Boiler & Heater Group

Widest Range of Boilers & Fired Heaters

Improving your business
is our business
Thermax offers products, systems
and solutions in energy and
environmental engineering to Thermax has always kept its primary focus on customer
industrial and commercial satisfaction through constant upgradation of
establishments around the world. Its technologies and an in-depth understanding of market
business expertise covers heating, needs. In the process, we have acquired a reputation for
cooling, waste heat recovery, captive successfully delivering on challenging projects.
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 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.

01
Thermax Today
! Group turnover of over US$ 840 million
! Six core businesses in energy and environment

6 Boilers and Heaters for Industry 6 Chemicals

6 Boilers for Power Utilities 6 Air Pollution Control
6 Absorption Coolers 6 Power (Turnkey Projects)
6 Water and Waste Treatment Solutions

! 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.

02
 Our Green Business
Philosophy and 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 fluidized 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.

03
“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

04
Corporate Milestones

1966 1989
Mr. A.S. Bhathena, Mumbai Thermax Babcock &
based entrepreneur Wilcox, a joint venture of
collaborates with Wanson, a Thermax Pvt. Ltd. and
Belgian company, to start Babcock & Wilcox (USA)
Wanson India for is formed.
manufacturing small, coil
type packaged boilers
B&W
("Vaporax") in Pune. 1995
On February 15, 1995
Thermax goes public
with an issue (IPO) of
60,88,700 equity
shares.
1980
Wanson India becomes
Thermax Pvt. Ltd.
“Conserving energy,
Preserving the
environment” adopted as
the corporate vision.

05
 2006
Work begins on an additional
manufacturing facility at
Vadodara, Gujarat, to cater to
2004 the growing business of the
Thermax buys out Boiler & Heater Division.
Babcock & Wilcox stake
in joint venture.
2008
Received the “Zero Lost
Time” safety award from
M/s Reliance Industries.
Thermax signs license
agreement with Babcock
& Wilcox for utility boilers
2005
Thermax among the 200
companies featured in the
Forbes Asia List of "Asia's
Best under a Billion"
companies.

200
Forbes Asia

Best Under A
t he c o m pa n y
a McDermott company

Billion

06
 THERMAX VISION
To be a globally respected high performance
organisation offering sustainable solutions in
energy and environment.

07
SOLID FUELS, AGRO-WASTES, BIOMASS
?Circulating Fluidized Bed Combustion Boiler (CFBC)

?Atmospheric Fluidized Bed Combustion Boiler (AFBC) 09

?Travelling Grate

OIL & GAS

? Bi-Drum Packaged/Site Erected Boiler (FM/HCFM/PFM)
? Singe-Drum High-Capacity Boiler ("Radiant" Boiler) 13
? Heat Recovery Steam Generator (HRSG)

LEAN GAS FIRED BOILER

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

?CO/H2 Gas Fired Boiler

17

FIRED HEATER
?Petrochemical

?Upstream Oil & Gas 19

?Refinery

WASTE HEAT RECOVERY BOILER (WHRB)

?Sponge Iron ?Chemical

?Coke Oven ?Sulphur Recovery

?Non Ferrous (Copper Smelter/Zinc Smelter etc) ?Exhaust Gas Boiler 23

?Refinery and Petrochemical ?Hydrogen Plant

?Cement ?Glass Furnace

WASTE TO ENERGY
?Spent Wash/Spent Grain Fired Boiler

?Municipal Solid Waste/Refuse Derived Fuel Fired Boiler

33

SERVICES
? Renovation and Modernisation 35

08
SOLID FUELS, AGRO-WASTES, BIOMASS

CFBC
Boiler

Circulating
Fluidised Bed
Combustion
Kanoria Chemicals Ltd.,
Renukoot - India
2
1 x 110 TPH, 65 kg/cm (g),
495°C Coal Fired CFBC Boiler

Based on Internal Re-circulation Circulating Fluidised

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

Product Features
! 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
Major Clients
! Bottom-ash cooler (wet and dry)
! Kanoria Chemical

! Indian Rayon & Inds. Ltd.

! Grasim Industries Ltd. Boiler-Turbine-Generator (BTG) package can be offered on

! Ultratech Cement Ltd. case-to-case basis.
! Grasim Cement Ltd.

! Saurashtra Cement Operating Range

! GHCL Ltd.
! Capacity : Upto 680 TPH
! Ballarpur Industries Ltd.
! Design pressure : Upto 200 kg/cm2(g)
! ACC Ltd.
! Steam temperature : Upto 560°C
! Fuels : Coal, lignite, petroleum coke, sludge, oil pitches,
biomass, high - sulphur coal, petcoke, washery
rejects, mill rejects

*Product is supported under technical collaboration agreement with B&W

Babcock & Wilcox, USA.

