Conserving Resources,

Process Heating
Preserving the Future.

Air Pollution Boiler and Build-Own

Control Heater -Operate

Projects and
Chemical Cooling Energy
Solutions

Process Renewable Water and Waste

Heating Energy Solutions

Head Office North East West South

Thermax Limited 14th Floor, Best Gariahat Mall, 5th Dhanraj Mahal, 2nd floor, TVH Belicaa Towers,
D-13, MIDC Industrial Area, Sky Tower, Netaji Floor, 13 Jamir Chhatrapati Shivaji Marg, 3rd Floor, Tower-1,
R D Aga Road, Chinchwad, Subhash Place, Lane, Near Regal Cinema, MRC Nagar, RA Puram,
Pune 411019, India Pitampura, Kolkata - 700019 Gateway of India, Chennai - 600028
[email protected] Delhi - 110034 Mob. : 9607971942 Colaba Mumbai - 400 039 Ph. No: 044-24303453
Customer Care: 1800-209-0115 Ph. No: 011- Ph. No: 022-67542222
46087220

www.thermaxglobal.com ULTRAPACTM
thermaxglobal thermax_global thermaxlimited Ultra performance boiler offering unmatched fuel-flexibility,
best-in-class efficiency & highest uptime
thermaxglobal thermaxmedia
[email protected]

This brochure presents only some of our products and we reserve the right to amend any product details without notice. Version 1.1 | 01.08.2023
The photographs used in the brochure are indicative and may not match the actual plant

© 2022 Thermax limited. All rights reserved.

Conserving resources, Features
Preserving the future.
Unique MPA Design Over 40%
Thermax provides systems and solutions in the critical domains of energy and environment. The products and services ∎ This design (MPA up to the RG) offers a large heat reduction in
developed by Thermax help industries achieve better resource productivity and improved bottom lines, while maintaining a transfer area, which helps in efficient utilisation of refractory
cleaner environment. The company’s vision for the future is firmly anchored in the belief that, to stay competitive, business radiant heat, prevents clinker formation, slagging,
houses need to adopt sustainable practices. and fouling by controlling bed and furnace
Thermax’s product portfolio covers the heating, cooling, water and waste management, and specialty chemicals. The temperature profile, thus improving boiler uptime.
company also designs, builds and commissions large boilers for steam and power generation, turnkey power ∎ The membrane panel assembly requires up to
plants, waste-to-energy systems and air pollution control projects. 50% less refractory which ensures reduced
maintenance, low startup time, application time
and clinker formation
∎ The baffle wall arrangement within the assembly
Ultrapac : Designed for ensures complete combustion and fly ash
separation.
the future ∎ The assembly comes with secondary & tertiary
Industries are moving towards fulfilling their sustainability air nozzles that provide high-velocity air for
goals using various green fuels for process heating and complete combustion.
energy generation requirements.

Accommodating a variety of fuels has remained a

challenge due to the fouling characteristics of green
fuels causing increased operating maintenance which
leads to frequent boiler shutdowns. Unique Shell Design
∎ The two-pass design maximises heat
Ultrapac offers the best-in-class efficiency, the highest
uptime, and multi-fuel flexibility. This robust product recovery from flue gases and in turn,
is highly compact, & modular designed to reduce reduces the fuel bill.
installation cost, time & space. It is specially designed ∎ This design allows for a higher water
to operate on a multitude of fuels with varying fouling holdup which in turn offers higher
characteristics without impacting the equipment’s thermal inertia to deal with load
uptime. fluctuations.
∎ This shell design with a large tube
Multi-fuel flexibility diameter in high flue gas temperature
zones minimises fouling in the tubes, thus
The age-old challenges faced in the combustion of biomass have been quite a few. The inconsistent supply of fuel and the improving the boiler uptime.
seasonal variation in fuel properties make the biomass fuels difficult to combust at desired efficiency levels. Biomass fuels
∎ Efficient cleaning and improved boiler uptime
are usually low in density, have higher moisture percentages, and offer lower calorific values.
due to no spirals
With its unique features, Ultrapac tackles these difficulties faced in biomass combustion and offers the best of fuel flexibility.
A few of the many fuels that Ultrapac efficiently combusts are.

Danblast
∎ Danblast is an automatic, online, and continuous soot-
blowing mechanism using Danish technology.

Husk Wood Chips Biomass Briquette Biomass Pellet Cashew Nut Shell ∎ Operating on compressed air, this mechanism sends out shock waves
through the boiler tubes to prevent soot build-up.
∎ The unique sequential operation of Danblast ensures minimal
use of compressed air for tube cleaning. Enhances
∎ The assembly comes with secondary & tertiary air nozzles uptime
that provide high-velocity air for complete combustion.
by 2X
Palm Kernel Shell Ground Nut Shell RDF Pellet / Briquette Indonesian Coal And More
Reciprocating Grate – A technology Fuel Feeding System
transferred from Lambion, Germany ∎ Fuel feeder with toothed screws having
∎ This technology efficiently combusts multiple biomass variable pitch helps to deal with fibrous &
fuels, including the difficult-to-combust low-density non-uniform fuel, and eliminate possibility
and fouling fuels. of jamming of screw.

∎ Zone wise speed and air control ensures efficient ∎ Inverted fuel hopper (dosing bin) enables
combustion for a wide variety of fuels fuel storage before fuel feeding screw.
This hopper is equipped with temperature
∎ Grate bars with multiple geometries and perforations
sensors and water jets for protection from
ensure the required air variation in a trolley to create a
backfire.
uniform combustion rate.
∎ Photo-electric sensors in the dosing bin
∎ Grate bar castings with higher proportions of chromium
help maintain fuel level over the fuel screw
(upto 26%) and nickel, help achieve desirable abrasion
feeder to reduce the possibility of backfiring.
resistance at higher temperatures and ensure high
reliability, minimal wear of the grate bars, and a
greater life.

