Thermodyne Boilers Industry Blog

May the spirit of the Christmas fill your home with peace, joy, and love. Thermodyne Boilers Team wish you all  Merry Christmas!

Why do we need a Bag Filter? : Bag Filter helps in separating the particulate matter from the flue gas coming out of the Boiler. The most common type of Bag Filter is Pulse jet type.

Industrial Chimney Thermodyne Engineering System is Manufacturer of the steam boilers and it's accessories like Chimneys , ID & FD Fan , Pressurized Condensate Recovery Systems (PCRM ) , Blowers , Steam Accumulators , Process Tanks , Pressure Reducing Station etc. Chimneys are a structure which provides ventilation for smoke from Steam boilers , furnace to the outside atmosphere. Chimney contains the filtration system to filter the hazardous chemical and dust particles from the smoke, which help us to keep the environment clean and green.  Chimneys are especially vertical to ensure that the gases flow on smoothly, drawing air into the combustion in what is known as the chimney effect. Chimneys can be designed and manufactured as per IS-6533 standard to ensure  compliance.

Wet Scrubbers are the pollution control equipment that helps in controlling the pollution by reducing the concentration of pollutants such as Sulfur dioxide (SO 2 ) and ash content in exhaust flue gases. As the pollution norms are getting stringent and the government is making sure that pollution laws are being implemented, many industries are coming up with various solutions and strategies for reducing the pollution and its management. One such solution is using pollution control equipment such as Wet Scrubbers . Industries or power plants generally have boilers or furnaces installed in their processes where combustion of fuel is taking place. Combustion of fuel generates flue gases that contain a large amount of heat which is transferred to water to convert into steam. These fuels generally contain carbon, sulfur, hydrogen, oxygen and on combustion with air, they form flue gases containing Sulfur dioxide (SO 2 ), Carbon dioxide (CO 2 ), Ash, Water vapor (H 2 O). Out of...

In winters, human bodies shiver, so we insulate ourselves by wearing woolen clothes. A  boiler  in operation doesn’t shiver to maintain its internal energy, even if it did, it would have been highly undesirable keeping in mind the impacts of vibration in a system. Ambient temp being extremely low, so the temperature difference between human body and ambient is large. This enhances the  heat transfer  between them, this woolen insulation helps in reducing this heat rejection to the atmosphere and in the end we feel warm. The Same condition applies to the  steam boilers . Combustion  in the furnace and the flow of the flue gases in the Boiler Shell tubes heat up their respective surface areas leading to steam generation or hot water heating. But some part of this heat also gets conducted away to the surface of the  Boiler shell . Now the  Boiler shell  gets heated up and is ready to transfer this heat to the surroundings. The situation be...

Savemax – Oil/Gas Fired Boilers Savemax – Oil/Gas Fired Boilers is the conventional three pass smoke-tube design Oil/Gas fired steam boiler having an internal water cooling furnace area. The superior and features make it the Boilers ideal choice for process heating requirements of the industry today. The 3-passes design packaged boilers are most suitable to the burn fuels like heavy/light oils & Gasses. The high combustion volume along with large water and Steam holding capacity makes it the most boilers in its classes. Advantages and Benefits: High Efficiency of 88 % on NCV saves running costs to the Boiler (Savemax – Oil/Gas Fired Boilers) . Large convective heating surface in the 2nd & 3rd pass tubes ensures excellent heat transfer Big water holding & steam holding space gives the quick response to fluctuating steam demands. Massive large heat transfer surface reduces the thermal stresses on the boiler surfaces. Dry steam reduces the processin...

Fusible Plug is a fitting used in Steam Boilers to enhance the safety during operation. It’s working depends upon the water level in the Boiler shell. A fusible Plug is a threaded metallic cylindrical object, with a tapered hole in it which goes through its entire length. It is usually of brass, bronze or even gunmetal. In a smoke tube steam boiler , it is fitted on the front tube sheet, just above the tubes (used for flue gas flow) arrangement but below the perforated feed line inside the shell. But the question is how exactly this little thing helps in preventing a huge disaster. It’s working is dependent only on the temperatures not on pressures. What happens is that during steam boiler operation , the feed pumps to supply water for steam conversion in the Boiler shell on the basis of the signal sent to it by the electrical panel. And electrical panel receives this signal from the mobrey (automatic water level controller) based on the fluctuating water levels due to continu...

