Industrial Boiler Product Range

B&W

Industrial Boiler Product Range

1

Table of Contents

Oil & Gas fired boilersFM Packaged Boiler 2

High Capacity FM (HCFM ) Boiler 3

Power for Industry Boiler ( PFI ) 4

Radiant Boiler ( RB ) 5

Heat Recovery Steam Generator ( HRSG ) 6

Solid fuel fired boilersAtmospheric fluid bed boiler - Underbed fuel feed design (AFBC - UB ) 7

Atmospheric fluid bed boiler - Overbed fuel feed design (AFBC - OB ) 8

Circulating fluid bed boiler ( CFBC ) 9

Traveling grate fired boiler ( TG ) 1 0

Dumping grate fired boiler ( DG ) 1 1

Pinhole grate fired boiler ( PG ) 1 2

Pulverised fuel boiler ( PF ) 1 3

Accessory equipmentsDeaerator 1 4

Renovation & Modernization 1 5

After Sales Service 1 6

Designs and information shown in this booklet are for purposes of illustration only. Equipment designed for specific applications may differ.

2

FM Packaged Boiler

Capacity Range : 5 TPH to 100 TPH

Pressure : Upto 74 Kg/cm2g

Temperature : Upto 4500C

Fuel : All liquid and gaseous fuels, Waste Fuels, BFG, Tar, Bio-Gas.

Typical Efficiency : 93% ( on LHV )

Design features : Bi-Drum, bottom supported, forced draft, natural circulation boilers.l Specialdesign of drum internals for high steam purity l Membrane / Studded wallwater cooled furnace construction l Minimum foundation required l Can beinstalled outdoor l Fully drainable superheater l Suitable for firing of heavyfuels / lean gases l Fine combustion control & high turndown ratios l Pre-engineered economiser l Short / attractive delivery

Superheater

Membrane Furnace WallSteam Drum Outer Casing

Burner

Water Drum

Wind Box

Convention Bank

3

High Capacity FM (HCFM/PFM) Boiler

Capacity Range : 80 TPH to 272 TPH

Pressure : Upto 124 Kg/cm2g

Temperature : Upto 4500C

Fuel : All liquid and gaseous fuels, Waste Fuels, BFG, Tar, Bio-Gas.

Design features : High Capacity FM (HCFM/PFM) boiler completely pre-engineered with modulardesign for dock or field assembly l Multiple burners for increased capacity.l Special design of drum internals - High steam purity l Membrane / Studdedwall water cooled furnace construction l Minimum foundation requiredl Can be installed outdoor l Fully drainable superheater l Firing of heavyfuels / lean gases possible l Fine combustion control & high turndown ratiosl Short / attractive delivery l Over 5000 operating units.

Superheater

Steam Drum

Convention Bank

Furnace Wall Base Frame

Burner

Saturated SteamSupply Pipes

Wind Box

BuckStray

Reach wll withheader arrangement

FurnaceSide Wall

4

Power for Industry Boiler ( PFI )

Capacity Range : 45 TPH to 208 TPH

Pressure : Upto 80 kg/cm2g

Temperature : Upto 5100C

Fuel : Liquid and /or gaseous fuels, blast furnace gas, CO gas and high ash liquid fuels

Design Features : Bi-drum bottom supported, multiple gas pass unit designed specifically to burnliquid and / or gaseous fuels. l Membrane walled water cooled furnacel Combined hot air & gas ducts integral with rear wall casing l Fullydrainable bottom supported superheater l Flat superheater temperature v/sload curve l Wash water drains

5

High Pressure Radiant Boiler ( RB )

Capacity Range : 80 TPH to 500 TPH

Pressure : Upto 140 Kg/cm2g

Temperature : Upto 5400 C

Fuel : All liquid and gaseous fuels

Design Features : Single Drum, bottom supported, forced draft, natural circulation, 2 pass typeboilers. l Furnace & second pass made of totally water-cooled membranewalls l Front wall firing on wide range of liquid & gaseous fuels l Higheroperational reliability l Steam drum outside the flue gas path, permittingquick start-up & load chasing l Fully welded construction l Fully drainable,horizontal, convective superheater l Steam cooled superheater support.

