Up to 1,000 TPH
IR-CFBC Boilers

Internal Recirculation Circulating Fluidised Bed Combustion (IR-CFBC) Boilers

High-efficiency IR-CFBC boilers offering reliable performance, low emissions, fuel flexibility, lower unburnt carbon in ash and reduced maintenance through advanced membrane wall design

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TBWES’ CFBC boiler has a unique internal recirculation circulating fluidised bed (IR-CFB) design and employs a patented two-stage particle separation system.

These cost-effective and efficient IR-CFBC boilers offer improved performance through their simplified design. Benefits include high combustion efficiency, reliability, and availability, along with low maintenance costs, reduced erosion, and low emissions. They also provide enormous fuel flexibility. Their top-supported, gas-tight, all-welded membrane walls eliminate hot expansion joints and reduce refractory use by up to 75% compared to cyclone designs. Additionally, vertical membraned tube panels perform evaporative or superheat duties within the furnace, further ensuring greater reliability and reduced maintenance.

Technical Data

  • Product capacity / performance range –

    • Capacity: Up to 1000 TPH

    • Pressure: Up to 200 kg/cm2 (g)

    • Temperature: Up to 565°C

  • Fuel type or energy sources – 
    Biomass, refuse-derived fuel (RDF), mill rejects, washery rejects, sludge, oil pitches, agro-wastes, char, fly ash, high-ash coal, high-sulphur coal, low-ash coal, high-moisture coal, lignite, petroleum coke, etc.

  • Compliance or standards followed – ASME / IBR / TRCU / PED 

  • Design – 

    • Field-erected configuration

    • Bottom-ash cooler (wet and dry)

    • No rotating parts

    • Two-stage separation for better bed inventory control

    • Impact separation with ‘U-beam’ particle separators

    • No soot blowers required

  • Flexibility or customisation options – The product can be customised based on customer needs or scale

  • Other technical information -

    • Automatic carbon monoxide purging logic for added safety

    • Maintenance-free recycle system

  • Variants available -
    Can be offered as:

    • Boiler island
    • Boiler-turbine-generator (BTG) package
    • Turnkey power plant (EPC)


B&W
Manufactured under License from Babcock & Wilcox, USA

Product features

Multi-fuel compatibility
Supports a wide range of fuels, including high-ash coal, high-sulphur coal, lignite, petcoke, industrial wastes, biomass, etc., for operational flexibility
Excellent efficiency
91% on NCV
Compact and economical construction
A U-beam particle separator is strategically located at the furnace exit, unlike hot cyclone-type CFBC, resulting in significantly lower furnace exit gas velocity and requiring less building volume, optimising overall footprint and efficiency
Two stage separation for better bed inventory control
Ensures greater than 99.8% particle collection efficiency, improved carbon burnout, and better heat transfer, while reducing operating costs and enabling multi-fuel firing in a single unit for exceptional fuel flexibility
Internal primary solids recirculation with ‘U-beam’ particle separators
The compact U-beam separator at the furnace exit uses gravity-assisted recycle to recirculate suspended solids to the lower furnace, eliminating additional rotating equipment and reducing pressure drop to enhance efficiency and reliability
Best-in-class compliance with environmental norms
Our IR-CFBC boilers control SO2 through limestone injection, while low and uniform furnace temperatures combined with staged combustion inherently reduce NOx, with further reduction achieved using a selective non-catalytic reduction (SNCR) system
Optimised refractory for improved availability
Eliminating hot cyclones and return legs allows for minimal, thin, cooled refractory, enabling quick load response and faster start-ups while reducing maintenance needs and virtually eliminating forced outages due to refractory failure, enhancing overall boiler availability and reliability
No interface erosion
Our patented reduced diameter zone (RDZ) tube section eliminates localised erosion at the refractory interface in the lower furnace, preventing solids accumulation and significantly reducing maintenance
Low, uniform velocities at the furnace exit
Features low velocity particle separation, significantly reducing erosion in the upper furnace and superheater
High turndown (up to 4:1) without auxiliary fuel support
Exceptional 4:1 turndown capability, eliminating auxiliary fuel needs and enabling wider, cost-effective load swings
No soot blowers are required
Eliminates steam consumption, maintenance costs and forced outages typically associated with soot blowers
Gravity fuel feed and fly ash recycle system
Reduces maintenance, forced outages and auxiliary power requirements by eliminating the mechanical fuel injection
91% on NCV Up to 565°C Up to 200 kg/cm²(g)
Subscribe to 91% on NCV

Registered Office Address

D-13, MIDC Industrial Area,
R. D. Aga Road, Chinchwad,
Pune 411019, Maharashtra, India

Corporate Office Address

Thermax Limited
Thermax House,
14 Mumbai-Pune Road, Wakdewadi,
Pune 411003, Maharashtra, India

Corporate Identity Number

L29299PN1980PLC022787

Toll Free Number

1800-209-0115

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