Steam Boilers

Product Details:

Internal Furnace Top Feed Husk Fired Boiler is said so because of their unique automatic fuel feeding from the top of the Internal Furnace boiler. Until now automatic feeding was only possible in case of an external furnace where the furnace is not a part of the boiler.

Thermodyne Engineering Systems has a dedicated team of qualified researchers and designers who always strive for the best and unique designs. This Husk Fired Steam boiler shows the true example of engineering concepts used in practice.

Design of Husk Fired ( Internal Furnace Top Feeding ) Steam Boiler : 

In the rice plant cleaning process, it produces husks which are often treated as waste. This agri waste used as fuel in boiler systems and such boilers called Husk Fired Boiler.

They are basically used for feeding Rice Husk because of its low density. Their design is exactly the same as our INTECH (smoke tube type internal furnace boilers) models where the furnace and smoke tubes are an internal part of the boiler.

Combustion of fuel takes place inside a furnace where most of the radiation heat transfer occurs between flue gases and water while convective heat transfer dominates when flue gases are traveling at high velocity inside the tubes.

Main differences in the design when compared to internal furnace boilers:

• Instead of manual feeding, feeding is done automatically.
• Forced Draft Fan is provided instead of Induced Draft Fan.

Fuel Feeding Mechanism

Rice Husk is fed into a hopper placed above the ducting, connecting the boiler at one end and the Forced Draft Fan at the other. High-Pressure air is sent from the fan via ducting. A damper is provided to manually regulate the flow. Just below a hopper, a low-pressure zone is created by high-velocity air which is responsible for pulling the rice husk into the ducting.

Then the rice husk gets carried by the high-pressure air to the top of the shell where it is fed into a furnace through a narrow passage. This is how the rice husk is fed automatically into a boiler furnace. Fuel feeding is regulated according to the steam capacity requirement and the fuel is regulated by the airflow through a forced draft fan.

Product Details:

Intech as it’s name implies is a 3 Pass Internal Furnace Package Boiler. It is a conventional 3 pass smoke-tube design, designed for the combustion of coal and wood in an internal furnace and is therefore sometimes known as coal/wood fired steam boiler.This packaged boiler comes in dry back, semi-wet back, and fully wet-back options and is most suitable for a manual firing of solid fuel like coal, wood or briquettes. The boiler furnace is fully submerged in the water, this helps in transferring the maximum heat from the furnace to the surrounding water. The grate bars on which the fuel is burnt are placed in the furnace toensure desired grate area for burning fuel.

Also Read: Dry Bottom Boiler:-
The fuel of packaged type boiler is fired on the grate and flue gases are released on combustion of fuel. The flue gases then travel from the furnace to the flue gas outlet through the second and third pass smoke tubes, reversing from smoke boxes on their way out. Flue gases traveling at high speed ensures maximum convective heat transfer rate and 3 passes (2 tube passes and 1 furnace pass) extract the maximum amount of heat from the gases. An induced draft fan is provided in the boiler assembly, for proper combustion and maintaining draft in the furnace. This conventional design also ensures effective distribution of thermal and mechanical stresses in the heating equipment thereby increasing the boiler life. Water pre-heater or economiser may be provided in a shell and tube design to increase the efficiency of a boiler. This implies recovering waste heat from flue gases by reducing the exhaust temperature leaving the boiler.

Types of Intech Packaged Boilers:-

• Single furnace packaged type boiler
• Dual furnace packaged type boiler

Intech: Packaged Boilers Advantages:

• The large convective heating surface area in the 2nd and 3rd pass tubes ensures maximum heat transfer.
• Large water holding and steam holding space are extremely helpful in overcoming the fluctuating steam demands needed for the process.
• High dryness fraction of the steam increases the usable heat.
• Dry steam generated, helps in reducing the processing time, saves steam and improves the quality of processed goods.
• Horizontally packaged boilers – less site work required, quick commissioning and hinged doors are provided, for easy inspection & maintenance of boiler.

Intech: Packaged Boilers Capacity:

• Intech – Three pass internal furnace Packaged type boiler is available in capacities ranging from 0.3 TPH to 4 TPH for Wood / Coal/ Briquettes.