6

Heat Recovery Steam Generator ( HRSG )

Capacity Range : Upto 100 MW

Pressure : Upto 135 Kg/cm2g

Temperature : Upto 5600 C

Design Features : Single drum / Bi-boilers with or without supplementary firing on Gas TurbineExhaust l Supplementary fired / unfired mode l Fresh air firing optionl Multiple Pressures (levels) l Natural Circulation l Single drum all weldedconstruction l Low gas side pressure drop l Cold casing insulation l Fullydrainable superheater finned tubes l Modular design l Integral Deaerator / make-up water heater option l Low power consumption l High tolerance to TurbineExhaust Gas flow maldistribution l 99.99 % availability l Lower capital costsl Easy maintenance and accessibility

7

Capacity Range : Upto 300 TPH

Pressure : Upto 135 Kg/cm2g

Temperature : Upto 5400 C

Fuel : Coal / Lignite / Rice Husk / Pith / Petcoke / Washery Rajects / Char / Oil /Agricultural Waste etc.

Design Feature : Top or bottom supported, Single or Bi-drum design boilers suitable for firinglow calorific value fuels. Suspension burning of fuel - higher combustion efficiencyl Coal Size 6 mm l Bubbling Bed Ash Coolers l Stainless Steel Fluidizing Nozzlesl Boiler bank without Baffles l High Steam Purity l Membrane walled furnacel Start-up by oil / charcoal.

Atmospheric Fluid Bed Combustion Boiler ( Underbed feed system design )

8

Atmospheric Fluid Bed Combustion Boiler ( Over bed feed system design )

Capacity Range : Upto 300 TPH

Pressure : Upto 135 Kg/cm2g

Temperature : Upto 5400 C

Fuel : Coal / Lignite / Rice Husk / Pith / Spent Coffee Ground / Spent Tea Ground /Washery Rejects / Char / Oil / Gas / Agricultural Waste / Sludge etc.

Design Feature : Top or bottom supported, Single or Bi-drum design boilers suitable for firinglow calorific value fuels. Suspension burning of fuel - higher combustionefficiency l Coal Size upto 12 mm accepted l Bubbling Bed Ash Coolersl Stainless Steel Fluidizing Nozzles l Boiler bank without Baffles l HighSteam Purity l Membrane walled furnace l Start-up by oil / charcoal.

9

Circulating Fluidized Bed Combustion Boiler ( CFBC )

Capacity range : Upto 500 TPH

Fuel : Coal, Lignite, Petroleum Coke.

Design Features : Top supported Internal Recirculation CFB with U-Beam Impact Separatorsavailable in Single or Bi-drum design Suitable for firing wide range of low calorfic,high ash fuels with less expensive fuel preparations l Lower emissions levelsl High availability and lower maintenance l Reduced Boiler building volumel Wide load swings with high turn-down l Low power consumption l Low startup time l Two - stage solids collection for better performance

10

Travelling Grate Fired Boiler ( TG )

Capacity Range : Upto 140 TPH

Pressure : Upto 106 Kg/cm2g

Temperature : Upto 5150 C

Fuel : Bagasse / Rice husk / Coal / Lignite, Other biomass

Design Feature : Travelling Grate stoker fired, Bi-drum, top or bottom supported, balanceddraft, natural circulation boilers l Modulating secondary air system for evendistribution of bagasse l Tall furnace for higher residence time l Continuousash discharge l Compact low operating pressure hydraulic drive l Suspensionburning for complete combustion & quick response to load variationl Special design of drum internals - High steam purity l No undergroundducting l No air leakage l Flexibility in firing various fuels

11

Dumping Grate Fired Boiler ( DG )

Capacity Range : Upto 100 TPH

Pressure : Upto 106 Kg/cm2g

Temperature : Upto 5150 C

Fuel : Bagasse / Other biomass / Other low ash fuel

Design Feature : Dumping Grate stoker fired, Bi-drum, top or bottom supported, balanced draft,natural circulation, water tube boilers l Modulating secondary air system for evendistribution of bagasse on grate l Tall furnace for longer residence timel Suspension burning for complete combustion & quick response to load variationl Special design of drum internals - High steam purity l Flexibility in firing variouslow ash fuel.

12

Pinhole Grate Fired Boiler ( PG )

Capacity Range : Upto 300 TPH

Pressure : Upto 106 Kg/cm2g

Temperature : Upto 5150 C

Fuel : Bagasse / Other biomass / Other low ash fuel

Design Feature : Pinhole Grate Stoker fired, Bi-drum, top or bottom supported, balanceddraft, natural circulation boilers. l Modulating secondary air system for evendistribution of bagasse on grate l Tall furnace for longer residence timel Stationary water cooled grate design with no moving parts, avoiding mechanicalfailures l Steam nozzles for simplified on line ash removal l Suspension burningfor complete combustion & quick response to load variation l Special design ofdrum internals - High steam purity l No underground ducting

13

Pulverised Fuel Boiler ( PF )

