Lafil Global

Boiler Accessories

Air Preheater

Tube Bank

Economizer

Steam Superheater

Water Wall Panel

Condensate Recovery

Air Soot Blower

Air Preheater

What is an Air Preheater?

An Air Preheater (APH) is an important Boiler auxiliary which primarily preheats the combustion air for rapid and efficient combustion in the furnace with the primary objective of increasing the thermal efficiency of the process.

The purpose of the air preheater is to recover the waste heat from the outgoing boiler flue gas and transfers the same to the combustion air, which increases the thermal efficiency of the boiler. As every 550 0C drop in flue gas temperature improves the Boiler efficiency by about 2.5%.

Types of Air Preheater

 There are two basic types of air preheater

  • Recuperative – Tubular type
  • Regenerative- Feed water type

 Advantages of Air Preheater

  • Increases thermal efficiency of the system
  • Payback period is very short and increase combustion rate
  • Improve and strengthen the combustion
  • Reduces the loss of furnace and the exhaust gas temperature, improve the boiler thermal efficiency.
  • Air preheater is suitable for all standard fuels
  • They are easy for retrofit into existing systems
  • These air preheaters are suitable for all waste heat boiler / flue gas boiler / boiler types.
  • They strengthen the heat transfer

Disadvantages of Air Preheater

  • There are formations of clinkers, on the grate due to higher combustion temperature.
  • Natural draught is not possible with air preheater as temperature of flue gases is reduced, also pressure drop take place in the flow of the flue gases. Hence, forced draught is required.

Features at glance

  • Large heating surface
  • High heat efficiency
  • Precise temperature control
  • Automatic
  • Energy-saving
  • Clean combustion

Tube Bank

Steam boilers can produce low quality steam that requires additional superheating of the steam after water vaporization. Removal of water vapor from a steam system is critical to maintaining performance. LAFIL steam superheating systems, coupled with SCR power control, can provide instantaneous drying of process steam while only using the exact amount of power needed. This results in a steam supply that is both consistent temperature and quality throughout the distribution lines.

Features:

Materials of construction include carbon steel, stainless steel, as well as nickel and specialty alloys.
SCR Power control adjusts rapidly to flow variations.
Controller schemes can regulate temperature to +/-1°F.
Boilers, superheater, power control panels can all be assembled on a modular skid package.
We manufacture and export Super Heater Coil. These are fabricated out of carbon steel and alloy steel tubes to customers’ drawings and specifications. These super heater coils are used in primary or secondary stages of super heaters of Thermal Power Plants or Captive Power Plants. Special care is taken for ovality and thinning at the bent portion, during fabrication. Customised or tailor made coils are offered. IBR or 3rd party inspection undertaken.

BANK TUBES: Boiler Bank Tubes are Bent to Shape Tubes or Steam Generating Tubes where Water is converted to Steam. Boiler Bank Tubes carry a mixture of water and steam. Fabricated from Tubes in various sizes and shapes, bending of these tubes is generally to larger Radius hence they need some Tube Bending Expertise to avoid wrinkles, surface cracking, irregularities, ensuring long life of tube resulting in smooth and efficient operation of the Boiler.

These tubes for replacements in boilers have been supplied by us to various industries like Sugar, Refineries Steel Plants, small and Large Utility / Captive Power Plants. These Shaped Tubes are generally fabricated from Seamless/ ERW Tubes. The sizes of tubes having different shapes vary from 114 mm OD. X 4 mm Thk. to 50.8 mm OD. X 5.60mm Thick with or without Swaged Ends and with or without Welded Fins and with Wrap.

WATER WALL PANELS: are used in modern day Boilers in place of Steam Generating Tubes to reduce heat loss due to their gas tight nature and reduce insulation costs. We fabricate Water Wall Panels using automatic Fin to tubes welding machines and large Tube Panel Benders to achieve desired shape of panels which can have Swaged Ends, Stub Welded to Headers. We supply Panels with integrated manhole openings in the panels.

We have fabricated panels made of Rifle Bore Tubes of Size 50.8 mm OD x 5.6 Mm MWT conforming to SA- 210 Gr. C in Lengths of upto 24 mtrs. X max.28 tubes (2 mtrs. wide) with Straightness within a tolerance of + / – 3mm.

BOILER DRUM: We offer high quality fabrication services of Boiler Drums. Our drums maintenance and installation services are widely acclaimed in the market for the features like cost efficiency, reliability, flexible approach and quality compliance. We have hired trained employees, who are fully conversant with the current technology of the fabrication industry. Our boiler installation and repairing services find use in different thermal based industries.