09
 SOLID FUELS, AGRO-WASTES, BIOMASS

AFBC
Boiler

Atmospheric
Fluidized Bed
Combustion
Nav Bharat Ferro Alloys Ltd.,
Polancha, A.P, India
2
1 x 110 TPH, 93 kg/cm (g),
485°C Coal Fired AFBC Boiler

Product Features
! 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

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

case-to-case basis. Major Clients
! Bhushan Ltd.

! Nav Bharat Ferro Alloys Ltd.

Operating Range
! Usha Martin, Jamshedpur
! Capacity : Upto 300 TPH ! Shree Cement
! Design pressure : Upto 160 kg/cm2(g) ! Gujarat Ambuja
! Steam temperature : Upto 540°C ! JK Cement
! Fuels : Coal, lignite, rice husk, petcoke, spent ! Madras Cement
coffee ground, washery rejects, low ash ! Nestle
coal, paper sludge, roasted chaffs, DOB, ! JSW Energy Ltd.
bagasse, pith woodchips, biomass ! Grace Industries

! West Coast Paper Mills Ltd.

! Khanna Papers Mills Ltd.

! ITC

! DCW
*Product is supported under technical collaboration agreement with B&W ! Chemplast
Babcock & Wilcox, USA.

10
SOLID FUELS, AGRO-WASTES, BIOMASS

Biomass
Fired
Boiler

FBC
Technology
A Case Study

Biomass Boiler Based on FBC Technology

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

Operating Parameter
! Capacity : 70 TPH
! Design pressure : 66 kg/cm2(g)
! Steam temperature : 490°C
! Type : AFBC Boiler with “Hopper Bottom”
! Fuels : Rice husk, indian coal and char

11
 SOLID FUELS, AGRO-WASTES, BIOMASS

Biomass
Fired
Boiler*

Travelling
Grate Boiler
Bannari Amman Sugar Ltd.,
Nanjungud, Karnataka, India
1 x 120 TPH, 67 kg/cm (g), 485°C
2

Bagasse, Biomass Fired

Travelling Grate Boiler

Product Features
Green
! Continuous ash discharge Energy
! Grate driven by hydraulic drives Product
! 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
attemperator
! Even fuel distribution on grate
! Modulating cyclo motor
! Tall furnace for complete combustion
! Pinhole grate or water cooled pusher grate is offered for specific Major Clients
applications
! JGC for Rio Tuba Nickel HPP
Project, Philippines
Boiler-Turbine-Generator (BTG) package can be offered on
! Davangere Sugar Co. Ltd.
case-to-case basis.
! Bannari Amman Sugars Ltd.

Operating Range ! Bajaj Hindustan

! Mawana Sugars Ltd.

! Capacity : Upto 180 TPH
! NCS Sugar Ltd.
! Design pressure : Upto 135 kg/cm2(g)
! Dhampur Sugars Ltd.
! Steam temperature : Upto 540°C
! JHV Sugar Ltd.
! Fuels : Biomass, lignite, rice husk, spent coffee ! A. B. Sugar Ltd.
ground, washery rejects, low ash coal, paper
! Bharat Sugar Ltd.
sludge, roasted chaffs, DOB, bagasse, pith
! Sri Chamundeshwari Sugars
wood chips, coal
! India Cane Sugar Ltd.

! Mufindi Paper Mills Ltd., Tanzania

*Product is supported under technical collaboration agreement with B&W
! Madhucon Sugar Ltd.
Babcock & Wilcox, USA.

12
OIL AND GAS

Bi-Drum
Packaged /
Site Erected
Boiler
FM/HCFM/
PFM
KBR for Chevron Energy, Nigeria
2
3 x 167 TPH, 63 kg/cm (g),
400°C Natural Gas/Tail Gas fired
HCFM Boiler

Product Features
! 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
Major Clients ! Fully drainable convective superheater
! Fine combustion control and high turndown ratios
! Galaxy Project FZCO for Burrup
Fertilizers Pty. Ltd., Australia
! Lurgi Aktiengesellschaft Ein
Unternehmen der for PDH AlfaseL,
Operating Range
Saudi Arabia ! Capacity : Upto 300 TPH
! KBR for Chevron Energy, Nigeria
! Pressure : Upto 110 kg/cm2(g)
! Sabic Petrokemya, Saudi Arabia
! Temperature : Upto 538°C
! Uhde India A/c Egyptian Propylene
! Fuels : All liquid and gaseous fuels, waste fuels,
& Polypropylene Company
tar, hydrogen, refinery gases
! 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 B&W
*Product is supported under technical collaboration agreement with
Babcock & Wilcox, USA.

