When you get an idea, what you can expect from us is an answer to many of your imagination & converting them into Product by Design & Engineering. We can get a solution to your problem and shape your ideas & imagination of your existing or future plants.

We provide comprehensive concept of Product Design on Thermal Engineering, Combustion Perception, Thermodynamic + Hydrodynamic studies and Energy Saving efficient devices.

We have expertise in the Design & Engineering of :
  1. For new installation of Steam & Hot Water Boiler
  2. For existing Boiler installation
  3. For Combustion Engineering
  4. For Superheater
  5. For Economizer
  6. Consultancy
  7. Combustion System with Preheated Air


1. For new installation of Steam & Hot Water Boiler

  • Boiler design for steam / hot water using conventional fuel.
  • Waste heat recovery boiler for exhaust gas.
  • Energy Conservation & Waste Heat recovery system.
A Shell type Boiler has one, two or three internal cylindrical furnaces Boilers are designed from a very small size to a size with a steam raising capacity of 55000 kg/h in a single unit. A steam pressure upto 40 bar depending upon size. An integral Superheater with steam temperature up to 450 C is designed irrespective of size.

In the event of a higher steam pressure, a water tube waste heat recovery boiler would be an automatic choice, as shell type boiler has certain limitations on maximum pressure and capacity. However, a shell type boiler is always preferred within these limitations, because of its robust construction, easy maintenance and less susceptibility to inferior quality of water.
 






2. For existing Boiler installation

  • Determining optimum performance.
  • Cause of under performance.
  • Repeated failure analysis.
  • Change over from one fuel to another.
  • Changing performance: capacity, pressure & temperature.
Furnace is a hard working section in a conventional boiler that transfers 65 to 75 % of heat depending upon pressure and other parameters. Furnace configuration is critical & needed to be designed carefully to allow heat flux density uniform over the sections undergoing higher thermal stress. At the end of furnace, a box type reversal chamber is possible upto some pressure. Beyond this an external tubular Reversal Chamber is unavoidable. Design of such construction should ensure a free natural circulation with sufficient upward fluid movement.


 
A good deal of thought goes in favour having furnaces well sized and tube nest heating surface disposed & designed to suit circulation pattern within shell type boiler. Every effort is made to see that the bubbles do not attach to the surface for a prolonged period. So triangular or rectangular pitches in the tube nest are favoured depending upon circulation pattern.

Inspite of all care, during shut down the tubes are often found with deposits and some cracks on the heating surfaces. Some of the specialists would categorized these cracks as a result of stress corrosion and would attribute to the design of boiler and not on quality of water. Whatever may be the cause, a systematic survey always starts from the basic design and then proceed to operational conditions.








3. For Combustion Engineering

  • Oil, Gas & Solid fuel firing system to existing & new plant.
  • Fluidised Bed Combustor for coal, Husk, Bark.
  • Exploration Well. For more details please visit UNI-Geraete web site. UNI-Geraete of Germany is specialized in a wide range of valves like Solenoid Valves for Gas, Steam, Water or any type aggressive fluids. Valves are having a widest possible range in size, pressure & temperature.



Selection of burner & flame geometry are complimentary to furnace design. In a modern burner it is possible to have flame geometry changed during operation to suit furnace. A combination burner handling three fuels like Hydrogen, Natural Gas and Oil can now be made available for simultaneous firing with option of any one individually.

Impingement of flame on the heating surface is avoidable as far as possible, however, certain degree of flame impingement on the heating surface is permissible if sufficient natural or forced circulation is ensured on water side and metal skin temperature is calculated and verified.

Impingement of hot gases on tube sheet e.g. at entry to second pass, sharply increases the metal surface temperature and may cause cracks on tube sheet surface & tube joints. A lot of thought has gone into the design of a tube nest and ligament on tube sheets, to avoid such failures. Design of tube sheets undergoes a sea of change with the rise in flue gas temperature and CO2 & H2O radiation specially in case of waste heat recovery boiler.








4. For Superheater

  • Retrofitting in existing Boiler.
  • For proposed Boiler.
  • Desuperheating Steam by spray & surface technology.
  • Pressure Reducing & Desuperheating station.
An integral superheater can be placed at a selective place in the flue gas passage of a boiler depending upon the required steam temperature. This can be made possible with an exiting boiler also as retrofitting. Some more possibility exists where steam produced from one boiler is fed into a supperheater belonging to another boiler.
 








5. For Economizer

  • Retrofitting in existing Boiler.
  • Air Heater for drying and other utility.
  • Gas Turbine exhaust heat recovery and supplementary firing system.
Exhaust gas from Gas Turbines contains high percentages of Oxygen in the form excess air at a temperature more than 500 C. This eventually leads to excessive loss of heat which remains unabsorbed from exhaust gas.

A supplementary firing is technically feasible and a suitable Firing Equipment is used where flue gas is utilized as combustion air and finally the heat is absorbed in a specially designed Shell Type Boiler.
GAS TURBINE WITH BOILER








6. Consultancy

  • Designing Steam Generation / CO-Generation plant.
  • Flash Steam Recovery & Energy Conservation (Baelz technology) www.baelz.de
  • Specification of Boiler & Peripheral: Chimney, Water Treatment Plant, Deaerators.
  • New technology & its Adoption & Collaboration.
A supplementary firing is technically feasible and a suitable Firing Equipment is used where flue gas is utilized as combustion air and finally the heat is absorbed in a specially designed Shell Type Boiler.
COMBINED PROCESS





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