 

Economizer

Steam boilers can produce low quality steam that requires additional superheating of the steam after water vaporization. Removal of water vapor from a steam system is critical to maintaining performance. LAFIL steam superheating systems, coupled with SCR power control, can provide instantaneous drying of process steam while only using the exact amount of power needed. This results in a steam supply that is both consistent temperature and quality throughout the distribution lines.

Features:

Materials of construction include carbon steel, stainless steel, as well as nickel and specialty alloys.
SCR Power control adjusts rapidly to flow variations.
Controller schemes can regulate temperature to +/-1°F.
Boilers, superheater, power control panels can all be assembled on a modular skid package.
We manufacture and export Super Heater Coil. These are fabricated out of carbon steel and alloy steel tubes to customers’ drawings and specifications. These super heater coils are used in primary or secondary stages of super heaters of Thermal Power Plants or Captive Power Plants. Special care is taken for ovality and thinning at the bent portion, during fabrication. Customised or tailor made coils are offered. IBR or 3rd party inspection undertaken.

BANK TUBES: Boiler Bank Tubes are Bent to Shape Tubes or Steam Generating Tubes where Water is converted to Steam. Boiler Bank Tubes carry a mixture of water and steam. Fabricated from Tubes in various sizes and shapes, bending of these tubes is generally to larger Radius hence they need some Tube Bending Expertise to avoid wrinkles, surface cracking, irregularities, ensuring long life of tube resulting in smooth and efficient operation of the Boiler.

These tubes for replacements in boilers have been supplied by us to various industries like Sugar, Refineries Steel Plants, small and Large Utility / Captive Power Plants. These Shaped Tubes are generally fabricated from Seamless/ ERW Tubes. The sizes of tubes having different shapes vary from 114 mm OD. X 4 mm Thk. to 50.8 mm OD. X 5.60mm Thick with or without Swaged Ends and with or without Welded Fins and with Wrap.

WATER WALL PANELS: are used in modern day Boilers in place of Steam Generating Tubes to reduce heat loss due to their gas tight nature and reduce insulation costs. We fabricate Water Wall Panels using automatic Fin to tubes welding machines and large Tube Panel Benders to achieve desired shape of panels which can have Swaged Ends, Stub Welded to Headers. We supply Panels with integrated manhole openings in the panels.

We have fabricated panels made of Rifle Bore Tubes of Size 50.8 mm OD x 5.6 Mm MWT conforming to SA- 210 Gr. C in Lengths of upto 24 mtrs. X max.28 tubes (2 mtrs. wide) with Straightness within a tolerance of + / – 3mm.

BOILER DRUM: We offer high quality fabrication services of Boiler Drums. Our drums maintenance and installation services are widely acclaimed in the market for the features like cost efficiency, reliability, flexible approach and quality compliance. We have hired trained employees, who are fully conversant with the current technology of the fabrication industry. Our boiler installation and repairing services find use in different thermal based industries.

 

Steam Superheater

Steam boilers can produce low quality steam that requires additional superheating of the steam after water vaporization. Removal of water vapor from a steam system is critical to maintaining performance. LAFIL steam superheating systems, coupled with SCR power control, can provide instantaneous drying of process steam while only using the exact amount of power needed. This results in a steam supply that is both consistent temperature and quality throughout the distribution lines.

Features:

Materials of construction include carbon steel, stainless steel, as well as nickel and specialty alloys.
SCR Power control adjusts rapidly to flow variations.
Controller schemes can regulate temperature to +/-1°F.
Boilers, superheater, power control panels can all be assembled on a modular skid package.
We manufacture and export Super Heater Coil. These are fabricated out of carbon steel and alloy steel tubes to customers’ drawings and specifications. These super heater coils are used in primary or secondary stages of super heaters of Thermal Power Plants or Captive Power Plants. Special care is taken for ovality and thinning at the bent portion, during fabrication. Customised or tailor made coils are offered. IBR or 3rd party inspection undertaken.

BANK TUBES: Boiler Bank Tubes are Bent to Shape Tubes or Steam Generating Tubes where Water is converted to Steam. Boiler Bank Tubes carry a mixture of water and steam. Fabricated from Tubes in various sizes and shapes, bending of these tubes is generally to larger Radius hence they need some Tube Bending Expertise to avoid wrinkles, surface cracking, irregularities, ensuring long life of tube resulting in smooth and efficient operation of the Boiler.