13
 OIL AND GAS

Single-Drum
High
Capacity
Boiler

Radiant Boiler
Reliance Industries Ltd,
Jamnagar, India
2 x 125 TPH, 115 kg/cm2(g)
510°C Oil Fired Radiant Boiler

Product Features
! 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
Major Clients
! Fully drainable, horizontal and convective superheater for long life and
high reliability ! Southern Petrochemicals Ind.

! Steam cooled superheater supports for increased reliability Corp.

! Gujarat Narmada Valley
! Low refractory and thus reduced maintenance
Fertilizer Co.
! Arabian Petrochemical Co.
Operating Range ! L&T for Tata Fertilizer
! Capacity : Upto 500 TPH ! OEP for Oswal Chemical &
! Pressure : Upto 160 kg/cm2(g) Fertilizer
! ! Madras Fertilizers
Temperature : Upto 560°C
! ! Reliance Petroleum Ltd.
Fuels : Liquid fuels such as natural gas, purge gas, coke
oven gas, #2 oil, # 6 oil, heavy fuel oil, residue oil, ! Toyo Engg. for Chambal

HSD, naphtha, hydrogen gas, bio gas, waste gas. Chemicals & Fertilizers Ltd.
! Hindustan Fertilizer Corporation
Ltd., Dibrugarh

B&W
*Product is supported under technical collaboration agreement with
Babcock & Wilcox, USA.

14
OIL AND GAS
Heat
Recovery
Steam
Generator
(HRSG)*
Aban Power Ltd, Tamil Nadu, India
1 x 168 TPH, 110 kg/cm2(g),
542°C Frame 6 FA
Supplementary Fired HRSG Boiler
Major Clients
! 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
15
Product Features
! Proven design with more than 100 installations
! Natural circulation design for higher reliability, availability and
lower power consumption
! Single drum construction for reduced thermal stresses during startup
and shut down
! Fully welded construction for quicker start-ups and shutdowns
! Special drum internals which promote circulation and ensure high steam
purity
! Gas tight internally insulated ducting and casing for lower thermal loads
! Safe location of welds–outside gas path for higher reliability and longer
life
! 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
Boiler-Turbine-Generator (BTG) package can be offered on
case-to-case basis.
Operating Range
! Capacity : Gas turbine size of 320 MW
! Pressure : Upto 160 kg/cm2(g)
! Temperature : Upto 566°C
! Fuels : Natural gas/ naphtha / HSD / kerosene /
refinery fuel gas etc.
*Product is supported under technical collaboration agreement with B&W
Babcock & Wilcox, USA.

Reliance Industries Ltd.- Jamnagar Refinery Expansion Project
HRSG Parameters: 315 TPH, 49 kg/cm2(g), 396 °C
Gas Turbine Model: GE Frame-9E
! Six HRSGs with supplementary firing arrangement
with 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 gas
turbine load
! Superheat control range is from 60-100% of gas
turbine load in unfired mode
! Firing temperature of 800°C
Jacobs Netherlands for Schoonebeek Oilfield Redevelopment Project
HRSG Parameters: 408 TPH, 82 bar(g), 310°C
Gas Turbine Model: Frame-9E
! One HRSG with supplementary firing and fresh air
firing arrangement
! First HRSG being exported to European market from
India for a Frame-9E application
! NAM (Netherlands Aardolie Maatschappij) is the end
customer while Shell and Exxon Mobil are important
stakeholders
! HRSGs designed to generate 205 TPH in fresh air
firing mode
! FGR fan is used to achieve the required NOx level
OIL AND GAS
HRSGs on
Frame-9E
Gas Turbine-
Selected
Case
Studies
Reliance Industries Ltd.,
Jamnagar, India
Refinery Expansion Project
315 TPH, 49 kg/cm2(g), 396°C
Gas Turbine Model: GE Frame-9E
! 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 industrial
boilers rated at 275 TPH @ 49kg/cm2(g) and 396°C
and five nos. waste heat recovery boilers
! In all 3,400 TPH of steam generating capacity supplied
to the new Reliance refinery expansion project
! Boiler feedwater pumping station has 2.5 MW drive
motor with VFD control
! HRSG to be supplied in compliance with CE, PED and
Atex codes
! HRSG to be shipped in modular form (pressure parts
module)
! 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
16
LEAN GAS FIRED BOILER