Features

• Skid mounted
• No external furnace
• Internal furnace
• Compact
• Rigid

Advantage

• No special foundation required
• Brickwork is not required
• Lesser heat losses
• High efficiency
• Low maintenance

Benefits

• Space and cost saving
• Cost and time saving
• Early paybacks
• Low operating cost
• Long life

Product Details:

Revosteam is the conventional forced-circulation type water tube coil type boiler incorporating the unique principle of combustion known as ‘Reverse Flow’. This increases the combustion efficiency and allows a high rate of heat release. It can be offered in both IBR and Non-IBR designs.

Construction:
The boiler comprises of a jacketed MS shell housing a helical coil. The combustion air is forced through the jacketed shell by means of a centrifugal blower thereby getting pre-heated. The flame travels downwards inside the coil and the flue gases reverse upwards thereby giving two passes in the radiant zone ensuring complete combustion and higher heat flux. The third pass of the flue gases is in the convective zone between the coil and the inner shell. Flue gases then travel to the Economiser forming the fourth pass.

Advantages:

• Fully Automatic unit
• Unique four pass design
• High efficiency and low running cost
• Minimum site-work, low installation costs
• Instant steaming within 5 minutes of cold start
• Built-in economiser increases the operating efficiency
• Fail-safe design and dependable operating instruments

Product Details:

Combitherm Steam Boiler or is known among others as Combi boiler is a unique water cum smoke tube type design. It is the combination of both Water Tube Boiler and Smoke Tube Boiler where some tubes form the enclosed part of the external furnace in which water flows and rest of the tubes are placed in a shell in which flue gases flow.

What is Combi Boiler?
Our shell in case of combitherm (Combi Boiler) is a 2 pass design to increase the residence time and at the same time keeping the velocity optimum to achieve high convective heat transfer. Our shell and water wall tubes provide large water & steam holding capacities to give the maximum advantage.

Combitherm (Combi Boilers)Working:
Water is fed to the boiler from a feed pipe connection. Firstly the water fills in the shell and then gets transported to the Bottom Header of water wall from the Down-comers welded to the Boiler Shell.

From here the water rises up in the tubes of water wall and gets thrown back to the boiler shell from the top header. As firing is done in the furnace, because of radiation the surface temperature of the water wall membrane rises and the water present in the tubes gets heated up and starts getting converted to steam.

Now this steam, being lesser dense (creating a natural circulation of steam-water in the system), rises up to the top header and gets to the Boiler Shell. The flue gas from the furnace (1st pass), traveling in the membrane, then enters the tube of Boiler Shell. In Boiler Shell flue gasses flow in the tube.

These Boiler Tubes are divided in 2 passes (2nd pass & 3rd Pass) where flow gas travel from both the passes and transfer heat to water through convective heat transfer. Steam coming from both the sides get collected at the top of the Boiler shell and then supplied through steam lines for the desired process application.

3 Pass Smoke Cum Water Tube Boiler design can burn a variety of fuels like Coal, Lignite, Rice Husk, Wood, Bagasse, Groundnut shells, and several other fuels thus providing you with lowest energy costs depending upon the fuel available in your area.

The large furnace grate area and furnace volume in case of Combitherm Boilers provide optimum time for fuel to get burnt. On the basis of fuel firing our Combitherm boilers can be divided into 2 types: Manual firing boiler and Automatic firing boiler.

When fuel feeding to the boiler is done manually generally in case of small capacity boilers where the amount of fuel fed to the boiler is generally less is said to be manual firing boiler and when fuel feeding is done automatically usually with the help of screw feeder, drum feeder, chain grate, pulsating grate etc. are said to be automatic firing boiler. Manual and automatic firing also depends upon the type of fuel.

Advantages:

• The flexibility of fuels with choice of agro waste fuels
• Combines the advantage of both water tube and smoke tube designs
• High thermal efficiency and low operating costs
• The higher degree of Equipment’s Reliability
• Dependable quality of components like valves, pumps, safeties & instruments
• Can be converted to liquid/gaseous fuels as well
• Heat recovery unit may be offered for enhanced efficiency
• Easy access for cleaning and inspection
• Capacity Range:
• Combi Boiler or Combitherm Boiler, Membrane water wall type boiler is available in capacities from 1 TPH to 15 TPH.