These tubes for replacements in boilers have been supplied by us to various industries like Sugar, Refineries Steel Plants, small and Large Utility / Captive Power Plants. These Shaped Tubes are generally fabricated from Seamless/ ERW Tubes. The sizes of tubes having different shapes vary from 114 mm OD. X 4 mm Thk. to 50.8 mm OD. X 5.60mm Thick with or without Swaged Ends and with or without Welded Fins and with Wrap.

WATER WALL PANELS: are used in modern day Boilers in place of Steam Generating Tubes to reduce heat loss due to their gas tight nature and reduce insulation costs. We fabricate Water Wall Panels using automatic Fin to tubes welding machines and large Tube Panel Benders to achieve desired shape of panels which can have Swaged Ends, Stub Welded to Headers. We supply Panels with integrated manhole openings in the panels.

We have fabricated panels made of Rifle Bore Tubes of Size 50.8 mm OD x 5.6 Mm MWT conforming to SA- 210 Gr. C in Lengths of upto 24 mtrs. X max.28 tubes (2 mtrs. wide) with Straightness within a tolerance of + / – 3mm.

BOILER DRUM: We offer high quality fabrication services of Boiler Drums. Our drums maintenance and installation services are widely acclaimed in the market for the features like cost efficiency, reliability, flexible approach and quality compliance. We have hired trained employees, who are fully conversant with the current technology of the fabrication industry. Our boiler installation and repairing services find use in different thermal based industries.

Water Wall Panel

Steam boilers can produce low quality steam that requires additional superheating of the steam after water vaporization. Removal of water vapor from a steam system is critical to maintaining performance. LAFIL steam superheating systems, coupled with SCR power control, can provide instantaneous drying of process steam while only using the exact amount of power needed. This results in a steam supply that is both consistent temperature and quality throughout the distribution lines.

Features:

Materials of construction include carbon steel, stainless steel, as well as nickel and specialty alloys.
SCR Power control adjusts rapidly to flow variations.
Controller schemes can regulate temperature to +/-1°F.
Boilers, superheater, power control panels can all be assembled on a modular skid package.
We manufacture and export Super Heater Coil. These are fabricated out of carbon steel and alloy steel tubes to customers’ drawings and specifications. These super heater coils are used in primary or secondary stages of super heaters of Thermal Power Plants or Captive Power Plants. Special care is taken for ovality and thinning at the bent portion, during fabrication. Customised or tailor made coils are offered. IBR or 3rd party inspection undertaken.

BANK TUBES: Boiler Bank Tubes are Bent to Shape Tubes or Steam Generating Tubes where Water is converted to Steam. Boiler Bank Tubes carry a mixture of water and steam. Fabricated from Tubes in various sizes and shapes, bending of these tubes is generally to larger Radius hence they need some Tube Bending Expertise to avoid wrinkles, surface cracking, irregularities, ensuring long life of tube resulting in smooth and efficient operation of the Boiler.

These tubes for replacements in boilers have been supplied by us to various industries like Sugar, Refineries Steel Plants, small and Large Utility / Captive Power Plants. These Shaped Tubes are generally fabricated from Seamless/ ERW Tubes. The sizes of tubes having different shapes vary from 114 mm OD. X 4 mm Thk. to 50.8 mm OD. X 5.60mm Thick with or without Swaged Ends and with or without Welded Fins and with Wrap.

WATER WALL PANELS: are used in modern day Boilers in place of Steam Generating Tubes to reduce heat loss due to their gas tight nature and reduce insulation costs. We fabricate Water Wall Panels using automatic Fin to tubes welding machines and large Tube Panel Benders to achieve desired shape of panels which can have Swaged Ends, Stub Welded to Headers. We supply Panels with integrated manhole openings in the panels.

We have fabricated panels made of Rifle Bore Tubes of Size 50.8 mm OD x 5.6 Mm MWT conforming to SA- 210 Gr. C in Lengths of upto 24 mtrs. X max.28 tubes (2 mtrs. wide) with Straightness within a tolerance of + / – 3mm.

BOILER DRUM: We offer high quality fabrication services of Boiler Drums. Our drums maintenance and installation services are widely acclaimed in the market for the features like cost efficiency, reliability, flexible approach and quality compliance. We have hired trained employees, who are fully conversant with the current technology of the fabrication industry. Our boiler installation and repairing services find use in different thermal based industries.

