Project overview
A leading fertiliser manufacturer faced the challenge of ensuring continuous and reliable steam supply for its critical process units, operating under demanding conditions where efficiency, safety, and long-term performance were essential.
Thermax partnered with the customer to address this requirement through a carefully engineered approach, combining domain expertise, customised design, and end-to-end project execution. The focus was on delivering a solution capable of supporting uninterrupted operations while ensuring durability and operational stability over the long term.
Challenges
- The fertiliser company required a reliable solution to meet the high and continuous demand for process steam, especially for its ammonia and urea synthesis units.
- The challenge was to ensure efficiency, safety, and long-term performance under demanding operating conditions.
Solution
- Thermax delivered a 175 TPH radiant boiler (pressure: 115 Kg/cm²g, temperature: 510°C, fuel: natural gas/diesel). The scope included design, manufacturing, supply, transportation, and supervision of erection and commissioning assistance.
01
Fully welded boiler system with membrane walls and welded drum connections for durability
02
Steam drum placed outside the flue gas path to avoid thermal stress during load changes
03
Large furnace volume for stable combustion with conservative heat release rates
04
Fully convective superheater positioned away from direct flame radiation
05
Steam-cooled supports for enhanced reliability of the superheater
Result
- The solution ensured uninterrupted and efficient steam generation for the ammonia and urea synthesis units. With its robust design and engineering innovations, the boiler provided the customer with improved operational reliability, longer equipment life, and optimised performance for critical processes.
