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Boiler & Heater Group
New Trends in Tail Gas Fired Boiler
Carbon Black Conference 2017 –
Chennai, India
Boiler & Heater Group
A leading engineering company providing equipment and solutions related to
Energy and Environment
About Thermax
Boiler & Heater
• Large capacity
power boilers
• Thermal oil /
water heaters
• Package
boilers
• Energy
recovery
systems
Turnkey Power Plants
• Solid fuel based
• Gas based combined
cycle
• Waste heat recovery
based
• RE based incl.
Biomass, Bagasse,
solar, etc.
• O&M of power plants
Chemicals
• Ion exchange
resins
• Cooling water
chemicals
• Fireside chemicals
• Polyelectrolyte
Water and
wastewater
• Wastewater &
Effluent water
treatment systems
• Water recycling
• Waste
management
Enviro
•ESP & Bag filters
• Scrubbers
• Air purification
• Retrofit &
Revamp
Boilers & Heaters Cooling & Heating Power Generation Chemicals & Water Air Pollution Control
THERMAX
Renewable
Solar
• Heating
• Cooling
Cooling
• Exhaust & Multi-
energy fired chillers
• Steam fired chillers
• Hot water fired
chillers
• Direct fired chillers
Heating
• Steam/Hot water
power plants
• Packaged solid/oil/gas
fired boilers
• Fired thermic fluid
heaters
• Exhaust waste heat
recovery boilers
Our Core Business
•Cement Heat Recovery
•Carbon Black
•Sponge Iron Exhaust
•Blast Furnace Gas
•Coke Oven Gas
•Coke Dry Quenching
•DG Set Exhaust Gas
•Gas Turbine Exhaust Gas
•Fluid Catalytic Cracking Unit
•Sulphur Recovery Plant
•Coal Gasification
•Sulphuric Acid Plant
•Incinerators
•Iron Pyrites Roasters
•Zinc Pyrite Roasters
•Copper Smelters
•Copper Convertors
•Glass Furnace
•Electric Arc Furnace
•Coke Calcination
•Nitric Acid
•Caprolactum
Experience in Waste Heat Recovery Applications
Key Points Flow Diagram of Carbon Black Making Process -
Fuel
Hot air
Cold
Air
Reactor
Burner
Reactor
Boiler
Feed
Heater
Tail
Gas to
Boiler
Tail Gas
to Dryer
Feed
Input
Reactor Air
Pre-heater
Bag Filter
Key Points
Tail Gas Utilization
• Tail gas is normally used for steam and power generation.
• In case of non-utilization for steam / power generation the tail gases are either incinerated or flared.
Key Points
Tail Gas Characteristics
• Typical constituents: CO, H2, CH4, N2, C2H2, O2, H2O, H2S, CO2
• Low Calorific value (LCV: 600 - 850 kcal/nm³) lean gas.
• Combustion requires Temperature, Time and Turbulence.
Key Points
Tail Gas Combustion Systems
• Water cooled furnace
• Refractory lined combustion chamber
Key Points
Typical ‘Tail Gas’ Fired Boiler Scheme
Stack
Burner
Economiser
Air preheater
Steam Drum
Convection Bank
Superheaters
Combustor
Key Points
Salient Features of the Tail Gas Fired Boiler
• Thermal Efficiency of 85 % (Based on LCV)
• Externally fired combustion chamber for complete combustion of tail gases.
• Tangential entry of tail gas along with radial entry of combustion and dilution air into combustor ensures complete combustion.
• Combustor Orientation : Horizontal / Vertical
• Sufficient residence time for complete combustion of lean gases
• No auxiliary fuel is required during normal operation.
• Forced Draft / Balanced Draft System
Key Points
Salient Features of the Tail Gas Fired Boiler
• Fully drainable Superheater.
• Superheater is placed in membrane panel construction, avoiding refractory lined casing.
• Screen tubes are provided before Secondary Superheater for protecting the same from direct radiation.
• Boiler Turndown Ratio – 1:4
Key Points
Salient Features of the Tail Gas Fired Boiler
• Rated superheat temperature is achieved for the given turn-down range because of Radiant Superheater.
• Convection section side walls consist of membrane panel construction. This ensures refractory less design.
• Boiler feed water pre-heater is provided to preheat feed water before entering Economiser. This ensures no corrosion of Economiser tubes.
• Bare tube Heat transfer surfaces to avoid gas side choking.
Key Points
Emission Control Methods
• NOx Reduction
• SOx Reduction
Key Points
Nox Reducing Methodology
• Low NOx Burners
• Air Staging
• Fuel Staging
• Flue Gas Recirculation
• DeNOx System - SNCR / SCR
Modularization
Combustion Chamber
Modularization
Boiler Block
Modularization
Economiser Section
Modularization
Refractory Lined Stack
Key Points Observations
• Captive power generation is a great success and makes these plants self sufficient.
• Continuous plant availability makes these plants highly reliable.
• If wheeling of power is allowed, Carbon black plants can be net exporters of power.
• Tail gas burning and conserving energy is also Environmentally friendly.
THANK YOU