Block Bars Side Plate Nozzle-1 Nozzle-2 Nozzle-3 Nozzle-4 Nozzle-5

Grate Bar

Ultrapac comes enabled with

Heat Recovery Unit – Economiser EDGETM Live, an intelligent IIoT
∎ Ultrapac comes with an Economiser as a Heat Recovery ∎ It comes with a retractable automatic rotary soot-blowing solution with ensured data
Unit and is a vertical serpentine coil-type design that system which helps in effective online cleaning of its security that enables
ensures a high uptime of the unit. tubes.
∎ Efficiency monitoring and diagnostics
∎ Data-driven preventive maintenance
scheduling
ThermowizTM Nxt
∎ Remote monitoring of all critical
Advanced electrical control system parameters
Experience the power of technology with
Thermowiz™ Nxt, a digitally powered device
for monitoring, control, and protection of
equipment.
∎ User comfort - Touch screen graphical
operator interface Ultrapac’s Benefits
∎ MIS reporting - Real-time trends, and data
logging downloadable on a USB drive
∎ Networking - Embedded ports on Ethernet. Best-in-class Multi-fuel High
Serial. CAN Open protocols upto (88%) flexibility uptime

∎ Program modification - Download programs

through a USB drive

Ideal for Compact Low installation

fluctuating loads design time
Boiler Components Tech Specifications
4
3 2
UPRGA
Description Unit UPRGA 40 UPRGA 50 UPRGA 60 UPRGA 80 UPRGA 100
16 120
1 Performance Parameters
18
Boiler type Packaged Hybrid Boiler
Max steam output
5 Kg /Hr 4000 5000 6000 8000 10000 12000
(F & A 100 DegC)
31 11.25
13 Design Pressure (SVLOP) Kg /cm2(g) 11.25 /17.5 11.25 /17.5 11.25 /17.5 11.25 /17.5 11.25 /17.5
17 /17.5
Operating Temperature °C 188 188 205 188 188 188
Dryness % 98 98 98 98 98 98
15
Efficiency (On NCV Basis
7 - As per BS 845 Part t- I
Indirect Efficiency meth-
8 od at full load)
Biomass briquettes % 87 87 87 87 87 87
9 Woodchips (Total Mois-
% 87 87 87 87 87 87
ture - 25%)
14 Woodchips (Total Mois-
% 86 86 86 86 86 86
ture - 40%)
26
Rice husk % 85 85 85 85 85 85
25 21
23 Groundnut Shell % 88 88 88 88 88 88
12
6
Pellets % 88 88 88 88 88 88
PKS % 88 88 88 88 88 88
Indonesian Coal (Total
% 87 87 87 87 87 87
Moisture - 10%)
30
Indonesian Coal (Total
% 85 85 85 85 85 85
27
Moisture - 35%)
Fuel consumption @ 100
%
29 % Load
Biomass briquette kg/hr 677 846 1015 1353 1691 2030
Woodchips (Total Mois-
kg/hr 841 1051 1261 1682 2102 2522
ture - 25%)
28
Woodchips (Total Mois-
kg/hr 1118 1397 1676 2235 2794 3353
ture - 40%)
Rice Husk kg/hr 871 1089 1307 1743 2178 2614
Groundnut Shell kg/hr 582 727 872 1163 1454 1745
Pellets kg/hr 643 804 965 1287 1608 1930
20
PKS kg/hr 548 684 821 1095 1369 1643
Indonesian Coal (Total
kg/hr 446 557 668 891 1114 1337
Moisture - 10%)
Indonesian Coal (Total
kg/hr 658 822 987 1315 1644 1973
10 Moisture - 35%)
11 19
24 22
Mode of firing Automatic using screw feeder
Ash removal mode Automatic using wet/dry bed ash screw conveyor (optional)
1. Boiler Shell 13. Economiser Assembly 23. Ash Removal Point (MPA)*
2. Boiler Trim Access Platform 14. FW Pumping System 24. Ash Removal Point (RG) Design Code IBR 1950 with latest amendments
3. Main Steam Stop Valve 15. Feed Pipe Assembly from pump 25. Staircase for Platforms Installed Length mm 15883 16300 16300 16700 16900 17500
4. Safety Valves to economiser Economiser(Steel)* Installed Width mm 5100 5400 5700 5700 6200 6500
5. Level Gauge Glass Assembly 16. Feed pipe assembly from 26. Staircase for Platforms Fuel Installed Height mm 7400 7750 7900 8200 8300 8402
6. Probe Level Controller economiser to shell Feeders & Shell (Steel)*
Weight of the heaviest
7. Top Membrane Panel Assembly 17. Smoke Tubes Access Platform* 27. Screw feeder Tonnes 6.00 7.00 8.00 10.00 11.00 13.00
single module
8. Bottom MPA with Baffle Walls 18. Flue Gas Ducting* 28. Level switch for fuel feeding
9. Access Door (multiple) 19. Primary Air Ducting* system Note: Heat Recovery unit (Economiser) is essential for the efficiency & output commited above. Please refer detail
10. Primary Fan Assembly 20. Secondary Air Ducting 29. Dosing bin technical specifications for fuel composition.
11. Secondary Fan Assembly 21. Shell Blowdown Valve 30. Fire extinguisher
12. Sloped Reciprocating Grate 22. Economiser Rotary Airlock Valve 31. Danblast