Thermodyne Boilers Industry Blog

Dear All,  It has been a pleasure working passionately to save energy costs for our customers. We thank all our vendors who have whole heartily supported us in all our projects. We are grateful to our customers and clients for trusting us. We are proud of our staff and workers who tirelessly & happily performed their duties & contributed towards our growth. We are looking forward to working with all of you in the coming year 2016 to make it another great year. Wishing all of you a prosperous and Happy New Year

Boiler fuels Fuels  are used to heat water or produce steam from  boilers . The common fuels fall into one of four categories are:- Solid Liquid Gaseous Electricity The first three are used most commonly to fire boilers and are composed mainly of carbon and hydrogen with small amounts of sulphur and incombustible material. All the three  fuels  are easily available for  industrial , commercial and domestic use. Electricity may also be used as a second generation fuel and is used to  heat small steam and hot water boilers  where emissions are prohibited.

Losses in Steam Boiler Dry Flue Gas Losses (Stack losses) H2 Losses Moisture in Fuel Moisture in Air CO Losses Surface Losses – Due to Poor Insulation Fly Ash Losses – Heat Carried by Fly Ash Bottom Losses (Unburnt Losses) OTHER LOSSES Losses due to poor Smoke side Boiler sealing. Losses due to Steam leakages. Blow-down loss. Losses due to the part load operation.

Energy Efficiency Improvement Process in Boilers There are several practices to improve the efficiency of the steam boiler. We are going to point out the main processes to improve the efficiency of a boiler . Increase Feed water Temperature – save fuel Optimize Excess Air –Reduce Exhaust Losses Recover Water Heat   – Install  APH/HRU  Reduce Scale and Soot deposits  – Increase Heat Transfer Control TDS- Reduce Blow Down Recover waste heat from a blowdown Operate at  Optimum Load – Achieve Peak Efficiency Preheat combustion air –  Improve Combustion  Switch to lower cost fuel – Reduce Running Cost Replace Insufficient  Boiler Install VSD / VFD – Save Energy Plug Steam Leaks – Reduce Losses Recover Condensate – Save Energy and Water Insulated  Boiler and Steam  Line – Save Steam

11 Attributes of a Good Boilers   HighThermal Efficiency Simple construction Optimum Heat Transfer Area Compact small foot Print Ability to meet Load Fluctuations Ease of maintenance & Inspections Low furnace Heat Release Rates Good water side circulation Large steam disengaging area Strong Ruben to with stored wear & Corrosion. Joints should be accessible and away from direct flame implements.

Going forward, this blog will serve all who are interested to read more about Steam Boilers. Thermodyne Engineering Systems is a leading Boiler manufacturing unit of Northern India. Our all Product Line Includes Steam Boilers , Hot water / Hot AirGenerators , Waste Heat Recovery Boilers , Thermic Fluid Heaters , and their accessories viz. Chimneys , Tanks, Pressure Vessels etc.. We made a modest beginning in the year 2000 but slowly by virtue of our strong commitment to customer service and continuous improvement we learned very fast and in the short span of 15 years we have acquired a major market share of Boiler market and have become a trustworthy name in Boiler industry. We design and produce a number of designs for various fuel options. Our main Product Models are: Intech                                -       ...

Industrial Fans & Blowers Industrial Fans and Blowers: Specially designed,  high-efficiency fans  are offered for all boiler applications: Forced draft & Induced draft fans for Steam Boilers Range varies from 1000 m3/hr to 50,000 m3/hr flow and up to 300oC temperature Can be offered with Variable speed controls depending upon specific requirements. All impellers are dynamically balanced before fitments to give trouble-free operation.

3 _ Pass_ Internal_Furnace_Packaged_Steam_Boilers Description:                  Intech (3 passes Internal Furnace Packaged Type Boiler) Boiler  is the conventional  three pass   smoke-tube design coal / wood   fired steam boiler  having the internal furnace. This  packaged Type Boiler  comes in  dry back ,  semi-wet back and fully wet-back  options and is most suitable for manual firing of Solid Fuel  likes  coal, wood or briquettes . The  furnace is totally submerged  in water and the grate bars are fixed inside the furnace. The fuel of  Packaged type Boilers  is fired on the grate and the flue gases travel inside the smoke tubes of a second and third pass. A  Water pre-heater  may be provided of  shell and tube design  to enhance the  efficiency of the systems  by   recovering waste heat  from flue gases going ...

