Cooling & Heating

POWERMAX

TM

Bi - drum, water tube, high efficiency boiler

Improving your business

is our business

Thermax offers products, systems

and solutions in energy and

environment engineering to
industrial and commercial
establishments around the world.
Its business expertise covers
heating, cooling, waste heat
recovery, captive power, water
treatment & recycling, air pollution
control & waste management and
performance chemicals. Thermax
brings to customers extensive
experience in industrial
applications, and expertise through
technology partnerships and
strategic alliances.

POWERMAXTM - the ideal boiler

for continuous operations and
superheated steam
Sutable for
n Indian Coal
n Imported Coal
n Kutch Lignite
n Rice Husk
n Castor DOC
n Other select multifuel options

Suitable for
n Bagasse
n Indian Coal
n Imported Coal
n Wood Chips
n Palm Kernel Shell
n Julia Flora

Firing technique
n Pneumatic spreading
n Mechanical spreading

Firing technique

and Combi-feed

Operating from its headquarters in

Pune (Western India), Thermax has
built an international sales & service
network spread over South East
Asia, Middle East, Africa, Russia, UK
and the US. It has a full fledged
manufacturing set up that is
certified for ISO 9001:2000, ISO
14001 and safety management
according to OSHAS (ISO 18000).
In process heat, Thermax offers a
wide range of steam boilers, thermal
oil heaters and hot water
generators. It has expertise in a wide
range of fuels - oil, gas, solid and
agro-waste/ biomass. Supporting a
broad array of industries in
generating, transferring and
conserving heat across a host of
applications, Thermax process heat
products and systems are exported
to North and South America, South
East Asia, Middle East, Africa,
Europe, CIS, Australia, Antarctica
and SAARC.

Traveling Grate

Fluidised Bed

n Under Bed, Over Bed

Presenting the versatile two drum, water tube design, solid fuel fired boiler, popularly
known as the Bi-Drum, that is custom made for your application.
PowermaxTM comes with several major advantages: n High pressure steam due to its water tube design
n Uninterrupted operations n High degree of Superheat due to large super heater n The combustor can be
adapted any type of fuel firing - Fluidized Bed Combustion, Travelling Grate, Reciprocating Grate or
Dumping Grate - making the boiler suitable for burning any kind of solid fuel

Fluidising
Air Nozzles

Sand Bed

Fuel Feeding
Nozzles
Fuel Feeding
Venturi

Suitable for biomass

fuels like
Bagasse
Wood Chips
Firing technique
Pneumatic spreading
Rotary Fuel
Feeder
Pneumatic
Spreader

Dumping
Grate

Customised options available for

Hydraulic
Drive

Travelling
Grate

Combustion
Air

Convective
Superheater
Riadiative
Superheater

Dosing Bin
Variable Pitch
Feeding Screw

Reciprocating Grate
Air Supply

Mechanical
& Pneumatic
Spreader

Ash Collecting
Hopper

Fuel
Feeding
Cross
Plenum
Chamber

Dumping Grate

Rotary Fuel
Feeder

Hydraulic Drive
Ash Scraping
Mechanism
Sumerged Ash
Handling system

Reciprocating Grate

Suitable for
n Biomass Briquette and Pellete
n Rice Husk
n Wood Chips
Ash
n
Palm Kernel Shell
Collecting
Hopper
n Palm Fibres
n Other sized Biomass
Primary air supply
n High Moisture Biomass
for zone wise
n Process Wastes
combustion Precisely controlled n Jungle Waste
by electrically
n And many more...
actuated damper

Combustion
technology
from Germany

Membrane Water Wall Furnace

The furnace of the PowermaxTM is made of membrane walls. This is an arrangement
in tube and fin construction, which provides the advantage of a gas tight chamber,
preventing the influx of air which, in turn, results in higher efficiency.
The fuel characteristics determine critical parameters like height and footprint of a
furnace, which ensure complete combustion.
In superheated boilers, the furnace is provided with a nose wall. This provides
radiation shielding to the convective zone of the superheater and prevents any
overheating of the convective zone of the superheater tubes. The nose wall guides
the flue gases to cover the entire convective superheater area.
The membrane wall furnace also ensures that flue gases are cool enough to enter the
boiler bank, and that no fouling takes place.

Superheater
TM

Powermax comes with a superheater located at the top of

the furnace. This superheater is a heat exchanger, which
converts saturated steam into superheated steam.
The superheater is constructed in two halves - radiation
and convective zones - connected to each other by an
attemperator.
The convective zone of the superheater is shielded from
radiation by a nose wall, which also guides the flue gases to
cover the entire convective superheater area.
The attemperator is a water injecting device that ensures
temperature of the outlet steam is controlled within
specified limits.

Boiler Bank

The boiler bank is a tube nest connecting the water and

steam drums, where water is converted into steam.
Downcomer portion of boiler bank, take the water to the
water drum, and then a mixture of steam and water rises
through, the riser portion of boiler bank tube to the steam
drum. Water and steam are separated in the steam drum,
and while the steam goes out, water gets re-circulated.
The flue gases turn around in the bottom drum against the
baffle wall and rise towards the steam drum.
Ash separation takes place during reversal, and ash is
collected in the hopper below the water drum.
Flue gas
from
superheater

Left Side
Membrane Wall

Baffle Plate
Front Side
Membrane Wall

Nose/ Rear
Membrane
Wall
Right Side
Membrane Wall

Flue gas
to
economiser

Ash collection
at flue gas
reversal

Ash collection hopper

Economiser
The Economiser, made of bare tubes, aids in heat recovery
and improving efficiency. Coming after the boiler bank, it
uses the heat of the flue gases coming out from the boiler to
preheat water going into the steam drum.