What is Boiler?   A boiler is defined as “a closed vessel in which water or other liquid is heated, steam or vapor is generated, steam is superheated, or any combination thereof, under pressure or vacuum, for use external to itself, by the direct application of energy from the combustion of fuels, from electricity or nuclear energy”. Furnaces compatible with solid fuels(wood/coal/briquettes/pet coke/rice husk) and liquid fuels (LDO/Furnace oil) and Gaseous Fuels ( LPG, LNG, PNG) can be used to carry out the combustion for the specific purpose. The boiler has a very a wide application such as power sector, textiles, plywood, FMCG etc. We, at Thermodyne, design, manufacture and supply ISO 9001:2008 certified steam boilers , for such processes and several others too. Thermodyne boilers can help you by saving up to 30% of the fuel cost by providing high-efficiency boilers , the Energy consultancy, and customized heating solutions. Fuel saving is not only importa...

Instatherm – Hot Water Generator Instatherm - Hot Water Generator   Instatherm is the efficient and cost-effective way to generate hot water instantly. It is a packaged type, silent and instant hot water generator. It is designed 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 efficiency Minimum site works and ease of install...

Chimney:- Chimney , as we know, is used to reject the flue gases to the atmosphere, coming from the Steam Boiler during operation. Also, it is a megastructure in Steam Boiler assembly and any discrepancy in its structural and foundation work can cause extremely serious damages, may even lead to casualties or plant shut off till its re-erection. The designer must consider all the factors while designing chimneys and one of the major factors amongst them is the wind factor. Blowing wind tries to overcome its static inertia but fails, if spirals are provided on the surface of the chimney. BUT THE QUESTION IS HOW????? Consider a chimneys (without spiral wings) , when the blowing wind comes in contact with its upstream surface, stagnation point (zero velocity) is achieved at that point i.e. pressure generated is high at that point and at the downstream end a vacuum is created as the wind coming in contact with the chimneys , gets deflected and meets after some point (wake regio...

A steam boiler is a device used to create steam by applying heat energy to water. Although the definitions are somewhat flexible, it can be said that older steam generators were commonly termed steam boiler and worked at low to medium pressure (1–300 psi or 6.895–2,068.427 kPa) but, at pressures above this, it is more usual to speak of a steam generator. Source – Wikipedia   Purpose of steam boilers For generating power in steam engines or steam turbines In process industries for various processes. For heating the buildings in cold weather and for producing hot water for hot water supply Primary requirements of a steam boiler The water must be contained safely The steam must be safely delivered in the desired condition (as regards its pressure, temperature, quality and the required rate Boiler terms Shell : Consists of one or more steel plates bent into a cylindrical form and welded together. The shell ends are closed with end plates Grate/ Bed...

A boiler designed to get 5000 kg/hr steam for & at,100-degree Celcius at mean water level won't offer a similar quantity of steam if shifted to an elevated place. it'll provide less steam. Due to reduced air density at higher altitude, it'll consume a similar volume of air however won't consume a similar mass of air. This leads to less fuel consumption & less steam generation rate. Due to the reduction of mass flow of gases through tubes of a boiler, convective heat transfer also decreases that more leads to reduced evaporation rates. Combustion could be a method that desires the constant air provide for its survival, however as we move up the world i.e. at higher altitudes, things aren’t a similar as they used to be at sea level. The oxygen content in the air reduces exponentially. not like body, a boiler doesn’t acclimatise itself to this shortage. Though the Blower provides a similar volume of air the reduced density of air (oxygen to be ...

