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Bagasse and Biomass Fired Boilers

With vast experience of more than 100 types of biomass fuels and having supplied more 400+ boilers across 50 countries, Isgec with John Thompson technology is leading the market in providing green energy solutions and caters various types of industries.

Isgec have set benchmark in the market by offering tailor made solutions to burn all types of biomass fuels including critical biomass like Mustard Husk, Paddy straw, Cotton Stalk, Soya husk, Julia Flora, Empty fruit bunch, Cane trash, King Grass and many more. Our boilers are designed with perfection to ensure efficient combustion and highest availability even on critical biomass fuels which are difficult to burn. 

Isgec offers many options in grate technologies depending on the type of fuel and its properties. Some of the grate technologies are: 

Travelling Grate Boilers 

• Original Technology from world renowned company - John Thompson Water Tube Boilers, U.K. 
• Suitable for Cogeneration and Captive Power 
• Multi-Fuel Firing 
• Commissioned more than 350 Boilers worldwide
• Highest market share in 125 Kg/cm2 operating pressure 
• Single / Bi-Drum Boiler Options

Reciprocating Grate Boilers 

The most proven and reliable combustion system for burning a wide range of Biomass fuels. 

Features: 

• Wide fuel flexibility
• Insensitive to fuel size
• Simpler fuel preparation
• Robust construction with minimum maintenance, resulting in longer life and reliable operation
• High alloy steel air-cooled grate bars 
• Simple and rapid installation
• Simple control
• Efficient combustion due to better air distribution
• Low NOx emission through the use of high-pressure secondary / over fire air injection
• Efficient fuel feed system using hydraulically operated feed piston and divergent hoppers

Constructional Features: 

• Staircase structured air-cooled Reciprocating Grate, consists of a series of fixed and moving grate bars arranged in stepped sections from fuel inlet to the bottom discharge section
• Hydraulically driven moving rows of grate bars with variable length & number of strokes
• Zoned partition walls below the grate for separation of different primary air zones 
• As the fuel moves from the inlet to the discharge it passes through distinct drying, volatilization, combustion and burn-out zones 
• Ash conveying system at the end of the grate for ash discharge

Dumping Grate Boilers  Range: 

• 20 TPH - 150 TPH 
• High or low set options 
• High Efficiency features 
• Generously sized grate 
• Grit refiring system 
• Soot Blowers for on load cleaning of heating surfaces 
• Secondary air distribution system 
• Environment friendly 
• Electrostatic Precipitator type pollution control for limiting particulate emission upto 30 mg/Nm3 

Other Features:

• On-line bagasse storage silo for stable Boiler operation 
• Single or three drum feeder option for bagasse feeding 
• Space tube or Membrane panel furnace options 
• Pneumatically operated sectionalized dumping grate 
• Two stage superheaters with single stage attemperator for accurate steam temperature control 

Pin Hole Grate Boilers:

• For burning only bagasse, we offer low cost and reliable pin hole grate boilers. 
• Pin hole grate boilers are equipped with stationary pin hole grate with steam jets for ash removal. The steam nozzles are staggered; hence de-ashing is smooth and efficient
• The furnace bottom water wall tubes and the pin hole grate bars are arranged with slight slope for positive water circulation
• Grate bars are made of heat-resistant steel shaped to rest closely on a support floor of boiler tubes which are integrated with the furnace water walls
• Absence of moving components in pin hole grate makes it easy for use

Water cooled Vibrating grate (In partnership with BWE, Denmark) 




Salient Features: 

• Proven and reliable combustion system for burning a wide range of Biomass fuels 
• Taller furnace with adequate residence time to handle critical biomass combustion  
• Wide fuel flexibility 
• Low maintenance and Highest availability with ease of operation 
• Meeting latest emission norms and ensuring Low NOx emission through the use of high pressure secondary / over fire air injection 

Experience: 

400+ boilers for bagasse and biomass fuels with highest market share in India. Maximum installations on high pressure boiler of 125 kg/cm2  




Some of our Biomass fired boilers installed across the globe are as below: 

• GGC KITS Bio Industrial (Sbang), Thailand – 2 x 230 TPH TG 
• Ingenio Magdalena S.A.. Gautemala – 220 TPH TG 
• KPR Sugar, Karanataka, India – 210 TPH TG 
• Nirani Sugar, Karnataka, India – 3 x 150 TPH TG  
• DCM Shriram Group, Uttar Pardesh, India – 150 TPH TG 
• Godrej Industries, Gujarat, India – 45 TPH TG 
• Songkhla Bio Power, Thailand – 44 TPH RG  

Circulating Fluidised Bed Combustion Boilers

Isgec has tie up with Sumitomo SHI Foster Wheeler Energia Oy., Finland for Circulating fluidized bed Combustion (CFBC) Boilers (from more than 25 years). Sumitomo SHI FW is a World leader in CFBC technology. What sets this technology apart is the patented high efficiency steam / water cooled Compact separator design which has been proven worldwide to improve availability & minimise maintenance, lower SOx and NOx emissions, minimise start-up time, and eliminate erosion & choking. It also reduces the boiler footprint.