Blast
Furnace
Gas / Lean
Gas Fired
Boilers

JSW Steel Ltd., Bellary, India

1 x 80 TPH, 62 ata
485°C, BFG / COREX
gas fired boiler

! More than two dozen lean gas fired boilers supplied to Indian
Green Steel Industry
Energy ! More than 50 installations of B&W worldwide
Product
! Burners manufactured indigenously based on proprietary Babcock &
Wilcox design, ensuring perfect match and integration with furnace
geometry

Salient Features
! 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
Major Clients
! Safe operation of boiler under varying load conditions
! Tata Steel, Jamshedpur
! Low volumetric heat release rate with larger boiler furnace
! Jindal Vijaynagar Steels Ltd.,
! Furnace refractory lining for stable combustion of BFG
Bellary
! Scroll burner for high mixing energy of air and BFG for efficient
! Kalyani Steels Ltd., Hospet

! Nagpur Alloys and Castings Ltd.,

combustion
! Safety interlocks to ensure proper burning of BFG without support fuel
Raipur
! Kirloskar Ferrous Industries Ltd., ! Zero oil/gas support within 70-100% MCR
Hospet
! Steel Authority of India Ltd.,
Operating Range
Rourkela
! Bramhani Industries Ltd., Bellary ! Capacity : Upto 500 TPH
! Pressure : Upto 100 kg/cm2(g)
! Temperature : Upto 560°C
! Fuels : Blast furnace gas, coke oven gas, corex gas,
LD gas & other lean gases.

17
 LEAN GAS FIRED BOILER

Waste
Gas
Fired Boiler
(CO/H 2)

Thai Carbon Black Company

Pvt. Ltd.,Thailand
2
100 TPH, 45 kg/cm (g),
420°C CO Fired
Waste Gas Fired Boiler

Waste gas fired boilers are designed to burn waste gas/tail gases to
generate steam for process or power. Typical systems include: Green
! Carbon Black Plants (CO Gas)
Energy
Product
! Ferro Alloy Plants (CO Gas)
! Caustic Soda Plants (H2 Gas)

Salient Features
! 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 Major Clients
! Membrane wall water tube construction to minimize refractory and
! Hi-Tech Carbon Ltd.
increase radiant heat transfer
! Control systems to ensure complete combustion of lean gas ! Philips Carbon Black Ltd.
! Continental Carbon
! Cabot Corporation
Operating Range
! Thai Carbon Black
! Capacity : Upto 250 TPH ! Birla Carbon
! Pressure : Upto 100 kg/cm2(g)
! BA Energy, Canada
! Temperature : Upto 560°C

18
FIRED HEATER

Fired Heater
in Petro-
chemical
Plant

Reliance Industries Ltd.,

Hazira, India
5 x 10 MMKcal/hr
Dowtherm Vaporisers

The Fired Heaters in the Chemical and Petrochemical plants are for:
! Heating process fluids
! Thermal cracking

Two types of designs can be offered depending on the application

! Vertical cylindrical
! Box type furnace

Major Clients
! Reliance Industries Ltd.
! Indian Oil Corporation Ltd.
Application
LIQUID phase heaters for
! Mineral oils / Synthetic oils
! Molten salt heaters
PROCESS industry heaters
! Steam superheaters
! Charge heaters
! Start up heaters

! Hindustan Petroleum VAPOUR phase heaters for

Corporation Ltd.
! Shell
! Finolex Industries Ltd.
! Bharat Petroleum
Corporation Ltd.
! UHDE GmbH
! Synthetic oil / Mineral oil CRACKERS
vaporisers ! Ethylene di chloride cracker
! Hydrocarbon vaporisers ! Acetic acid cracker
! Gas cracker

! Qatar Petroleum
Operating Range
! Gas Authority of India Ltd. ! Capacity : Upto 70 MMKcal/hr (Single unit)

19
 FIRED HEATER

Fired Heater
in Petro-
chemical
Plant
Ethylene di
Chloride (EDC)
Cracker
Finolex Industries Ltd.,
Ratnagiri, India
1 x 11.56 MMKcal/hr, EDC Craker

Product Features
! 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

Application Major Clients

! EDC cracking ! Finolex Industries Ltd.

Operating Range
! From 2 MMKcals/hr upto 30 MMKcals /hr capacity

20
FIRED HEATER

Fired Heater
in
Oil & Gas
Industry
for the
Upstream
Segment
Reliance Industries Ltd.,
Kakinada, India
3 x 21.5 MMKcal/hr
Hot Oil Heater

The Fired Heaters in Oil & Gas industry for the Upstream Segment are for:
! Heating process fluids
! Thermal cracking

Two types of designs can be offered depending on the application

! Vertical cylindrical
! Box type furnace

Major Clients
! Reliance Industries Ltd.
Application
! Crude pumping stations
! Tank farm heating
! Hot oil heaters on gas turbine exhaust or incinerator exhaust
! Water glycol heaters

! Indian Oil Corporation Ltd.