Fuel:

• Coal,
• Lignite,
• Rice Husk,
• Wood,
• Bagasse,
• Groundnut shells,
• Petcoke, and several other Solid fuels

Product Details:

Savemax – Oil & Gas Fired Boiler are the basic 3 pass internal furnace smoke tube type design in which flue gases are inside the tubes while water is outside the tubes in the shell. The combustion of oil and gas in a furnace requires atomization of the fuel. Since the fuel entering the burner in bulk amount is either in liquid or gas form, therefore it needs to be separated in fine droplets so that every last particle of the fuel could get burnt without leaving any traces.

This process of separating the fluid particles is called atomization. Generally, atomization is done with the help of a high-pressure fan which also provides air for the combustion of fuel. Mostly burners come with the attached fan and their assembly is known as a Monobloc Burner which means fan mounted on a burner. The superior features make the boiler ideal choice in the industry Thermodyne. The 3-pass oil/gas fired boilers are most suitable for the burn fuels like heavy and light oils & gasses.

Both Oil and Natural Gas Boilers are highly efficient as the furnace temperature in case of both is around 1200 – 1300 ºC. Higher the Furnace temperature, higher will be the radiation heat transfer rate to the surrounding water. The high combustion volume, large water, and Steam holding capacity and superior design feature provide efficient operation.

Difference between Oil Fired Boiler and Gas Fired Boiler:

• Oil Fired Boilers generally require Day Oil Tank to store oil and this oil is transported to a burner through oil piping and oil pump.
• On the other hand, High-Efficiency Gas Fired Boilers are exactly same as Oil Fired Boilers in construction and the only difference is the transportation of gas to burner requires gas train which comprises of the gas regulator that regulates pressure, the gas strainer to remover dirt from gas while no such valves are required in oil fired boilers

Advantages and Benefits:

• Fully automatic and high efficiency of 88 % on NCV saves running costs to the Steam Boilers
• A large convective heating surface in the 2nd & 3rd pass tubes ensures excellent heat transfer
• Large water holding & steam holding space provides quick response to fluctuating steam demands
• Large heat transfer surface reduces the thermal stresses on the boiler surfaces
• Dry steam reduces the processing time, saved the steam & improved quality of processed goods
• Monobloc type burner – Reduce fuel consumption
• Horizontal packaged boilers– less site work & quick commissioning

Our savemax model works very smartly in a way that it saves a lot of your fuel. Both pressure and temperature gauge sense the outlet steam pressure and temperature and when it exceeds the set pressure and temperature, it automatically gives the signal to the burner which in turn reduces the fuel flow to the burner thereby reducing the operating cost.

Capacity:-

• Savemax – Oil/Gas Fired Boiler is available in capacities from 1 TPH to 10 TPH

Fuel:- 

• Liquid Fuel, heavy/light Oil, and any other Gaseous fuel, Natural Gas.

Product Details:

A boiler is an enclosed vessel that provides a means for combustion heat to be transferred into water until it becomes heated water or steam. The hot water or steam under pressure is then usable for transferring the heat to a process. Water is a useful and cheap medium for transferring heat to a process.

The boiler system comprises of: feed water system, steam system and fuel system. The feed water system provides water to the boiler and regulates it automatically to meet the steam demand. Various valves provide access for maintenance and repair. The steam system collects and controls the steam produced in the boiler. Steam is directed through a piping system to the point of use. Throughout the system, steam pressure is regulated using valves and checked with steam pressure gauges. The fuel system includes all equipment used to provide fuel to generate the necessary heat.

Steam boiler or simply a boiler is basically a closed vessel into which water is heated until the water is converted into steam at required pressure. This is most basic definition of boiler. The boiler is essentially a closed vessel inside which water is stored. Fuel (generally coal) is burnt in a furnace and hot gasses are produced. These hot gasses come in contact with water vessel where the heat of these hot gases transfer to the water and consequently steam is produced in the boiler.

Industrial steam boilers offer flexibility and power, two qualities that make them an ideal solution for a business, commercial setting, or industrial facility. They can use a variety of fuels to heat the water that is converted to steam, including natural gas and other fossil fuels, coal, and electricity. They allow you and your business to determine the most economical and environmentally-friendly option depending on your company’s budget, legal emissions regulations, and your priorities.

