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.

Boiler & Heater Group (B&H)

Thermaxs 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.

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.

Our Green Business Philosophy & Activities

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), 5155C, coal / bagasse fired travelling grate 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 .

Biomass Boiler

Flexible design - a variety of options

Capacity upto 300 TPH, Pressure upto 160 kg/cm2(g) and temperature upto 560C

Travelling Grate, Dumping Grate, Pinhole Grate, Pusher Grate or Hopper Bottom (fluid bed)

Membrane wall / tube and tile construction

Indoor and outdoor installation

Auto controls or remote - manual control option

Multifuel firing capability - Includes bagasse, husk, straw, coffee grounds, cane tops, coconut shells, lignite, coal, pith, wood chips, oil, gas etc.

Membrane panelled furnace design

Machine welded membrane wall furnace forms a gas tight enclosure preventing ingress of unwanted excess air

Requires no refractory in furnace walls and eliminates associated maintenance

Results in quicker boiler commissioning due to reduced site welding, simplified handling / erection

Higher overall efficiency

Optimum design & selection of auxiliary equipment to ensure the highest operational efficiency and availability of the plant

High efficiency steam separators ensure steam purity

Variable speed fuel feeder allows fine control of feed

Modulating cyclomotor to ensure even distribution of fuel

Tall furnace for complete combustion

Tall furnace increases residence time of flue gases, allowing fuel to burn completely before the gases enter the superheater zone

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), 515C, bagasse & coal fired travelling grate boiler

Travelling GrateSalient Features

Travelling Grate ensures uninterrupted combustion

Continuous ash discharge system avoids dependence on operators judgement

Grate speed can be varied continuously in range 0-12 m/hr.(0-45ft / hr)

Overlapping grate design prevents air leakages

Maintenance of grate can be carried out without shutting down the boiler

An overfire air system provides turbulence and thorough mixing of the volatile gases, thus assuring complete combustion

All other advantages of suspension burning are ensured

Dumping Grate can be offered in place of travelling grate on request

Proven Design & Rugged Construction for Reliable Continuous Operation

Catenary design provides for automatic take-up or tensioning of grate chains to prevent jamming. Effective catenary is maintained by gravity, thus making external shaft adjustments unnecessary.

Grate surface consists of a series of grates specifically designed for spreader stoker firing. The grates are constructed of best quality heavy duty heat-resisting cast iron alloy and

are made in short sections (230 mm to 300 mm long) which can be individually replaced, thus reducing grate maintenance costs.

Grate curvature design keeps the grate closed without the aid of auxiliary weights when making the turn around the sprockets.

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.

Front and rear grate shafts carry the grate chains on hardened sprockets.

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.

Three front undergrate air seals prevent air by-passing to the ash discharge end.

The rear seal is designed to allow rear water wall expansion while maintaining tightness.

Indian Cane Sugar Ltd., Bagalkot, Karnataka, India

1 unit of 125 TPH, 87 Kg/cm2(g), 515C, bagasse & coal fired travelling grate boiler

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.

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.

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.

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 fitting overlapping edges to prevent air leakage at the joints.

The hydraulic grate drive is a self-contained unit in a single housing with no external piping. Hydraulic pump and control regulate the flow 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 flange 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 infinitely regulated to control the grate speed from 0 to approximately 15 meters per hour.

Technical Features

Bajaj Hindustan, Gola, Uttar Pradesh, India

1 unit of 100 TPH, 45 Kg/cm2(g), 425C,bagasse fired pinhole grate boiler

Pinhole GrateSalient Features

Stationary inclined water cooled grate design with no moving parts for avoiding any mechanical failures and reducing maintenance in the furnace

Steam nozzles for simplified 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

An economical and viable option for high capacity boilers

Combustor can accept air of temperature upto 250C thus resulting in smooth combustion of fuel

Inherently capable of burning high-moisture bagasse

An overfire air system provides turbulence and thorough mixing of the volatile gases, thus assuring complete combustion

Adequate number of feeders for uniform fuel distribution

All other advantages of suspension burning are ensured

Jocil Limited, Dokiparru, A.P.

