January 27, 2020

Ref.:2020/CFHAG

Urja-Disha Boiler Technologies Coal Fired Hot Air Generator

Courtesy: CFHAG Gujarat Multi Gas Base Chemicals Pvt. Ltd. (GMGBC)

Coal Fired Hot Air Generation :

CFHAG is heart of process industry without any redundancy in the plant. Economy of production
will highly influenced CFHAG performance. Decades of field know-how, fuel and there

combustion techniques with thousands of successful running systems made Urja-Disha Boiler
Technologies possible to achieve betterment in technological and operational aspects of
CFHAG.
Metallurgy :
Wrong material selection effects on

 Frequent tube failure in high temperature zones

 Longer break down time for tube replacement
 Heavy initial investment with un-optimized material construction
 Inadequate service life of High temperature tube module

Product quality :
 Tube failure leads to mixing of flue gas into direct hot air stream
 Loss of production and product rejection cost
 Cost of re-establishment of process stream hygiene by necessary cleaning

Tube geometry :
Inappropriate tube geometry will lead to

 Shut downs due to Tube clogging

 Production loss
 High pressure drops and raise in Tube metal temperature
 ID fan load and its operating cost

Refractory engineering & furnace design :

Lack of experience with these aspect will bring

 Refractory falling and its related damage to furnace component

 Rise in metal temperature of structural members
 Lower combustion efficiency and increase fuel combustion

Innovative features :
 FGR technology for lower fuel consumption
 Upgraded to take of future stringent pollution control norm associated with flue gas
NOx & SOx emission levels
 Introduction of shock zone within high temperature region

Prompt response :
Bridging the gap between conceptualization to suit customized requirements and engineering
delivery to bring the benefits competitive trend
Safe & reliable :
Improvements through regular interaction with end users & HAZOP studies made possible to
deliver equipment operation safe and reliable to meet the expectations.

Urja-Disha Boiler Technologies CFHAG range :

Urja-Disha Boiler Technologies has developed technology for indirect, cheapest fuel fired, clean
and very high temperature air generator. With 10 Years of experience and successful running
installations, Urja-Disha Boiler Technologies delivers safest and guaranteed maximum life, with
added features for tomorrow’s emission norms.

Urja-Disha Boiler Technologies has expertise of various combustion modules & making
continuous successful move to cater wide range of solid fossil fuels. The overall process or final
product economics are largely affected systems installed at downstream and there operational
aspects. Firing costly fuels with conventional Hot Air Generation (HAG) system faces challenges
to control product cost and process hygiene. Additionally the low cost fuels like Lignite has high
ash, sulfur and moisture making conditions unfavorable for combustion, life and operation.

Over last decades, Coal firing with Fluidized Bed Combustion (FBC) principle becoming popular
in Power industry as it yields best possible combustion efficiency. To suit the need of Hot Air
Generation for Moderate and High temperatures with core know how Urja-Disha Boiler
Technologies has developed two models by utilizing Fluidized Bed Combustion (FBC) technique
for low cost bad quality coal range.

1. High Temperature model: Hot air Up to 750 Deg C

2. Moderate Temperature model: Hot air Up to 350 Deg C

Material selection, refractory selection, tube bundle arrangements, thermal expansion at high
temperatures, online cleaning, operational safety, ease of maintenance, transportation and
installation are the critical factor decide the operational health and overall life of High
temperature variant.

The moderate temperature hot air generations call for other factors, space requirement
refractory selection, and tube to tube sheet failures. Urja-Disha Boiler Technologies moderate
temperature CFHAG requires less space than a conventional HAG system base on FBC principle.
Our flexible tube to tube sheet design completely eliminates chances of tube to tube sheet
welding failure at elevated temperature.

Feedback from operating installations has been collected and utilized for continual
improvements. Based on inputs Urja-Disha Boiler Technologies has introduced FGR technology
for recovering the exit losses and reducing fuel consumption. Shock zone have been added with
high temperature zone improving equipments reliability and availability. Best engineering
practices has been followed for refractory selection and its application. Specially designed
anchorages are put in to service for reducing refractory falling tendency.

