WASTE HEAT RECOVERY BOILER DESIGN

We provide design and detailing services for waste recovery

boil​ers ,AUTO CAD drawings, for new systems and new projects.

 Sandhya design consultancy is one of the leading design consultancy started in 1963 founded by late Subrmanyam Roy, presently our branches in United States(u.s), Dubai uae and India.  We provide design calculations and detailing CAD drawings for petroleum  boiler & thermal design

       

           Our major clients in 2017 and 2018 are, faster wheeler, saipem, petrofac, aldia designs, dow chemicals etc..

    Total projects completed in 2017 - 256

    Total projects complect in 2018 - 430

We provide project management services for all type of boilers

 

Atmospheric fluidised bed combustion boilers - AFBC boilers

Biomass
India is one of the largest producer of Agro Waste Products and Agro Waste Fuels which is the alternative source for Power Generation. Power Generation is becoming more and more predominant with latest technological developments in firing systems. Rice Husk is the main Agro Waste Fuel. But the availability of the Rice Husk is restricted to season and suitability to the industry which are close to the vicnity of this fuel. Hence the power plant owners are looking for other Agro Waste Fuels like Julia Flora, Cotton Stalk, Chilli Stalk, Rice Straw, Wood Chips, Coal, etc. as fuels depending upon the availability of various Agro Waste Fuels
.

CARBON BLACK

Due to low amount of CO, the heating value of the Offgas is low compared to conventional fuels like Oil and Gas. This results in low adiabatic combustion temperatures (1,300°C) whereas those of Oil and Gas are high (2,000 °C). The low calorific value gas needs a longer time to burn and produces an unstable flame. This shows obviously that the conventional methods used for Oil / Gas Combustion systems with membrane wall Boiler cannot be applied to Offgas..

CEMENT

Sandhya  has developed special inhouse designs to meet the stringent process conditions especially High Dust content and Low Gas temperatures.

COKE DRY COOLING (NR)

It is our philosophy that the Heat Recovery Boiler (WH BOILER) shall adopt and follow the Up-Stream Process conditions and shall be reliable, available and maintainable. Similarly HR Boiler shall also follow the requirements of Down-Stream equipment like Steam Turbine Generator, etc. This is true for COKE OVENS also. Some of the characteristics of COKE OVENS are :

COKE OVEN BATTERIES (NR)

It is our philosophy that the Heat Recovery Boiler (WH BOILER) shall adopt and follow the Up-Stream Process conditions and shall be reliable, available and maintainable. Similarly HR Boiler shall also follow the requirements of Down-Stream equipment like Steam Turbine Generator, etc. This is true for COKE OVENS also. Some of the characteristics of COKE OVENS are :

Sandhya is the first Indian Company DESIGN OF  8 x 60TPH Waste Heat Recovery Boilers for Coke Oven Batteries for JSW STEELS, Ballary against stiff International competition.

FERRO ALLOYS

With vast experience for the last 12  years in Waste Heat Recovery for various critical process services and with continuous upgradation of technology, RAJ  has successfully developed design to meet the aggressive service conditions of this sector.
GASIFICATION
With vast experience for the last 12  years in Waste Heat Recovery for various critical process services and with continuous upgradation of technology, RAJ  has successfully developed design to meet the aggressive service conditions of this sector.

LNG & NATURAL GAS

Sandhya has supplied many packages as a sub-supplier to Off-Shore and On-Shore platforms meeting the high quality requirements and involving multiple agencies approvals and Inspections.
METHANOL
Waste Heat Recovery Systems are DESIGN  for catalytic cracking plants for the production of Ammonia, Methanol, Town Gas and Hydrogen. They utilize the fuel gas heat from the furnace heating and provide process gas cooling by means of Steam Generation and preheating of the medium used as well as of the feed and process water.
Process Gas Boiler is installed behind Steam Reformer to cool high pressure – high temperature process gases thereby generating high pressure saturated steam.
We use GAPFREE WELDING for tube to tube sheet joints to avoid CREVICE CORROSION and to have COOLED WELD JOINT.
In addition we offer CONVECTIVE BANK to cool the flue gasses from the Reformer to preheat feedstock, fuel gas, steam, combustion air, etc.
Hydrogen, Methanol, Ammonia Process Gas Boiler Convective Bank.