Product Details:

This is a unique design membrane water wall type boiler combining the advantages of water tube & smoke tube designs. The radiation zone of the furnace is covered on three sides by water tubes forming the first pass and the conventional smoke tube shell has tubes lined up forming the second and third pass of flue gases. Thus the water wall furnace recovers the radiation heat of the furnace and the smoke tube shell provides large water & steam holding capacities to give maximum advantage.This design can burn a variety of fuels like Coal, Lignite, Rice Husk, Wood, Bagasse, Groundnut shells, and several other fuels thus providing you with lowest energy costs depending upon the fuel availability in your area.

Advantages:

• Flexibility of fuels with choice of agrowaste fuels
• Combines the advantage of water tube and smoke tube designs
• High thermal efficiency and low operating costs
• Dependable quality of components like valves, pumps, safeties & instruments
• Can be converted to liquid/gaseous fuels as well
• Heat recovery unit may be offered for increased efficiency
• Easy access for cleaning and inspection.

Product Details:

These are fully water tube design boilers for High Pressure Water Tube Steam Boiler requirements. Water circulation through the boiler may be either natural circulation due to density difference or by forced circulation.

Advantages:

• The heat of combustion is utilized more efficiently by the use of small diameter tubes in large numbers
• To avoid large resistance to the flow of water, Powertherm boilers have a parallel set of arrangement of tubes
• The boiler components can be arranged horizontally, giving greater accessibility and operational convenience
• All the parts are uniformly heated; therefore the danger of overheating is reduced. Also thermal stress problem is avoided
• The tendency of scale formation is eliminated due to the high velocity of water through the boiler tubes.

Additional Information:

• Item Code: Combitherm

Product Details:

Industrial Electric Steam Boiler or electrode type steam boilers are a unique type of design where you do not have to worry about any fuel and it’s handling problems because they do not use any fuel for heating. You also don’t have to worry about the pollution norms, since fuel is not required so flue gases will not be generated which are generally the main sources of pollution. Overall, Electra is energy efficient, environmentally friendly, ready to start boilers which can also be installed in a closed area or room and requires very less space. Overall, Electra is energy efficient, environmentally friendly, ready to start boilers which can also be installed in a closed area or room and requires very less space.

Working of Our Industrial Electric Boiler Model Electra
As the name implies, Electra or Electrode type boilers require electrode which acts as a good conductor to transfer electricity from main supplies to water. Electra Boiler works on a principle of electrical resistance and here water acts as a resistance in the path of electricity.
As the electrical load increases at the supply, the amount of current drawn from the electrodes will increase. So higher the current, higher will be the rate of heat dissipation to water thereby converting water to steam.
This rate of heat dissipation will determine the rate of conversion of water to steam and since there is minimal or no electrical losses all the heat is dissipated directly into the water thereby making them the most efficient boilers.

Electra – Electrode Type Steam Boilers (Electrode Boilers) Construction
ELECTRA – Electrode Type steam boilers (Industrial Electric Boiler) are manufactured as a packaged unit mounted and a chassis, the installation comprises the fitting of the steam pipe, cold feed, blowdown, drain, safety valve, air vent pipe and the connection of the electrical supply.

The current source consists of specially designed electrodes in the form of scrolls in order to maximize the electrodes area. Automatic controls for high steam pressures and the high and low water level inside the boiler shell are provided through a fully pre-wired control panel thereby making the operation highly user-friendly and easy.
The water fills in the Steam Boiler shell and as soon as the water comes in contact with the electrodes, the current in the system rises and due to short-circuiting in this system. An amount of energy (proportional to the magnitude of the current flow) is released, heating up the water surrounding it and generating steam.

Advantages Of Electra – Electrode Type Steam Boilers

• Compact size
• Safe, easy-to-use heat source – no on-site products of combustion.
• No emissions to the atmosphere, hence Eco-friendly
• Easy and quick to install, they require only water connection and electrical hook-up.
• Steam available at the flip of a switch.
• Highly efficient design with minimum losses.
• Designed as per IBR 1950, duly approved by the IBR inspectorate.

 

Product Details:

Steam Distribution Header Boiler is usually located inside the boiler house. This could take inlet of steam from 1 or more boilers and distributes steam to the process lines as per the quantity & pressure requirements. The size of header depends upon the no. & size of connected boilers and the out-flow lines.

It is also installed at places where different pressures are required in process at different locations. These are designed as per IBR requirements and can be supplied with accessories like valves, NRVs, steam trap assemblies etc.