3 Pass Smoke Cum Water tube Membrane Type Boilers Description:- Combitherm Boiler  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 the maximum advantage. Working: The filling of  the  boiler  is done  through a feed pipe connection. This water flows through the  water wall membrane . It circulates the water from the  water wall membrane  to pressurized part of the  boiler .As firing is done it raises  the temperature of water of  wate...

Condensate Recovery Systems Introduction: An introduction to the reasons for  condensate recovery System ,  that including energy costing, water charges and  water treatment costing  and included calculations for potential savings. Steam are mostly generated for one of two reasons • To produce electrical power, the example in the steam power stations and co-generation plants. • To supply the heats for heating unit and process system. When 1kg steam condenses completely, 1kg condensate is formed at the same pressure and temperature. An efficient steam will reuse this condensate, makes non-financial, technical and environmental sense. Saturated steam is used for heating to gives up its latent heat, which is a too large proportion of the total heat its contain. The remainder of the heat in the steam is retained in the condensate as sensible heat in fig. Pressurised Condensate Recovery Module (PCRM)  is a unique system wherein the condensate genera...

Air Pre Heaters   Air pre heaters                 Air preheaters are provided in boilers to preheat the combustion air. Types           There are two main types: Tubular or recuperative air  pre heaters Regenerative air pre  heaters  Tubular or recuperative air pre-heaters are provided in boilers of a medium and small range of steam generation . This type of air pre-heater becomes very large in size if they have to be used in very high capacity boilers like 600 TPH of steam production and above.  Regenerative air per-heaters are compact and can have a stationary or rotating hood. A combination of a tubular and regenerative type of air pre-heaters is used in very high capacity boilers . " The tubular being used for primary air heating and the regenerative used for the secondary air heating ." In case the boiler designers do not want to go for a combination of tubula...

Coil Type Boilers (NON IBR) This type of boilers 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 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 1.Fully Automatic unit 2.Unique four pass design 3.High efficiency and low running cost 4.Minimum site-work, ...

Thermic Fluid Heater  is a heat source that is supply heat of temperature from 300 oc to  High Temperatures , This heats a  fluid (Thermic Fluid)  to required temperature and the fluid then be passed to process points where heating is required .  The heat energy  could be extracted from this  hot Thermic fluid  by means of radiation by circulating the fluid around process vessels that need to be heated or by other suitable means and finally recycled to the  Thermic Fluid Heater . Fuel Combustion Fuel  Feeder Primary Coil Connecting Duct Secondary Coil Air Preheater (APH) Forced Draft Fan(FD Fan) Dust Collectors Induced Draft Fan(ID Fan) Construction The  hot thermic fluid  is circulated in a closed circuit by a  high temperature  circulating pump and the heat is transferred to the process through an appropriate  heat exchanger  at user’s end. A combined de-aerator cum expansion t...

ID FAN for Boilers Specially designed,  high-efficiency fans  are offered for all boiler applications: Forced draft & Induced draft fans for Boilers Range varies from 1000 m3/hr to 50,000 m3/hr flow and upto 300oC temperature Can be offered with Variable speed controls depending upon specific requirements. All impellers are dynamically balanced before fitment to give trouble-free operation.

High Pressure Boilers These are fully water tube design boilers for high-pressure steam requirements. Water circulation through the boiler may be either natural circulation due to density difference or by forced circulation. Advantages 1.      The heat of combustion is utilized more efficiently by the use of small diameter tubes in large numbers. 2.      To avoid large resistance to the flow of water, Powertherm boilers have a parallel set of the arrangement of tubes 3.    The boiler components can be arranged horizontally, giving greater accessibility and operational convenience. 4.      All the parts are uniformly heated; therefore the danger of overheating is reduced. Also, the thermal stress problem is avoided. 5.     The tendency of scale formation is eliminated due to the high velocity of water through the boiler tubes. Can be converted to liquid/gaseous fuels as well ...

Hot Water Generators Description:   Instatherm  is the efficient and cost-effective way to generate  hot water instantly .  Instatherm  is a  packaged type , silent and  instant hot water generator  exclusively catering to the  hot water requirements of Hotels, Hospitals, Resorts, swimming pools, Dairies, Laundries and various other process industries. Construction     Hot Water Generator  comes in both  coil type, water tube and shell & tube type smoke tube designs.  The multiple passes of flue gases ensure maximum efficiency thereby  Hot Water Generator  providing low operational costs. Heating Options Liquid Fuels – Light oil / Heavy oil Gaseous fuels –  LPG or CNG Solid Fuels – Coal or Wood or Briquettes Electrical operation – Element heaters or Electrodes Advantages Fully automatic unit Trouble free operation. Outside the purview of  IBR. High system ...