A   combi boiler   or combination boiler is the most commonly used boiler in India.   Combi Boiler  is a unique membrane design water wall type boiler which combines the advantages of both   water tube & smoke tube steam boilers .  A combination type of   steam boiler   is the one which has the operational characteristics of both   smoke tube and water tube steam boiler   respectively. Unlike the   packaged type Boilers , here the furnace is external to the boiler shell.  During its operation, the combustion takes place in the water wall so the flue gases from here travel in this membrane (as in a   Water Tube Boiler ) and enter the Boiler shell. Now the flue gases travel in the smoke tubes (as in a   Smoke Tube Boiler ). Combi Boiler During its course of motion, it transfers heat to the – Water present in the tubes in the Water Wall Membrane Water present in the Boiler shell through tubes ...

                      DON'T WASTE ENERGY ON STEAM LEAKAGE What is a steam trap? They are valves that were created to discharge condensation, and vent air without losing steam. Just like any mechanical item that uses various mechanisms, over time you are going to have increased wear and tear. When this happens you run into a common, yet real problem when your steam trap begins to leak. When steam traps begin to leak wasting energy, affecting production immensely, creating safety issues, and raising your maintenance costs. In order to control a leaking steam trap, you have to be very proactive before the leak gets out of control. Some of the most common reasons for a steam trap leak are dirt, unplanned pressure surges, and oversized traps. Following these few steps below will help in lessening your chance for a leak. 1. You want to develop a regular routine and maintenance on the steam trap. Keeping up the checks, and ...

Wet steam might lead to following disadvantages- Destruction of turbine blades due to  presence of water droplets in steam Erosion in steam lines due to excessive presence of water in steam Contamination in product due to water droplets Water hammer Reduced heat transfer Corrosion & Scaling Damage to equipment

Dry steam is formed when water is heated to its boiling point   & then vaporized with additional heat. All the heat present is used in transforming water into steam therefore, no water droplets are present. Wet steam is a mixture of   steam & water containing more than 5 % water. Wet steam is formed   when a portion of its water molecules have given up their energy (latent heat) and condense to form tiny water droplets.

  When writing to the boiler manufacturers , the following information should be furnished to them: Lowest ambient temperature likely to be reached during a year at the proposed place of operation. Elevation of the place above MSL Maximum working pressure Maximum steam demands at the working pressure of the boiler. Fuel to be used and its analysis report. Whether the load on the boiler is likely to be steady or fluctuating and if fluctuating, then between what limits? Analysis of the raw water to be used in the boiler after treatment. In the case of solid fuel fired boilers, whether mechanical firing is preferred. In the event of any proposed standardization of both the HPs & the make of electric motors that fact should be intimated.  Information the Manufacturer should be requested to furnish   Gross Efficiency of boiler Accessories included Quality of steam dryness fraction Flue gas temperature Grate area(for solid fuel fired boiler...

The most often encountered  condensate system corrosion in boilers   is caused by carbon dioxide  The dissolved gases normally present in water cause many corrosion problems. Carbon dioxide exists in aqueous solutions and as the combine forms of carbonate and bicarbonate ions.  Carbon dioxide dissolves in water & produces corrosive carbonic acid . The low pH resulting from this reaction a enhances the corrosive effect of oxygen.                                                                                                                                                        CO2...

Galvanic corrosion occurs by electrical coupling of dissimilar metals or alloys. CAUSES OF GALVANIC CORROSION IN BOILER Scratches on the metal surface Differential stresses in metals Conductive deposits on boiler surface Acid cleaning of the boiler

BOILER EXPLOSION  A boiler explosion is a ruinous failure of a boiler. Any Boiler explosion results in two major events:   The steam under pressure is suddenly exposed to much lower pressure i.e. Atmospheric Pressure resulting it to expand to almost 10-15 times expansion of its volume.   The tremendous amount of energy stored in the pressurized boiler water is suddenly released prompting sudden evaporation of 15 to 20% of the water to get converted into Flash steam . This steam also expands to more than 1700 times its original volume causing catastrophic damages.