R-BSG : 2 24 th September, 2011

M/s. Bindal Papers Ltd.,

8th K.M. Bhopa Road,
MUZAFARNAGAR – 251 001.
U.P.
Ph. No.0131-2468381 / 82
E-mail : technical@bindalpapers.com /
recovery.plant@bindalpapers.com /
v.vinay_garg@rediffmail.com

Kind Attn. Mr. Vinay Garg,

General Manager – Recovery

Dear Sirs,
OFFER FOR 300 TPD CHEMICAL
RECOVERY BOILER

We thank you for your enquiry for above and take pleasure in enclosing our offer.
We trust you will find our offer acceptable and we look forward to receive your
valued order.

Should you however need clarification on our offer kindly inform.

With regards,

Yours faithfully,
For Pressels Pvt. Limited.
Encl : As above.

( S. C. MULLICK )

scm/bsevp/pkb.
ENCLOSURE TO OUR LETTER NO. R-BSG : 2 DT. 24.09.2011

M/S. BINDAL PAPERS LTD.,

8TH K.M. BHOPA ROAD,
MUZAFARNAGAR – 251 001.

OFFER FOR CHEMICAL RECOVERY BOILER

Capacity - Solid Firing Capacity 300 TPD

Raw Material for Pulp - Bagasse.

Wheat Straw for 3 months.

Desired Steam Condition at S.H. Outlet

Pressure - 65 bar (g)
Temperature - 460oC. + 10oC.

We have assumed that black liquor will be available to us at 48% concentration.

We have based our calculation on following elemental analysis of Black Liquor
Solids provided by you.

Parameters Value
Carbon as C % w/w 40.47
Hydrogen as H % w/w 4.36
Nitrogen as N % w/w Nil
Sulphur as S % w/w 0.20
Sodium as Na % w/w 15.4
Potassium as K % w/w 1.10
Calcium as Ca % w/w 0.06
Chloride as NaCl % w/w 0.87
Silica as SiO2 % w/w 2.48
Gross Calorific Value Cals/gm 3020
Contd…..P/2-
 : 2 :

Viscosity, mpasec % Total Solids/Temp 90oC. 100oC

40 28 25
50 158 118
60 794 490

The main blocks of equipments in our scope is illustrated in the Enclosed Drg. No.
PID - 132 .

RECOVERY BOILER

The recovery boiler is of tower type construction with membrane water wall
furnace and single drum design. The entire pressure parts are suspended from
the top and free to expand down ward. The preliminary drawing of the boiler no.
CD- 65.2 is enclosed.

We would like to point out that there are two advantageous features in our design
which is not found in contemporary makes.

The first is the special arrangement of top steam collecting headers. This being a
very tall furnace the natural circulation ratio is high. In contemporary designs the
drum is a part of the circulation circuit as all riser headers open into drum. In our
design most of the circulating mass is made to by pass the drum & returns directly
to the bottom water distribution system. This ensures a better separation of
moisture from steam and eliminates surging in the drum level when sudden load
change occurs.
Contd……P/3-
 : 3 :

The second aspect is that all tubes in the boiler bank and economizer are bent at
the lower end and the bottom headers are inclined which helps in self cleaning of
chemical ash. Ash accumulation is a major operational restraint in chemical
recovery boiler operation.

We have observed that with wheat straw pulping due to higher percentage of
chlorides and contaminated silica ( due to non proper washing ) hard deposits take
place at places even with less than 500 oC. flue gas temperature. Therefore in our
improved design we have introduced a cooling chamber without tube bundles to
cool the gas to below 500 oC. Further to increase availability we have now
provided wider spacing of boiler bank tubes to increase the interval for cleaning.

In our improved design we have provided sliding supports for 2 nd stage super
heater panels from water cooled screen tubes to eliminates serpentine bending of
super heater coils, a common phenomena in recovery boilers.

With our long experience in this field we are confident to supply you a good
recovery boiler.

Contd……P/4-
 : 4 :

TECHNICAL DATA ON THE BOILER

Furnace Cross Section - 4136 mm x 4294 mm.

Ht. of Furnace above hearth

at the front - 28 M

Heating Surface
Radiant Furnace, Water Wall
and Boiler Bank - 1575 M2

Economiser - 465 M2

Super Heater (Stage – 1) - 270 M2

Super Heater (Stage – 2) - 220 M2

Estimated Steam Generation - 30 TPH with Bagasse.

26 TPH with Wheat Straw.

MATERIAL OF CONSTRUCTION FOR PRESSURE PART

Furnace Wall Tube - 63.5 mm OD x 6 mm Thick.

Boiler Bank Tube - 63.5 mm OD x 4.06 mm Thick.

Screen Tube - 63.5 mm OD x 6mm Thick.

Economiser Tube - 38.1 mm OD x 4.06 mm Thick.

Specification of above tubes - BS : 3059 Part. II Gr.360 Seamless.

