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.

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-today 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 inhouse 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.

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

Biomass Boiler
Thermax has always been responsive to the energy needs of industry and to the everchanging 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

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 Grate
Salient 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 takeup 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.

Indian Cane Sugar Ltd., Bagalkot, Karnataka, India

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

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.

Technical Features
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.

Bajaj Hindustan, Gola, Uttar Pradesh, India

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

Pinhole Grate
Salient 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.

Major Installations
CLIENT

CITY

NOS.

TPH

KG/CM2G

DEG.C

FUEL

YEAR

Dumping Grate
Bannari Amman Sugars

Coimbatore

32

42

410

Bagasse

1990

UP

50

32

390

Bagasse

1990

Phoenix Pulp & Paper

Thailand

80

65.3

480

Bark/Oil

1991

Lampang Sugars

Thailand

50

16

265

Bagasse

1992

Seksaria Sugar Mills

Pinhole Grate
Bajaj Hindusthan

Lakhimpur Kheri, UP

80

45

4205

Bagasse

2000

Bajaj Hindusthan

Gola

100

45

425

Bagasse

2003

Hopper Bottom (Fluidised Bed Combustion)

Shree Cements Ltd.

Beawar, Rajasthan

80

65

4955

Imported Coal, Petcoke,

Lignite

2001

Philippines

24.95

18

Saturated

Spent Coffee Grounds,

green coffee residue,
roasted chaffs & HFO

2004

Orissa

165

88

5205

Washery rejects, char

2004

Holcim Group - Ambuja

Cements

Chhattisgarh

80

67

4955

Coal/Rice husk/coal/
biomass/pet coke

2006

Usha Martin Ltd.

Ghamaria,
Jamshedpur

140

69

4905

washery rejects, char fired

Hopper bottom

2006

Bhadrachalam

90

65

480

F Grade coal / biomass

2008

Sabah, Malaysia

75

65

480

Wood, Bark & Sludge

2010

Coal/Bagasse

2000

Nestle Philippines Inc.

Bhushan Limited

ITC Limited
Sabah Forest Industries Sdn Bhd.

Travelling Grate
Kakatiya Cement Sugar
& Industries

Hyderabad

90

86

5155

Tamilnadu Newsprint
& Papers Ltd.

Appakudal

85

87

515

Bagasse/Imported coal/pith/
lignite

2001

U.P.

80

87

515

Bagasse/Rice Husk

2001

Philippines

105

49

400

Indonesian coal

2002

Bannari Amman Sugars Ltd.

Nanjangud

120

67

485

Bagasse/biomass

2002

Davangere Sugar Co. Ltd.

Kukkuwada

90

87

515

Bagasse,coal / biomass

2002

Mawana Sugars Ltd

Nagalamal

120

87

515

Bagasse, Rice husk & Indian

coal

2005

Dhampur Sugars Ltd.

Dhampur, UP

170

105

540

Rice husk & coal

2005

Hulliatti Karnataka

120

108

540

Bagasse & coal

2006

Bangalore

135

108

540

Bagasse & coal

2006

Indian Cane Sugar Ltd.

Bagalkot

125

87

515

Bagasse & coal

2006

Madhucon Sugar Ltd.

Khammam

120

108

540

Bagasse

2006

Nava Bharat Ventures Ltd.

Hyderabad

100

87

5155

Bagasse

2006

Yashwantrao Mohite Krishna

Sahakari Sakhar Karkhana Ltd.

Satara, Maharashtra

90

87

5155

Bagasse

2008

Samarth Sahakari Sakhar

Karkhana Ltd.

Jalna, Maharashtra

95

87

510

Bagasse

2008

Saha Cogen Lamphun A/c

Jurong Engg

Thailand

65

53

412

Wood Chip

2009

Mitr Kalasin Bio Energy

Company

Thailand

170

105

520

Bagasse, wood chips, rice

husk

2010

Lokmangal Sugar Ethanol & CoGeneration Company Ltd.

Solapur

90

67

505

Bagasse, imported coal

2010

Dan Chang Bio-Energy Co.,Ltd.

Thailand

170

105

520

Bagasse, wood chips, rice

husk

2010

Uttarakhand

110

110

540

Bagasse

2010

Kamadhenu Ventures
(Cambodia) Ltd.

Cambodia

135

110

540

Bagasse

2010

Jamkhandi Sugars Ltd.

Bagalkot

120

110

540

Bagasse

2010

Balrampur Chini Mills Ltd.

Rio Tuba Nickel HPP project
through JGC

Bharat Sugars Ltd.

Sri Chamundeshwari Sugars

Lakshmi Sugar Mills

Company Ltd.

Canada

Ireland

U.S.A

REGIONAL OFFICES
Baroda Office & Works
Plot No. 21/1,2,3, GIDC,
Manjusar (Savli),
Taluka Savli, Dist - Vadodara,
Gujarat 391775

Mexico

Phone: +91-2667-264727
Fax: +91-2667-264728
Mumbai
Dhanraj Mahal 2nd floor,
Chhatrapati Shivaji Maharaj Marg,
Near Gateway of India,
Mumbai 400 039

OVERSEAS OFFICES
SOUTH EAST ASIA
Thermax Limited

Phone: +91-22-22045391, 22045324

Fax: +91-22-22040859

3rd Floor, South Wing, Bangunan Getah

Asli, 148 Jalan Ampang, Kuala Lumpur 50450, Malaysia

New Delhi

Phone: +603 2166 98 01 / 03 / 04

Fax: +603 2161 2685

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

Email: akabra@thermaxindia.com
Cell: +60 122056623
Email: pghelani@thermaxindia.com
Cell: +60 172454569
MIDDLE EAST
Thermax Limited

Phone: +91-44-24353831 / 4
Fax: +91-44-24353841

C/o. Gulf Power International (Dabbagh

Group), P. O. Box: 74426, Al-Khobar
31952, KSA

Kolkata

Phone: +966 3 887 4557

Fax: +966 3 882 3041

Azimganj House, 5th Floor,

7 Camac Street, Kolkata 700 016
Phone: +91-33-22826711 / 13
Fax: +91-33-22826796

Email: devdas@thermaxmena.com
Cell: +966 553 915 403
EUROPE

Hyderabad

Thermax Ltd,

6-3-649, Behind Medinova,

Nalanda Complex, 2nd Floor,
Somaji Guda, Hyderabad 500 082

Avenue Charles Thielemans 109

Phone: +91-40-23310254 / 23312013

Fax: +91-40-23312335

Colombia

B - 1150 , Brussels, Belgium

Phone: 32(0) - 27369244 / 473450186
Email: alain.dessoy@thermaxprocessheat.be

Brazil

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.

Germany
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

www.thermaxindia.com

design@synergydesign.in

Email: 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.