Inbed Heat Exchanger

Inbed heat exchanger is required only in fluidised bed
combustor, where the heat exchanger is immersed in a
bubbling sand bed, to help take away the heat from the
bed. This helps in maintaining combustor temperature
below the ash melting point using minimal excess air,
which also results in higher efficiency.
Since sand is continuously rubbing against the inbed
tubes during operation, special studding is provided on
inbed tubes to avoid erosion.

Flue gas in
Water out

Water in
Flue gas out
Flue gas out

Air Preheater
The air preheater is also heat
recovery equipment situated
last in the flue gas path. It is a
cross flow gas-to-gas heat
exchanger, which provides hot
air for combustion.

Air out

Air in

Flue gas in

Pollution control equipment

Cyclomax

Bag Filter

The Cyclomax is an arrangement

of multi-cyclones. When dust
laden gas enter the cyclone
tangentially, the centrifugal force
that develops due to the cyclonic
action makes the dust particles
move outward radially, they finally
strike the wall and drop out of the
gas stream into the hopper. Clean
gas then flows out through the
exit tube.
For boiler applications, Cyclomax
enables achieving emissions as
low as 300 to 350 mg/Nm3.

Electrostatic Precipitators

Bag filter is an arrangement of filtration material in the form of

bags. When dust laden gases pass through the fabric, the
dust is retained while clean air passes through. This dust,
deposited on the outer surface of the bags, is removed by
high pressure compressed air, operating in a pre-determined
cycle. This air flow is led into the bags through a pulsesolenoid valve combination which is energized by a solid
state sequential controller. Thermax bag filters come with
features like casing entry, with perforated sheets that
facilitates better gas distribution and pre-separation of
coarser dust; bags with snap rings that ensure low outlet
emissions; leakproof inlet-cum-bypass-damper and outlet
damper for automatic system isolation under high/ low
temperature situations for safety.
For boiler applications, bag filters enable achieving emissions
as low as 100 mg/nm3.

Electrostatic Precipitators (ESP) is an

arrangement of electrically charged
electrodes. When dust laden gases
enter the ESP through the inlet nozzle,
dust particles get electrically charged
by the emitting electrode. Due to the
influence of this electrical field, these
charged dust particles migrate to the
grounded collecting electrode. The
accumulated dust particles on the
collecting plate are dislodged into the
hopper due to periodic mechanical
rapping. Clean gas then flows out
through the outlet nozzle of the ESP.
For boiler applications,the ESP enables
achieving emissions as low as 50 mg/
Nm3.

Power generation
PowermaxTM can support any of your power needs, be it extraction, condensing or a combination
High Pressure steam

Back Pressure

Complete Condensing

Power generation using back pressure turbine is quite

beneficial to many process industries. Normally, steam
generation is controlled according to process demand and
the power generated is incidental.
The power generated may or may not be sufficient for the
complete power requirement of the process house.
The generated power is normally consumed parallel to the
grid power or suitable alternative arrangements.

High Pressure
Steam from Boiler

Extraction cum Condensing

Power generation through condensing turbine is

normally done with power generation as the prime
objective.
Here steam demand is controlled according to the
requirement of power generation, and the power is
normally consumed in an islanding mode.

High Pressure
Steam from Boiler

When power and process are both critical, and need to be

catered to equally, Extraction-cum-Condensing Turbines
are used.
Steam generation is controlled according to the combined
need for process steam and power. This power is
consumed either by using a grid parallel or islanding
system.

High Pressure
Steam from Boiler

Water from
cooling tower
Steam to Condense
Low pressure
steam to process at
constant pressure

Water to
cooling tower

Water from
cooling tower
Water to
cooling tower

Steam to Condense
Low pressure
steam to process at
constant pressure

A typical coal handling plant

Product
Bucket
Elevator

Roof Truss
with
Sheeting

Recycle
Bucket
Elevator

Roofing Shed
Loading Zone

Vibrating
Screen

Crusher

R.P.
Gate
Vibro
Feeder

A typical ash handling plant

Ecomomisher/ Air
pre-heater hopper

Boiler bank
hopper

Air line

Polluction control
equipment hopper

Air
out
Air
in

Fly Ash Silo

Pneumatic
Gate Valve
Distance
Piece
Ash
Conditioner
Support

A typical layout

Registered Office
D-13, MIDC Industrial Area,
R. D. Aga Road Chinchwad, Pune - 411019, India
Tel.: +91 - 20 - 66122999, 66155000
Fax: +91 - 20 - 27472049
enquiry@thermaxglobal.com

www.thermaxglobal.com
In view of our constant endeavor to improve the quality of our products, we reserve the right to alter or change specifications without prior notice. All photographs
shown in this publication are representative in purpose and are to be used for reference purpose only. Whilst this information is given in good faith, no warranty or
representation is given concerning such information which must not be taken for establishing any contractual or other commitment binding on Thermax Ltd. For
actual details and specifications, please refer the Thermax offer document.

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