 

Condensate Recovery

Any process that allows energy contained in Steam condensate to go unutilised, is losing money in terms of fuel costs. Steam condenses to water at saturated temperature and so, depending on the pressure during condensation, the temperature of water may be 100 oC or more. Heat content in condensate is about 20% of the fuel energy burnt in the boiler. This is usable heat energy; it would be waste of money and resources, if not recycled for reuse as boiler feed water or any process hot water requirement. Lafil Thermocompressor systems, condensate contaminate detection systems, Pressure powered pumps & condensate heat recovery systems  are some of the specialised equipment that help make the best use of the energy available in condensate. Depending on your unique requirements, our engineers can suggest solutions for you to extract the maximum from your condensate and save fuel costs.

Typical Installation

Air Soot Blower

By utilizing our years of experience, we bring forth a qualitative array of ID-FD Fans that is used in boilers, furnaces & various other applications. The offered fan is manufactured utilizing finer quality raw material and most up-to-date technology. Moreover, a squad of our quality regulators performs a string of quality tests on this fan to find out any faultlessness. In line with international benchmark, we provide this fan in assorted customized options and at the most competitive price.

What is a soot blower? 

A soot blower is a system for removing the soot that is deposited on the internal furnace tube of a boiler during Combustion, it prevents plugging of the gas passes and maintains boiler efficiency.

Types of soot blowers

  • Wall Blowers also known as IRs (Insertable Rotating)
  • Long Retractable Soot Blower (LRSB) or IK (Insertable Kinetic)
  • Air Heater Blower
  • Fixed Rotating

 Blowing medium

  • Steam
  • Air
  • High Pressure Water
  • Dual-media air heater

Manually operated soot blower is normally installed and are limited to shell-type boiler plants and small watertube boilers.

Electrically controlled and remotely operated soot blowers are mostly installed and are an essential feature on large watertube boilers including marine boilers.

Twin opposing-nozzle type soot blowers with rotation facility, which are fully traversing and retractable when not in use are installed in high-temperature zones, like superheated tube banks and (seldom) in combustion chamber on watertube boilers.

Single or multi-jet soot blowers with lateral movement and non-retractable nozzles are installed in lower-temperature zones.

Multi-jet non-retractable type Stationary or traversing-element soot blowers are installed in the convection tube banks and economizer of watertube boilers.

Causes of Soot Build up

Soot is the inevitable by product of burning fossil fuels, during combustion some mineral constituents and compounds get deposited in a molten or plastic state.

  • Ash constituents get deposited on the heat absorbing surface causing slagging and fouling.
  • Large amounts of soot can be caused by a dirty, clogged or malfunctioning burner.
  • Inadequate draft or low air-to-fuel ratio is a cause for large amount of soot.
  • Use of low-grade fuel in oil boilers also produces more soot than.

Soot Prevention and Maintenance

  • Regular cleaning of boiler, chimney and flue should prevent soot building up to levels that hinder the boiler’s operation.
  • Manual brushing of flue pipe and chimney is the simplest way to clean the system if they are easily accessible.
  • Use of suitable special machinery to blow the soot.
  • Use of high-quality fuel should lessen the amount of soot.

Soot Puffbacks

Puff-backs are considerably more serious issue than a soot build up. They occur in oil boilers and furnaces, due to excess unburned or partially burned fuel oil which leaks back into the combustion chamber at the end of the cycle and can explode at the beginning of the next cycle causing injury to anyone in the vicinity of the boiler, it also blows a cloud of soot out of the boiler and into the boiler room. If the puff-back is severe, it can damage the boiler and the boiler room.

Causes of Puffbacks

  • Leak in the oil supply piping
  • Dirty spray nozzle
  • Boiler shutdown problems and poor maintenance

Prevention of Puffbacks

  • Regularly cleaned and well-maintained boiler is the best way to avoid puff-backs, but they can still occur.
  • Contact a technician and avoid running your boiler until the problem has been fixed.

Advantages Of  Soot Blowers

  • Increases the boiler thermal efficiency by 5% to 10%.
  • Prevents the blockage and plugging of gas passages in the boiler
  • Maintains flue gas temperatures within design conditions at key locations
  • Soot blower used with temperature controlled mode increases overall efficiency by 2% to3%
  • The effectiveness of cleaning around the superheaters & economiser
  • Low operating and maintenance cost.
  • Supports the optimum operation of air emissions control equipment
  • Reduces the risk of soot fires