Salient Features: 

• Highly efficient patented Compact Separator (Cyclone) design with tall furnace, high residence time and uniform furnace temperature. High Collection efficiency for very low particle size as low as 65 microns. 
• Environmentally Friendly design with Low SOx emission due to uniform combustor temperature & effective limestone utilization, Low NOx emission due to staged combustion & controlled combustion temperature and Low CO emission due to efficient carbon burn out.  
• Executed smallest capacity CFBC boiler of 50 TPH capacities for various customers.  
• Higher Reliability and Availability with certain Installations operated continuously for more than 500 days (without any stoppage). 
• Capable of firing widest variety of fuels from 1600 GCV waste Coal to high GCV Imported Coal or Petcoke (8000 Cal /kg GCV). Firing very high ash fuel up to low ash fuels. 
• Firing High Sulphur Petcoke (8%) in CFBC Boilers for Refinery and other plants.  
• Firing Industrial waste gases – BFG, RFG, COG and Other Gases Hydrogen. 

Experience: 

• 115+ CFBC Boilers (1st Indian Boiler Manufacturer to achieve milestone of 100 nos. CFBC Boilers) 
• 40+ CFBC Boilers on waste Coal (such as Char, Washery Rejects or Coal middling’s). 
• 25+ boilers supplied in the range of 50-100 TPH Capacity. 
• 10+ Boilers supplied for Biomass firing along with Coal. Biomass such as Rice Husk, Mustard Husk, Wood Chips, Saw Dust, Soya Husk, Bagasse etc.tt 
• Supplied 410 TPH Reheat CFBC Boiler for M/s Nirma Limited for their Cogeneration plant for supplying process steam in different combination along with power generation with reheat cycle. Boiler is designed to operate on 6 different fuels. 
• Global experience in executing CFBC boiler projects - Latin America, Turkey, Morocco, Indonesia, Jordon & Vietnam.  
• Repeat CFBC Boilers Orders from Corporate Houses - Aditya Birla, Tata Group, DCM Shriram, Rashmi Group etc. 

Cement Waste Heat Recovery Boilers

Indigenously developed Waste Heat Recovery Boilers for PH & AQC. Also, Offering Alkali Bypass Boiler. 

Offering WHRB's for Cement Plant Capacity of 1500 TPD to 15000 TPD or more

Salient Features: 

• WHR Boilers are designed based on plant capacity & maximum heat utilization 
• For optimizing the space and placed in the congested area, both PH & AQC Boiler having Vertical configuration
• Water tube and natural circulation design with dual pressure steam cycle 
• Optimum gas velocity across heat Transfer area in order to minimize the pressure drop across the Boiler
• PH Boiler – Having cross flow design having specially designed double seal hammering arrangement 
• AQC Boiler - Finned tube construction and having integrated pre-dust collector to remove dust from the gas entering boiler
• For Higher Availability and low Maintenance
• Inline arrangement for both PH and AQC Boiler – In staggered arrangement, it is very difficult to identify the tube leakage and duration of maintenance will increase
• Casings are designed with adequate stiffeners, and fully seal welded sturdy corner joints 

Experience: 

• Executed one of the World’s largest steams generating Cement Waste Heat Recovery Boilers for Shree Cement Limited for their Integrated Nawalgarh plant
• Our CWHR Boilers / plants are running successfully in leading Cement Groups: 
• Shree Cement Limited 
• Ultratech Cement Limited  
• Dalmia Cement Bharat Limited 
• Bharathi Cement (Vicat cement)  
• Chettinad Cement Limited 
• Star Cement Limited 
• KJS Cement Limited  
• Executing CWHRB CPP for The Ramco Cement on EP basis  

Slop Fired Boilers

Spent Wash / Slop / Vinasse Fired Boilers for Zero Liquid Discharge (ZLD) in Distilleries  

Salient Features: 

• Latest generation slop fired Travelling grate technology for meeting Zero Liquid Discharge (ZLD) by burning 100% guaranteed slop quantity 
• Designed to burn slop generated from B-Heavy / C- Heavy / Syrup 
• Highest availability with maximum continuous operation 
• Support fuel requirement is as low as 15% (on a heat basis) even with Bagasse 
• Other support fuels such as Rice Husk, Wood Chips, Biogas, Coal, and another biomass 
• Lowest auxiliary steam requirement 
• 100% steam generation on other fuel when no slop/spent wash is available.  
• Meeting stringent emission norms SPM <30 mg/Nm3 with ESP/Bag filter 
• Specially designed High Pressure and Temperature (87 ata / 515 0C) Hybrid boilers  