! Steam flood boilers
! Hindustan Petroleum
Corporation Ltd. Operating Range
! Finolex Industries Ltd.

! Bharat Petroleum Corporation Ltd.

! Capacity : Upto 40 MMKcal/hr (Single unit)
! UHDE GmbH, Germany

! Qatar Petroleum

! Bharat Oman Refinery Ltd.

! Shell Inc., Gabon (West Africa)

21
 FIRED HEATER

Fired Heater
in
Oil & Gas
Industry
for
Refinery

Indian Oil Corporation Ltd,

Barauni, India
1 x 20.08 MMKcal/hr Combined Feed
Heater for DHDT Unit

The Fired Heaters in Oil & Gas Industry for the Downstream
Segment are for :
! Heating process fluids
! Thermal cracking

Two types of designs can be offered depending on the application

! Vertical cylindrical
! Box type furnace

Application
! Crude distillation unit
! Vacuum distillation unit
! Delayed coker unit Major Clients
! Fluid catalytic cracker unit (FCCU) ! Reliance Industries Ltd.

! Diesel hydro desulfurization treatment (DHDT) plants ! Indian Oil Corporation Ltd.

! Naphtha vaporizers in hydrogen ! Hindustan Petroleum

! Motor spirits quality (MSQ) heaters Corporation Ltd.

! Finolex Industries Ltd.
! Naphtha splitter unit (NSU)
! Bharat Petroleum Corporation Ltd.

! UHDE GmbH, Germany

Operating Range ! Qatar Petroleum

! Capacity ! Bharat Oman Refinery Ltd.

: Upto 40 MMKcal/hr (Single unit)
! Shell Inc., Gabon (West Africa)

22
WASTE HEAT RECOVERY BOILER

WHRB
in Sponge
Iron Plant

Jindal Steel & Power Ltd., India

4 x 57 TPH, 66 kg/cm (g), 490°C
2

in Sponge Iron Plant

! Pioneer in waste heat recovery in sponge iron plant

Green ! More than 100 installations
Energy
Product ! 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

Salient Features
! Natural circulation water tube design
! Gas tight side wall of water wall construction

Major Clients Operating Range

! Jindal Steel & Power Ltd.
WHRB on 100 TPD, 350 TPD, 500 TPD, 650 TPD
! Bhushan Power & Steel Ltd.
! Pressure : From 44 kg/cm2(g) upto 115 kg/cm2(g)
! Bhushan Steel & Strips Ltd.
! Temperature : Upto 540°C
! Tata Sponge Iron Ltd.

! BMM Ispat

! Ispat Godavari Ltd.

! Shree Metallics Ltd.

! Singhal Enterprises

! Janaki Corporation Ltd.

23
 WASTE HEAT RECOVERY BOILER

WHRB in
Coke Oven/
Coke Dry
Quenching
Plant

Jindal Steel & Power Ltd.,

Raigarh, India
2
8 x 33.5 TPH, 72 kg/cm (g),
490°C WHRB in Coke Oven Plant
(Non Recovery Type)

! Pioneer in waste heat recovery in coke oven plant

! Water wall panel construction in 1st /2nd pass Green
Energy
! Site/port assembly with modularized construction Product
! Horizontal/vertical design
! Optional blast furnace firing capability
! Forced circulation design for coke dry quenching plant

Application
! Non recovery coke oven plant
! Recovery type coke dry quenching plant
! Recovery type coke by-product plant Major Clients
! Hooghly Metcoke & Iron Ltd.
(Tata Power)
Operating Range ! Jindal Steel & Power Ltd.
! Capacity : Upto 75 TPH ! Bhushan Power & Steel Ltd.

! Pressure : Upto 120 kg/cm2(g) ! Konark Metcoke Ltd.

! Temperature : Upto 540°C (Neelanchal Ispat Ltd.)

! Electrosteel Casting Ltd.

24
WASTE HEAT RECOVERY BOILER

WHRB in
Non-Ferrous
Industry

Birla Copper, Bharuch, India

WHRB for 300 TPD Copper Convertor
Unit to produce 21 TPH of steam
at 45 kg/cm2(g) at
saturation temperature

! Waste heat boiler on zinc pyrite roasters

! Waste heat boiler on copper smelters
Green ! Waste heat boiler on the copper convertors
Energy
Product
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.