1 unit of 30 TPH, 66 Kg/cm2(g), 485C, rice husk and coal fired

Hopper Bottom (Fluidised Bed Combustion) boiler

Hopper Bottom (Fluidised Bed Combustion)*Salient Features

FBC combustor does not have any moving parts thus reducing maintenance in the furnace

Uniform temperature distribution in the bed and agitating characteristic of fluidised bed ensures optimum combustion

Low excess air requirement resulting in higher efficiency

Lower NOx and CO emissions

Low temperature operation greatly helps in minimising the biomass fuel ash agglomeration and fouling tendency

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.

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 4205 Bagasse 2000

Bajaj Hindusthan Gola 1 100 45 425 Bagasse 2003

Hopper Bottom (Fluidised Bed Combustion)

Shree Cements Ltd. Beawar, Rajasthan 2 80 65 4955 Imported Coal, Petcoke, Lignite

2001

Nestle Philippines Inc. Philippines 1 24.95 18 Saturated Spent Coffee Grounds, green coffee residue, roasted chaffs & HFO

2004

Bhushan Limited Orissa 1 165 88 5205 Washery rejects, char 2004

Holcim Group - Ambuja Cements

Chhattisgarh 1 80 67 4955 Coal/Rice husk/coal/biomass/pet coke

2006

Usha Martin Ltd. Ghamaria, Jamshedpur

1 140 69 4905 washery rejects, char fired Hopper bottom

2006

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 & Industries

Hyderabad 1 90 86 5155 Coal/Bagasse 2000

Tamilnadu Newsprint & Papers Ltd.

Appakudal 2 85 87 515 Bagasse/Imported coal/pith/lignite

2001

Balrampur Chini Mills Ltd. U.P. 1 80 87 515 Bagasse/Rice Husk 2001

Rio Tuba Nickel HPP project through JGC

Philippines 1 105 49 400 Indonesian coal 2002

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 coal

2005

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 5155 Bagasse 2006

Yashwantrao Mohite Krishna Sahakari Sakhar Karkhana Ltd.

Satara, Maharashtra 1 90 87 5155 Bagasse 2008

Samarth Sahakari Sakhar Karkhana Ltd.

Jalna, Maharashtra 1 95 87 510 Bagasse 2008

Saha Cogen Lamphun A/c Jurong Engg

Thailand 1 65 53 412 Wood Chip 2009

Mitr Kalasin Bio Energy Company

Thailand 1 170 105 520 Bagasse, wood chips, rice husk

2010

Lokmangal Sugar Ethanol & Co-Generation Company Ltd.

Solapur 1 90 67 505 Bagasse, imported coal 2010

Dan Chang Bio-Energy Co.,Ltd. Thailand 1 170 105 520 Bagasse, wood chips, rice husk

2010

Lakshmi Sugar Mills Company Ltd.

Uttarakhand 1 110 110 540 Bagasse 2010

Kamadhenu Ventures (Cambodia) Ltd.

Cambodia 1 135 110 540 Bagasse 2010

Jamkhandi Sugars Ltd. Bagalkot 1 120 110 540 Bagasse 2010

Major Installations

Canada

U.S.A

Mexico

Colombia

Brazil

Algeria

U.K.

Ireland

REGIONAL OFFICES

Baroda oFFIce & WorkS

Plot No. 21/1,2,3, GIDC, 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

OVERSEAS OFFICES

SouTH eaST aSIa

Thermax Limited

3rd Floor, South Wing, Bangunan Getah 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

New Zealand

South Africa

Zambia

Tanzania

Sri Lanka

Indonesia

Australia

PhilippinesMalaysia

Netherlands Kazakhstan

Russia

Germany

Kenya

India

VietnamThailand

Bangladesh

Oman

Cambodia

Abu DhabiQatarBahrain

Jordan

Turkey

Kuwait

Uzbekistan

Turkmenistan

UAE

Nigeria

Algeria

U.K.

Egypt

Saudi Arabia

Yemen

Installations in 75 countriesGlobal Footprint of Boiler & Heater Group

For more details visit www.thermaxindia.com orWrite to info.bnh@thermaxindia.com

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.

Thermax limited,Boiler & Heater Group

Energy House, D-II Block, Plot No 38 & 39,

MIDC, Chinchwad, Pune 411 019

Phone: +91-20-661 2 6464 | Fax: +91-20-6612 6612 / 6612 6476

Email: info.bnh@thermaxindia.com www.thermaxindia.com

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