Experience: 

45+ Spent wash / slop / Vinasse fired boilers across the globe and received repeat orders from prestigious groups like Avadh Sugar (Birla), Bajaj Hindustan, Balrampur, Dalmia, DCM Shriram, Dhampur, Dwarikesh Sugar  

Some of our Incineration boilers installed across the globe are as below: 

• DSCL Sugar (Unit of DCM Shriram), U.P., India – 80 TPH (World’s largest Boiler) 
• Balrampur, U.P., India – 75 TPH  
• Bajaj Hindustan, U.P., India – 4 x 60 TPH & 2 x 40 TPH 
• KPR Sugar, Karnataka, India – 60 TPH  
• Sbang Co. Limited, Thailand – 60 TPH 
• SSM, Haryana, India – 42 TPH 
• Bindal Papers (Sugar Division), U.P., India – 25 TPH 

Paddy Straw Fired Boilers

In partnership with BWE, Denmark a leading name in Straw Fired Boilers for capacity > 40 TPH  

Salient Features: 

• Three (3) Pass Design with Four-stage superheater for better temperature control range 
• Fifth Generation Water Cooled Vibrating Grate ensures efficient burning of the fuel on the Grate
• 100% Rice Straw Fired Boilers with steam parameters up to 125 Bar, 540 Deg. C super-heated temperature
• The system is suitable for the Bale feeding system hence hassle-free fuel handling
• Availability of multi-fuel firing option 
• Highest thermal efficiency with Highest availability  

The project successfully commissioned and running 

• 75 TPH, 100% Paddy Straw Fired Boilers at Sukhbir Agro Energy Limited, Kurukshetra, Haryana 
• 75 TPH, 100% Paddy Straw Fired Boilers at Sukhbir Agro Energy Limited, Kaithal, Haryana 
• 77.8 TPH, 100% Paddy Straw Fired Boilers at Shree Ganesh Edibles Pvt. Ltd, Khanna, Punjab (For Process Industry) 

Operation & Maintenance

Offering O&M services globally for Power plants and boiler across a wide spectrum of industries, like: 

• Cement 
• Refineries 
• Fertilizer 
• Steel 
• Automobile  
• Sugar  
• Chemical 
• Independent Power Projects 

Offerings: 

• Plant Operation & Maintenance 
• Supervision of Operation & Maintenance 
• Plant Safety Procedure & Audit 
• Perioding Performance Review 
• Breakdown Maintenance 
• RLA studies 
• AMC services 

Advantage of Isgec :

• Vast Operational Databank from 1000+ Installation (Totalling 50,000MWe globally) 
• OEM for all Major Boiler Technologies - PC, CFBC, AFBC, Oil & Gas, HRSG, Slop Fired, WHRB and Biomass fired boiler as an OEM
• Minimum increased Plant Availability by 2% 
• Minimum Lower Auxiliary Consumption by 0.5%
• Dedicated Manpower – 1500+  

What we deliver:

• Process Integration 
• Better efficiency 
• Higher Availability 
• Operational flexibility 
• Guaranteed performance and extended plant life 
• One stop solution for services and spares

Experience: 

• Operational experience of 2000 MWe+ across 
• Independent Power Plant 
• Captive Power Plant 
• Co-generation 
• 3 x 30 MW Cogeneration plant supplied by Chinese company at an Aluminium Refinery in India. 
• 100% Petcoke fired boiler along with MHS in refinery in India 
• 3 x 35 MW Power Plant in Latin America
• Utility Boiler in refinery in India 

Waste to Energy

With increasing urban waste, there has been a global demand to sustainably eradicate regular municipal waste which has resulted into huge heaps of legacy-waste across cities and towns. We offer state of art solution to burn the Municipal Solid Waste and convert it to Energy. Our Boiler are suitable for firing wastes like Refuse Derived Fuel, segregated Municipal Solid Waste, agriculture waste, paper sludge, Non-Recyclable Solid Waste, & other Industrial process wastes, thereby, reducing carbon footprints and ensuring a sustainable society with cyclical economy. 

Salient Features: 

• Conservative grate area loading to ensure efficient combustion of fuel. 
• Higher furnace cross section to reduce flue gas velocity in the furnace so unburn fuel carry over can be avoided. 
• Proper split of primary and secondary air for efficient fuel combustion in the furnace 
• Adequate cleaning system in super heater, economiser, and air heater region for efficient on-load cleaning of heating surfaces. 
• Lower Auxiliary power consumption. 
• Adequate pitching of superheater, economizer, air heater assemblies to minimize the deposit and fouling. 
• Ensuring liberal design of pollution control equipment to accommodate SPM as well as gaseous pollution norms. 
• Solving extreme odour control solution for legacy waste. 

Experience:

• 1x11.3 MW RDF fired WtE at IL&FS, Delhi (Keppel Seghers Technology)