Oil / Gas Boiler This is the conventional three pass smoke-tube design Oil/ Gas fired steam boiler having an internal water-cooled furnace. The superior and features make it the ideal choice for process heating requirements of the industry today. Advantages High Efficiency of 88% on NCV saves running costs. Large convective heating surface in the 2nd& 3rd pass tubes ensures excellent heat transfer Large water holding and steam holding space gives a quick response to fluctuating steam demands. Large heat transfer surface reduces thermal stresses on the boiler surfaces. Dry steam reduces the processing time, saves steam and improves quality of processed goods Horizontal packaged boilers  - less site work & quick commissioning Capacity Range Savemax is available in capacities from 1 TPH to 10 TPH

Hot Water Generator Instatherm   is that the economic and price effective thanks to generate  hot water instantly . it's a pre-packaged kind, silent and instant  hot water generator   completely catering to the hot water needs of  Hotels, Hospitals, Resorts, swimming pools, Dairies, Laundries  and numerous different process industries. Construction                       This comes in each  coil type, water tube and shell & tube type smoke tube designs . The multiple passes of flue gases guarantee most potency thereby providing low operational prices. Heating choices Liquid Fuels – lightweight oil / heavy oil Gaseous fuels –  LPG or CNG Solid Fuels – Coal or Wood or Briquettes Electrical operation – component heaters or Electrodes Advantages Fully automatic unit. Trouble free operation. Outside the view of  IBR . High system efficiency. Minimum site work and eas...

OIL and GAS Fired Steam Boilers Thermodyne Engineering System is in producing of the natural circulation, one drum, independent oil/gas fired boilers . The fuels are used for oil/gas fired boilers is fossil fuel, light-weight diesel fuel, low sulfur high-speed diesel etc. For oil/gas fired the boilers we've got involved with Thermodyne groups have done engineering of over 5000 installations throughout the world. Features: 1. Thermodyne boiler design relies on a really superior technology and following are the salient options that translate into definite advantages that the user will drive. Optimized design : The boiler design has originated from our German Principals. the design is tailor created for your specific needs, therefore, guaranteeing excellent compatibility. more than over the design has evolved after going through all theoretical design prospects and practical experience of our Principals for similar boiler installations everywhere worlds. Thus, the ...

      How boiler works?            Boiler is arrangement which is used to convert the heat energy into steam energy .                 Its application is widely spread in manufacturing industries . It is M.S fabricated        body. It consists of tubes installed inside the boiler. As we can see in the bellow sketch, we use the coal, rice husk, wood, baggese as the source for the combustion. As the combustion starts its flames flowing upside, it warm up the water tubes. The water present in the tube, it will become hot, at some saturated temperature it will start boiling. Through boiling, there is formation of steam. The steam is collected for various purpose like moving turbine blade, heating room from inside, steam engines etc. Boilers Working

What is Heat Ex-changer? Heat Ex-changer  works on the principle of  Fluid Dynamics .  Heat Ex-changer  is a device which is used to exchange the heat from one medium of fluid to other medium of fluid. It is widely used in heavy machinery like  Hot Water Generator , Air Conditioner, Adiabatic Coolers, Piston Pumps, Roll Oil Coolers, and Coil Condensers etc.                                 Heat Ex-Changer In this figure, there is coil in the medium and water is flowing through medium. In the coil, the hot water steam is moving, so there will be heat transfer from pipe to water, the water which is coming out, it would be hot and steam which is coming out, it would be cold. Types of Heat Ex-changer: 1.Shell & Tube Heat Ex-changer Shell & Tube Heat  is most common  heat ex-changer  which is used in the  industry . It consist of bunch of tu...

  Water Wall Membrane type Boilers(Combitherm) Horizontal Water Tube Boiler   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 the maximum  advantage. Combitherm – Ultra boiler ( Horizontal water tube boiler )  is factory assembled unit, installed on a skid base frame requiring minimum site work. It is an Our New Model .  Combitherm – Ultra Boiler  is 5 side  water wall membrane type ultra boiler  which includes the maximum site works and reduce boil...