ltd., Bagalkot, Karnataka, India
1 unit of 125 TPH, 87 Kg/cm2(g), 515°C, bagasse & coal ired travelling grate boiler

ƒ 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.
ƒ Front and rear grate shafts carry the grate
chains on hardened sprockets.
ƒ 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.
ƒ Three front undergrate air seals prevent air
by-passing to the ash discharge end.
ƒ The rear seal is designed to allow rear water
wall expansion while maintaining tightness.
Technical Features
ƒ 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.
ƒ 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.
ƒ 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.
ƒ 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
itting overlapping edges to prevent air leakage at the joints.
ƒ The hydraulic grate drive is a self-contained unit in a single housing with no
external piping. Hydraulic pump and control regulate the low 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 lange 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
ininitely regulated to control the grate speed from 0 to approximately 15 meters
per hour.
Bajaj Hindustan, Gola, Uttar Pradesh, India
1 unit of 100 TPH, 45 Kg/cm2(g), 425°C,bagasse ired pinhole grate boiler
Pinhole Grate
Salient Features
ƒ Stationary inclined water cooled grate design with no moving parts for
avoiding any mechanical failures and reducing maintenance in the furnace
ƒ Steam nozzles for simpliied 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
ƒ An economical and viable option for high capacity boilers
ƒ Combustor can accept air of temperature upto 250°C thus resulting in
smooth combustion of fuel
ƒ Inherently capable of burning high-moisture bagasse
ƒ An overire air system provides turbulence and thorough mixing of the
volatile gases, thus assuring complete combustion
ƒ Adequate number of feeders for uniform fuel distribution
ƒ All other advantages of suspension burning are ensured
Jocil Limited, Dokiparru, A.P.
1 unit of 30 TPH, 66 Kg/cm2(g), 485°C, rice husk and coal ired
Hopper Bottom (Fluidised Bed Combustion) boiler
 Hopper Bottom
(Fluidised Bed Combustion)*
Salient Features
ƒ FBC combustor does not have any moving parts thus reducing maintenance in
the furnace
ƒ Uniform temperature distribution in the bed and agitating characteristic of
luidised bed ensures optimum combustion
ƒ Low excess air requirement resulting in higher eficiency
ƒ Lower NOx and CO emissions
ƒ Low temperature operation greatly helps in minimising the biomass fuel ash
agglomeration and fouling tendency
ƒ 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.
 Major Installations
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 45 420±5 Bagasse 2000
Bajaj Hindusthan Gola 1 100 45 425 Bagasse 2003
Hopper Bottom (Fluidised Bed Combustion)
Shree Cements Ltd. Beawar, Rajasthan 2 80 65 495±5 Imported Coal, Petcoke, 2001
Lignite
Nestle Philippines Inc. Philippines 1 24.95 18 Saturated Spent Coffee Grounds, 2004
green coffee residue,
roasted chaffs & HFO
Bhushan Limited Orissa 1 165 88 520±5 Washery rejects, char 2004
Holcim Group - Ambuja Chhattisgarh 1 80 67 495±5 Coal/Rice husk/coal/ 2006
Cements biomass/pet coke
Usha Martin Ltd. Ghamaria, 1 140 69 490±5 washery rejects, char ired 2006
Jamshedpur Hopper bottom
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 Hyderabad 1 90 86 515±5 Coal/Bagasse 2000
& Industries
Tamilnadu Newsprint Appakudal 2 85 87 515 Bagasse/Imported coal/pith/ 2001
& Papers Ltd. lignite
Balrampur Chini Mills Ltd. U.P. 1 80 87 515 Bagasse/Rice Husk 2001
Rio Tuba Nickel HPP project Philippines 1 105 49 400 Indonesian coal 2002
through JGC
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 2005
coal
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 87 515±5 Bagasse 2006
Yashwantrao Mohite Krishna Satara, Maharashtra 1 90 87 515±5 Bagasse 2008
Sahakari Sakhar Karkhana Ltd.
Samarth Sahakari Sakhar Jalna, Maharashtra 1 95 87 510 Bagasse 2008
Karkhana Ltd.
Saha Cogen Lamphun A/c Thailand 1 65 53 412 Wood Chip 2009
Jurong Engg
Mitr Kalasin Bio Energy Thailand 1 170 105 520 Bagasse, wood chips, rice 2010
Company husk
Lokmangal Sugar Ethanol & Co- Solapur 1 90 67 505 Bagasse, imported coal 2010
Generation Company Ltd.
Dan Chang Bio-Energy Co.,Ltd. Thailand 1 170 105 520 Bagasse, wood chips, rice 2010
husk
Lakshmi Sugar Mills Uttarakhand 1 110 110 540 Bagasse 2010
Company Ltd.
Kamadhenu Ventures Cambodia 1 135 110 540 Bagasse 2010
(Cambodia) Ltd.
Jamkhandi Sugars Ltd. Bagalkot 1 120 110 540 Bagasse 2010
 Canada

Ireland

U.S.A

REGIONAL OFFICES
BARODA OFFICE & WORKS
Plot No. 21/1,2,3, GIDC, Mexico
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
Colombia
OVERSEAS OFFICES
SOUTH EAST ASIA
Thermax Limited
3rd Floor, South Wing, Bangunan Getah Brazil
Asli, 148 Jalan Ampang, Kuala Lumpur -
50450, Malaysia
Phone: +603 2166 98 01 / 03 / 04
Fax: +603 2161 2685
Email: akabra@thermaxindia.com
Cell: +60 122056623
Email: pghelani@thermaxindia.com
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: devdas@thermaxmena.com
Cell: +966 553 915 403
EUROPE
Thermax Ltd,
Avenue Charles Thielemans 109
B - 1150 , Brussels, Belgium
Phone: 32(0) - 27369244 / 473450186
Email: alain.dessoy@thermaxprocessheat.be
 Installations in 75 countries
Global Footprint of Boiler & Heater Group
For more details visit www.thermaxindia.com or
Write to info.bnh@thermaxindia.com

Russia

U.K.

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Netherlands
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Thermax Limited,
Boiler & Heater Group
Energy House, D-II Block, Plot No 38 & 39,
MIDC, Chinchwad, Pune 411 019
Phone: +91-20-6612 6464 | Fax: +91-20-6612 6612 / 6612 6476
Email: info.bnh@thermaxindia.com www.thermaxindia.com

design@synergydesign.in

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.