Major Clients
! Birla Copper
! Cominco Binani Zinc Ltd.
! Hindustan Copper Ltd.
! Pyrites Phosphates &
Chemicals Ltd.
Salient Features
! 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
Operating Range
! Capacity : 10 TPH to 100 TPH
! Pressure : 45 -60 kg/cm2(g)
! Temperature : Upto 400°C

25
 WASTE HEAT RECOVERY BOILER

WHRB in
Refinery &
Petro-
chemical
Plant

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

Fluid Catalytic Cracking Unit (FCCU)

! Waste heat recovery boiler downstream of FCCU
Green
! One of the world’s largest WHRB designed and supplied to Reliance Energy
Industries Ltd. India Product
! 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

Salient Features Major Clients

! Designed to take care of carry-over catalytic dust ! Reliance Industries Ltd.
! Complete membrane panel construction to take care of sulphur dew point ! Indian Oil Corp.Ltd., (IOCL)
! Soot blowers at suitable locations to take care of dust laden gases ! Hindustan Petroleum
! Vibration arrestors provided to prevent tube vibration and consequent Corporation Limited
failures ! Foster Wheeler A/c Samref,
! Natural circulation design Saudi Arabia
! Fully drainable design of superheater
! Co current and drainable economizer

Operating Range
! Capacity : Upto 200 TPH Superheated Steam
! Pressure : Upto 75 kg/cm2(g)
! Temperature : Upto 540°C

26
WASTE HEAT RECOVERY BOILER

WHRB in
Cement
Plant

J.K. Cements,
Nimbahera, India,
generating 72 TPH at
17 kg/cm (g), 325°C
2

Cement manufacturing is a highly energy-intensive process. Given the

fragile and dynamic nature of the fuel and power situation faced by cement
Green plants today, it makes sense for them to adopt waste heat recovery based
Energy solution for the following reasons:
Product
! 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)

Thermax along with technical assistance from M/s Taiheiyo Engineering

Corp. (Japan) offers this world-class solution for cement industry.

Product Features
Major Clients a. Waste heat recovery boiler for pre-heater and calciner
! J.K. Cements, Nimbahera ! Horizontal boiler with tubes located vertically for uniform dust disposal and gas
distribution
! 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

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

27
 WASTE HEAT RECOVERY BOILER

WHRB in
Chemical
Plant

Heat Recovery for

1800 TPD Sulphuric Acid Plant at
Bagfas Fertilisers, Turkey
generating 89 TPH capacity

Sulphuric Acid Plant

! Can be offered as fire tube / water tube construction Green
! Experience in offering flexible / fixed tube sheet design for fire tube Energy
Product
boilers
! Experience in handling high gas side operating pressures upto 5000
mmWC (special construction of economizer and superheater is provided)
! Cast iron gill ring economiser to prevent sulphur corrosion
! Equipment (boiler, superheater, economiser) is scattered around
converter
! Gas outlet temperature control at every equipment is required
for efficient conversion of acid gas
Major Clients
Nitric Acid / Caprolactum Plants ! Hitachi Zosen

! Mitsui Engg. & Shipbuilding Co.

! Nitric Acid Plants are either low pressure or high-pressure systems
! Sterlite Industries Ltd.
! The type of boiler used is either
! Bagfas Fertilizer Co., Turkey
> Natural circulation fire tube
! Birla Copper
> Forced circulation water tube ! Gujarat State Fertiliser
> The NH3 burner is normally included as a part of the unit ! Indian Explosives Ltd.

> 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

Operating Range
! Capacity : 20 TPD to 4500 TPD sulfuric acid production

28
WASTE HEAT RECOVERY BOILER

WHRB
in Sulphur
Recovery
Plant

Reliance Petroleum Ltd.,

Jamnagar, India
3 x 45 TPH at 38 kg/cm2(g) in
Sulphur Recovery Unit

Main Reaction Furnace

Green
Energy
Product
Major Clients
! Reliance Petroleum Ltd.
! Cochin Refineries Ltd.
! Indian Oil Corporation Ltd.
! Hindustan Petroleum Ltd.
! Bharat Petroleum Corp. Ltd.
! Bahrain Petroleum Co.
! Dolphin Energy Ltd., Qatar
! 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
! WHB downstream of tail gas incinerator
! Water tube / fire tube design
! Modularised construction
! Experience in supplying superheater made of T22, T91, Incoloy

29
 WASTE HEAT RECOVERY BOILER

Exhaust
Gas Boiler
(EGB)

Alok Industries Ltd.,

Vapi, Gujarat, India
6 Nos. x 6 MW Wartsila Engine
2
6 x 3.4 TPH at 10.5 kg/cm (g)