Capacity Range : 150 TPH to 500 TPH

Pressure : Upto 152 kg/cm2g

Temperature : Upto 5400C

Fuel : Coal / Lignite

Design Features : Top-supported, Single or Bi-drum, single gas pass unit l Membrane wallconstruction l Furnace nose arch, and economizer and / or air heater foreconomical heat recovery l Higher operational reliability l Steam cooledsuperheater support

14

Deaerator

Capacity Range : 10 TPH to 300 TPH

Pressure : 0.35 to 7 Kg/cm2g

Temperature : 105 to 1500 C

Design Feature : Spray & Tray type Deaerators l Fixed spray nozzle - assured performance &fine spray l Multiple levels of perforated trays l Large manhole access fordeaerator tower internal inspection l Canopied steam inlet l External ventcondenser for ease of maintenance & repair l Special deaerator internalspromote intense mixing of water & steam & ensure high oxygen removal.

15

Renovation & Modernization

Life Extension Studiesl Condition Assessment, Remaining Life

Analysis and Life Extension studies forSteam Generators.

l Boiler Performance Reviews and SystemAnalysis.

Engineering Studiesl Design and performance analysis of operating

boilers irrespective of make, age, design or fuel.l Evolution of techno-economic solutions for

further implementation.

Fuel Flexibility Upgradesl Fuel conversion

from / to liquid,gaseous or solidsin solo or multiplefiring mode.

l Conversion tofluidized bedcombustion.

l Conversion fromcoal to lignite andto biomass firing, such as husk, bagasse, pithetc.

Babcock & Wilcox, (B&W) USA, has been the pioneer in the field of Industrial, Utility and Supercriticalboilers since 1867. B&W has a rich experience in evolving and implementing Engineering solutions tosteam generator problems. Thermax Babcock & Wilcox shares this knowledge base on a two-way basiswith B&W. The Renovation & Modernization (R&M) Division of TBW implements Remaining LifeAssessment Study programs, Plant Improvement Project (PIP) and Replacements-in-Kind (RIK) Solutionsto existing boilers. Scores of Industrial and Utility boilers have benefited from TBW's R&M programs.

Capacity & Efficiency UpgradesRetrofitting modern fuel firing systems andpressure part upgrades to increase capacity ofthe existing steam generators.l Restoring original capacity of derated boilers.l Enhance steam-generating capacity above

original rating.l Improvement in thermal efficiency.

Pressure Part UpgradesModification of pressure parts by redesigningheat transfer surfaces such as Furnace waterwalls, Superheaters, Reheaters, Economizers, etc.

16

After Sales Service

Services on calll Prompt response to any customer call/complaint and deputation of engineer as required

Preventive /Predictive Servicel Annual Service Contract package comprising of site visits for performance monitoring &

optimization, annual shutdown and emergencies

Condition Assessment & Remaining Life -Analysis Studiesl Review & survey using special testing equipment & patented methodsl In-situ examination & analysis of pressure parts for present condition & remaining lifel In accordance with Central Boiler Board IBR regulation 391A

Boiler Performance Optimizationl Studies & engineering solutions to bring back the unit to optimum performancel Fuel conversions, capacity enhancement and technology upgrades

Test facilitiesl In-house test facilities encompass proven NDT & metallurgical testing

Mumbai

Delhi

,

Dhanrajmahal 2nd floor,

Chhatrapati Shivaji Maharaj Marg,

Near Gateway of India, Colaba,

Mumbai 400 039, India.

Tel: 91-22-22045391, 22045324,

Fax: 91-22-22040859

9, Community Centre, Basant Lok,

New Delhi 110 057, India.

Tel: 91-11-26145319, 26145326,

Fax: 91-11-26148679

Fatima Akthar Court, 3rd floor, 312 Anna Salai,

Teynampet, Chennai 600 018, India.

Tel: 91-44-24353831 24353834,

Fax: 91-44-24353841

Chennai

B&W

Thermax Babcock & Wilcox Limited

Pune - Corporate Office

D-1, MIDC, R. D. Aga Road, Chinchwad, Pune: 411 019

Tel: +91-20-4126464 Fax: +91-20-27479200

Website : www.tbwindia.com

Kolkata

Hyderabad

Raipur

Azimganj House, 5th Floor,

7 Camac Street, Kolkata 700 017, India.

Tel: 91-33-22826711/2/3,

Fax: 91-33-22826796

6-3-649 Nalanda Complex,

Somaji Guda, Hyderabad 500 082 India.

Tel: 91-40-23310254, 23312013, 23396820

Fax: 91-40-23312335

A-301,Golcha Plaza, 3rd Floor,

Nalghar Chowk, Raipur (C.G) 492001

Tel.: 0771-5001768

Mobile: 9893021768