Urja-Disha Boiler Technologies clientele for CFHAG :

Sr. Outlet Heat No. of

Project Variant Status
No. temp duty system
CFHAG-8750
14.06 High Under
1 Madhu Silica Pvt. 650⁰C 3 Nos.
MKcal/Hr temperature Commissioning
Ltd.(MSPL) , Gujrat
CFHAG-3000
4.75 Moderate Under
2 N.B. Enterprises, 280⁰C 2 Nos.
MKcal/Hr temperature Commissioning
Nagpur
CFHAG-4800
Gujarat Multi Gas 7.05 High
3 600⁰C 2015 1 No.
Base Chemicals Pvt. MKcal/Hr temperature
Ltd.(GMGBC)
CFHAG-6700
9.66 High
4 Par System, 250⁰C 2014 1 No.
MKcal/Hr temperature
Gujrat
CFHAG-7500
14.14 High
5 Madhu Silica Pvt. 750⁰C 2012 3 Nos.
MKcal/Hr temperature
Ltd., Gujrat (MSPL)
CFHAG-6000
8.57 High
6 Madhu Silica Pvt. 600⁰C 2011 3 Nos.
MKcal/Hr temperature
Ltd., (MSPL) Gujrat
CFHAG-2850 2.79 High
7 600⁰C 2007 1 No.
Aquagel , Gujrat MKcal/Hr temperature
CFHAG-2850
2.79 High
8 Madhu Silica Pvt. 600⁰C 2005 3 Nos.
MKcal/Hr temperature
Ltd., (MSPL) Gujrat

CFHAG 8750 means moisture Evaporation capacity 8750 Kg/hr

Coal Consumption details:

FUEL
AIR HOT AIR HEAT CONSUMPTION
COLD AIR
PROJECT FLOW OUT Deg. DUTY in Kg/Hr @ FUEL
IN Deg. C
Kg/Hr C MKcal/Hr CV 3500
KCAL/KG

MSPL 8750 KG/HR 62359 30 650 14.06 4017.19

NB ENTREPRENEUR 3000
54225 30 280 4.75 1357.92
KG/HR
GMGBC 4800 KG/HR 34208 30 600 7.05 2015.6

PAR SYSTEM 6700 KG/HR 121103 30 250 9.66 2761.02

MSPL 7500 KG/HR 53451 30 750 14.14 4038.95

MSPL 2850 KG/HR 13508 30 600 2.79 795.89

AQUA GEL 2850 KG/HR 13508 30 600 2.69 769.64

MSPL 6000 KG/HR 42760 30 600 8.57 2448.39

Urja-Disha Boiler Technologies company profile :

The origin of Urja-Disha Boilers dates back to 2004, with a burning passion to provide
technological services in the field of Steam Industries, Waste Heat Recovery and Special Heat
Transfer Equipments. We are the technologist in the field of fired and unfired (waste heat
recovery, process integrated) boilers, Fired Heaters, Boiler Accessories, Heat Exchangers etc. We
aim to design very cost effective solutions which also help to reduce carbon foot prints. We have
renamed ourselves as Urja-Disha Boiler Technologies in 2014 to set out to build robust brand as
a technologist in the International Market. We have certified by ISO 9001:2015 quality
management system.

Urja-Disha Boiler Technologies have successfully engineered and commissioned a wide range of
boiler configurations to suit process, combustion operational needs of the boiler and worked on
many non conventional systems. Our range of services starts right from the decision of boiler
configuration to commissioning and trouble shooting. We are able to design the boilers in the
range from as small as 200kg/hr to 200 ton/hr capacity boiler and from 10.5 kg/cm2 pressure to
110 kg/cm2.
We have experience in design of various combustion techniques in the boiler like stoker fired
(dumping grate, travelling grate, reciprocating grate), atmospheric fluidized bed combustion.
Urja-Disha Boiler Technologies able to provide technologies for various fuel firings like
renewable and nonrenewable fuels. We have Specialty in designing waste heat recovery boiler
for the waste gases from metallurgical industry, Cement Industry, diesel and gas fired engines,
gas turbines etc. We have been designing and developing modern tailor-made waste heat
recovery technologies in Steel Industry like Coke Drying System, Ore Drying System, BF Gas
heating and Air Preheating system etc. for energy saving by utilizing any available waste heat
energy from same plant.

We have strong expertise design and drafting team contributing their best potential for
servicing our customers for the designing of systems by utilizing latest software’s like Auto CAD,
STAAD Pro, ANSYS, CAESAR II, CFD, TEKLA, MAWP, CAD Works etc.

Our engineers are constantly working to refine our many proven solutions; we are
simultaneously pioneering new waste heat recovery techniques to facilitate persistent progress
within the metallurgical industries. The close relation with our customers is a major factor that
drives us to achieve results unparalleled in the industry. We pay close attention to our
customers’ requirements, determine the technological packages best suited to support their
targets and accompany them from the initial pre-planning phase of a project to the final
training of their staff, to ensure the best-possible return on investment. As technology pioneers
at heart, we are ready to inspire our customers to set the right course for continued success.

Thanking you & assuring you our best services at all times.

Yours faithfully,

For Urja-Disha boiler technologies,

Mr. Roshan Patil

Marketing Officer

+91-70208 45112