Salient Features
An exhaust gas boiler recovers heat from the flue gases of genset to Green
produce steam, hot water or thermic fluid for various heating / cooling Energy
Product
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

Applications
! Auxiliary oil heating, tank farm heating, line tracing
Major Clients
! Process heating
! GMR Vasavi- 200 mw IPP, India
! Combined cycle
! PPC, Greece-KOS, Paros &
! Steam / hot water for industrial chilling
Chios Power Plant-75 MW
! Moser Baer, India-60 MW

Operating Range ! Sandakam, Malaysia 32 MW IPP

! Nestle, Philippines, Srilanka &

! EGB installed on 0.5 MW to 50 MW genset installations
India
! 2 stroke and 4 stroke engines
! Alok Industries, India 28MW
! Light oil, heavy oil and gas fired engines Gas CPP
! Mangalore Chemical & Fertilizer
Ltd., India-48 MW

30
WASTE HEAT RECOVERY BOILER

WHRB in
Hydrogen
Plant

WHRB in Hydrogen Reformer at

HPCL Mumbai

Reformed Gas / Process Gas Boiler

! Fire tube boiler configuration
Green
Energy ! Flexible / Fixed tube sheet design
Product ! 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/cm2g)
! Gas rich in H2 / CO / CH4
! Common steam drum for reformed gas boiler and flue gas boiler

Major Clients
! Hindustan Petroleum Corp. Ltd.
! National Peroxides Ltd.
Flue Gas Boiler / Convection Section
of Hydrogen Reformer
! Water tube / fire tube type design
! Designed to handle heating of different liquids
! Capacity to design and manufacture high capacity boilers

Operating Range
! Capacity : 30 TPD to 5000 TPD Hydrogen Production

31
 WASTE HEAT RECOVERY BOILER
STEAM OUTLET

CHEVRON
SEPARATOR
WHRB on
STEAM
DRUM
Glass
Furnace
TUBE
BANK

WATER
DRUM
NATURAL CIRCULATION
2-DRUM WATER TUBE BOILER

Waste gases leaving glass-melting furnaces are at high temperatures of 1200

to 1400°C (or float glass furnace at temperatures ranging from 450°C to
550°C) and contain a high carryover of silicates and alkalis besides residues Green
from heavy oil firing. These waste gases have a high potential for heat Energy
recovery. Product

Steam Outlet
Salient Features
Steam Drum
! Compact single/ bidrum natural
circulation design
! Optimum tube sizes and pitch to
avoid choking
! Low gas velocities to avoid
erosion of tubes
Tube Bank Major Clients
! Special cleaning mechanism to ! Alembic Chemicals Ltd.
maintain surface cleanliness ! Ceat Ltd.
(e.g. hammering device, shot
ball cleaning)
Water Drum
! Optimum design factor consider
corrosive and errosive nature of
! Saturated/superheated steam for
Hopper
process / chilling / power
solution

32
WASTE TO ENERGY

Spent
Wash-Fired
Boiler

Bannari Amman Sugars Ltd.,

Nanjangud, Karnataka, India.
1 x 23.4 TPH, 32 kg/cm2(g), 350°C

Breakthrough Technology for

the Distillery Sector
! 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

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

Major Clients
Designed and Engineered for Excellence
! Bannari Amman Sugars Ltd.

! Sovereign Distilleries Ltd. ! Effective on-line cleaning system

! EID Parry India Ltd. ! Specially designed spent wash handling system
! Mohan Breveries Distilleries Ltd. ! Adequate residence time to ensure complete combustion
! System designed for maximum heat recovery
! Backed by a sustained R&D initiative

33
 WASTE TO ENERGY

MSW/RDF
Fired Boiler

Pusher grate technology to

convert waste to energy
(MSW/RDF)

Designed and Engineered for Excellence

! 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

Specially Designed Pusher Grate

! 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

34
SERVICES

Renovation
&
Modernization
(R & M)

! 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

Condition Assessment and Remaining

Life Analysis and Engineering Studies
Major Clients
! Patented non-destructive techniques
! Petronas Gas Bhd ! Life Extension Programmes
! Reliance Industries Ltd.
! Boiler performance reviews and system improvement analysis
! Indian Oil Corporation Ltd.