NON FERROUS METALS

Based on our experience we have selected a 3Pass, WH Boiler with Uptake, Downtake and Horizontal Convection Section. To avoid corrossion due to condensation of SO2-SO3 gases, we have selected Boiler operating pressure of 40bar to keep the tube metal temperature above Acid Dew point. Boiler casing with Hoppers, Evaporator Banks with Rapping Devices, Uptake & Downtake with complex circuit offer high resistance / pressure drop on water side. Further, the water circuits are not similar, hence pressure drops will be different. Also some of the heating surfaces in higher temperature zone generates more steam than the heating surfaces in lower temperature zone. It is also common that the off gas flow- rates- temperature are fluctuation during start-up, normal operation, upset conditions, etc.   

NITRIC ACID

Sandhya  has developed designs suitable for this service.  The design will address the corrosion problems in most appropriate manner.
RAJ  have advise to manfacturers  to use  special HELICAL Coil Bending machine to manufacture the PAN CAKE Coils and other items for this Boilers.
.

PETRO COKE CALCINATIONS

Due to the dedicated focus on Waste Heat Recovery for various applications, RAJ  is able to offer most Tailor made designs for this application.  The Waste Heat Boilers are convective and tail end type horizontal designs, Modular constructed to avoid site welds and long lead time for errection.
RAJ  have many successful references in large capacities such as 110 TPH steam generation, 110 BAR pressure, 500oC temperature meant for Power generation.

POWER PLANTS

RAJ CONSULTANCY  can offer Power Plant upto 50MW on Waste Heat Recovery and or Solid Fuel on EPC basis.  RAJ  has already executed many projects which involves the complete packages required for Power Plant such as Boilers, Steam and Water Piping, Water Treatment Plants, condensers for the turbines (with RAJ  own design for condensers), HP and LP heater (with RAJ  own design for HP and LP heaters), Turbines for drives etc., which gives the required technical edge and ability to Engineer and execute the Power Plant on EPC basis.
STEAM REFORMER
Waste Heat Recovery Systems are DESIGN for catalytic cracking plants for the production of Ammonia, Methanol, Town Gas and Hydrogen. They utilize the fuel gas heat from the furnace heating and provide process gas cooling by means of Steam Generation and preheating of the medium used as well as of the feed and process water.
Process Gas Boiler is installed behind Steam Reformer to cool high pressure –high temperature process gases thereby generating high pressure saturated steam.
We use GAPFREE WELDING for tube to tube sheet joints to avoid CREVICE CORROSION and to have COOLED WELD JOINT.
In addition we offer CONVECTIVE BANK to cool the flue gasses from the Reformer to preheat feedstock, fuel gas, steam, combustion air, etc.
Hydrogen, Methanol, Ammonia Process Gas Boiler Convective Bank.

SULPHURIC ACID PLANT

We have the distinction of having DESIGN  one of the world’s largest WHRS system for 2 x 3500 tpd in India and for 2400 tpd in Europe for Sulphuric Acid Plants.
Sandhya  CONSULTANCY  specialises in custom made process gas cooling systems for Sulphuric Acid Plant (SAP), Hydrogen, Methanol Ammonia & Sulphur Recovery Unit (SRU)
We offer optimised and cost effective design solutions for guaranteed satisfaction of the customer.

   Wide variation of HHV from 2000 to 5000 kcal/kg

 

Characteristics of RDF
    RDF contains alkalies normally concentration of potassium & sodium oxide lowers ash fusion temperature to 950°C.
    Presence of silica with alkalies creates agglomoration & fouling on heating surfaces.
    Silica in fly ash cause erosion of heating surfaces.
    Chloride compounds of RDF cause corrosion of heating surfaces.
    RDF combustion products contains SO2 / SO3 that cause acid dew point corrosion.

 

Ash fusion and slag formation
Combustion temperature above ash fusion temperature leads to ash fusion & clinker formation on grate.
Sandhya  is the first Indian company has developed this technology, keeping the national interest as a prime responsibility and to contribute to the society.
RAJ  has spent considerable financial resources , manpower resources etc to develop a suitable technology to address the ever increasing problem of disposal of municipal solid waste.
Sandhya  is closely working with mini International companies also such as Hafner, Italy and so far have DESIGN  Four (4) Boilers to European market for this application.
Corrosion in the furnace
1.Furnace combustion zone is changing between an oxidizing atmosphere (excess O2) & a reducing atmosphere (deficiency of O2) which    accelerate corrosion.

Acid dew point corrosion
1.Takes place in cold end of boiler (Eco.APH) whose metal temperature is less than sulphur dew point temperature.
Floating roof storage tanks is used only high vapour everopration , this tanks construction cost is high compere to the fixed roof storage tanks for more details click storage tank design

 

 

 

 

 

 

 

 

 

 

 

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