! Indian Navy

! Fertilizers & Chemicals

Fuel Conversion and Firing System Upgrade
Travancore
! From gaseous to liquid fuels and vice-versa
! Deepak Fertilizers &
! From liquid/gas to solid fuels and vice-versa
Petrochemicals Corporation
! Conversion to fluidized bed combustion for firing coal, lignite or
! National Thermal Power
Corporation biomass fuels
! Jindal Steel & Power Ltd. ! Upgrade from flat fluidized bed to hopper bottom design
! IFFCO ! Fuel feeding system upgrades
! Takreer Abu Dhabi Refinery

! Zuari Industries Limited

! Rashtriya Chemicals &

Fertilizers (RCF)

35
 SERVICES
What can you expect from
a 30 year old boiler?
Renovation
&
Modernization
(R & M)

...another 30 years

Performance Enhancement Solutions

! Steaming capacity enhancement
! Efficiency improvement
! Pollution abatement solutions
! Instrumentation and controls upgrade
! Troubleshooting and de-bottlenecking

Pressure Part Replacements and Upgrades

! Enhancing pressure parts by redesigning heat transfer surfaces like
furnace water walls, superheaters, reheaters, economizers etc.
! Replacement of pressure parts for life extension
Major Clients
! Tenaga Nasional Berhad,
Malaysia
Utility Boiler Revamps ! Tata Steel Ltd., India

! Ruwais Fertiliser Industries

! Remaining life analysis and life extension studies
(FERTIL), UAE
! Selective pressure part replacement/ upgrades
! Nestle, Philippines
! Re-engineering of fuel firing system
! Nestle, Russia
! Performance enhancement solutions
! IRPC, Thailand
! Emission control solutions (Thai Petrochemical)
! Bharat Petroleum Corporation
Limited
! Chennai Petroleum Corporation
Limited
! Finolex Industries Limited

! Gulf Petrochemical Industries

Company, Saudi Arabia

36
Installations in over 75 countries

Canada
U.K.
Ireland
Netherlands Germa

U.S.A

Algeria
Mexico

Nigeria

Colombia

Brazil Za

Afric

49
 Timashevsk, Russia

ny Kazakhstan

Uzbekistan

Turkey Turkmenistan
Kuwait
Jordan Bangladesh
Bahrain
Qatar Abu Dhabi Vietnam
Egypt India Thailand
Jiddah, UAE
Oman
Saudi Arabia
Cambodia
Philippines
Malaysia
Kenya
Sri Lanka

Tanzania Indonesia

mbia

a Australia

New Zealand

Global Footprint of
Boiler & Heater Group
For more details visit www.thermaxindia.com or
Write to info.bnh@thermaxindia.com
50
Boiler & Heater Group
Pune Admin Office & Works
D-1, MIDC, R. D. Aga Road, Chinchwad, Pune 411 019.
Tel.: +91-20-66126464, Fax: +91-20-27479200, 27479050
Baroda Office & Works
Plot No. 21/1,2,3, GIDC, Manjusar (Savli), Taluka Savli,
Dist - Vadodara, Gujarat 391775.
Tel: +91-2667-264727, Telefax: +91-2667-264728

REGIONAL OFFICES
Mumbai
Dhanraj Mahal 2nd floor, Chhatrapati Shivaji Maharaj Marg,
Near Gateway of India, Mumbai 400 039, India.
Tel: +91-22-22045391, 22045324, Fax: +91-22-22040859
Email: ganeish.waze@thermaxindia.com
New Delhi
9, Community Centre, Basant Lok, Near Priya Cinema,
New Delhi 110 057, India.
Tel: +91-11-26145326, 26145319, Fax: +91-11-26145311
Email: ajee@thermaxindia.com
Chennai
Fatima Akthar Court, 3rd floor, 312, Teynampet,
Chennai 600 018, India.
Tel: +91-44-24353831/4, Fax: +91-44-24353841
Email: rajesh.mrithyunjayan@thermaxindia.com
Kolkata
Azimganj House, 5th Floor, 7 Camac Street,
Kolkata 700 016, India.
Tel: +91-33-22826711/13, Fax: +91-33-22826796
Email: schakrab@thermaxindia.com
Hyderabad
6-3-649, Behind Medinova, Nalanda Complex, 2nd Floor,
Somaji Gujda, Hyderabad 500 082, India.
Tel: +91-40-23310254/23312013, Fax: +91-40-23312335
Email: nmeher@thermaxindia.com

OVERSEAS OFFICES
SOUTH EAST ASIA
Thermax Limited
3rd Floor, South Wing, Bangunan Getah Asli,
148 Jalan Ampang, Kuala Lumpur - 50450, Malaysia
Tel: +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 Babcock & Wilcox (A Division of Thermax Ltd.)
C/o. Gulf Power International (Dabbagh Group),
P.O. Box: 74426, Al-Khobar 31952, KSA
Tel: +966 3 887 4557, Fax: +966 3 882 3041
Email: devdas@thermaxme.com, Cell: +966 553 915 403

www.thermaxindia.com
synergy design