Super Heater (Stage – 1) - 44.5 mm OD x 4.5 mm Thick

Specification - SA 213 T.11
Contd……P/5-
 : 5 :

Super Heater (Stage – 2) - 44.45 mm OD x 5 mm Thick

Specification - SA 213 T.22

Header - All headers except Super Heater

ASTM-A-106 Gr.B

Super Heater Header - SA 335 P.11 & P.22

CONSTRUCTIONAL FEATURE

Furnace Wall Tube - Fin Welded Membrane Wall.

Pitch of Tube - 94 mm
Fin Width - 30 mm

Super Heater 1st Stage - Vertical Pendant in Panels.

Side Spacing of Panel – 376 mm
(Across Gas Flow)

2nd Stage - Vertical Pendant in Panels.

Side Spacing of Panel – 658 mm
(Across Gas Flow)

Desuperheater control is with inter stage attemperation.

Boiler Bank
Arranged in vertical panels with tubes bent at the bottom.

Economiser
Construction is similar to boiler bank.

AIR SUPPLY AND FLUE GAS DISCHARGE

These equipments are required for normal operation of the recovery boiler. Air for
combustion is supplied at three levels with different pressures and temperatures.

Air is entered through air ports and these air ports are sturdy and individual
dampers will be provided for each port for the better char bed control.

Primary is supplied at the lowest level just above the hearth and is heated to about
2000C.
Contd…..P/6-
 : 6 :

The secondary air is admitted into the furnace at 150 0C. near about liquor
injection level.

Tertiary air is supplied at ambient temperature at a higher level.

Primary Air Fan 62,000 NM3/hr.

at 200 mm of WG and 2000C.
Drive is from a 90 KW Motor.
Control is from VFD.

Secondary Air Fan 54,000 NM3/hr.

at 300 mm of WG and 1500C.
Drive is from a 90 KW Motor.
Control is from VFD.

Tertiary Air Fan 8,000 NM3/hr.

at 650 mm of WG and ambient temp.
Drive is from a 30 KW Motor.
Control from electrically actuated inlet damper.

I.D. Fan at 2,20,000 M3/hr. at 1600C.

Drive from 200 KW motor at 900 RPM
Control - VFD.

FEED WATER TREATMENT & FEEDING

Deaerator with level and temperature control.

Capacity - 30 M3/hr.
Temperature - 1200C.
Deaerator max. O2 Outlet - 0.002 ppm
Contd……P/7-
 : 7 :

Chemical Dosing L.P & H.P Dosing system.

Feed Pump 2 nos. - One working and one stand by

Capacity - 40 M3/hr. at 900 M head.
Temp. - 1200C.
The pumps are to be provided with VFD or soft start.

AIR PREHEATER

Primary air is preheated to 200oC. by a finned tube steam heater. The heating
medium steam is supplied at LP, MP & HP pressures. The HP Steam is at 35
Kg/Cm2 and is made available through a Pressure Reducing & Desuper Heating
Station from saturated steam from drum.

The secondary air is preheated to 150oC. with MP steam supply.

The condensate discharge is connected to a common flash steam recovery

system provided by us.

CLEANING FACILITIES

Adequate sight holes and access doors will be provided for inspection and
cleaning of various pressure parts. To clean the tube surfaces during operation,
adequate steam operated soot blowers will be provided. The soot blowers will be
sequentially operated. For starting the cycle, all the operator has to do, is to press
a start switch on the control panel which will actuate the following sequence. The
motorized valve will open establishing steam supply to soot blowing piping system
through a pressure reducing and desuper heating station. Simultaneously the
Contd…..P/8-
 : 8 :

drain valve at the lowest location of the piping system will open to allow for
condensate discharge and warning up of the steam line. After a predetermined
time soot blower will start operating in same sequence as the flue gas flow till the
completion of the cycle of the last blower, after which the motorized valve will
close. It will also be possible to by pass any location or locations. The soot
blower pressure will be 20 Kg/Cm2 and temperature 350oC.

STRUCTURALS, PLATFORMS AND STAIRS

The entire pressure part assembly will be top supported. The support structurals
will be liberally designed. The installation will be outdoor type with a canopy on
the roof. The structurals for support of platform and roof will be integrated with
boiler support structures. There will be two stair cases, one in the front reaching
up to top of the boiler and one at the rear upto liquor firing floor. In addition
provision will be kept in the layout for a lift upto boiler top. The working area
around all operational locations will be spacious.

INTEGRAL PIPING
Integral piping of the boiler between economizer and drum, drum and super
heater, extended super heater outlet header, continuous and intermittent blow
down lines upto blow tanks, blow tanks, vents upto roof level will be provided.

SAMPLING FACILITY
Sampling facility with sample coolers will be provided for feed water, super heated
steam, saturated steam and blow down water. There will be individual sample
coolers for each of the above applications with associated sampling lines, valves,
cooling water connections, drain piping etc. etc.
Contd…..P/9-

: 9 :
VALVES

Safety Valves
There will be two safety valves on drum and two on super heater outlet header.
The safety valves will be spring loaded full lift type. The exhaust pipe from the
safety valve shall terminate at a safe height above boiler roof.

Main Steam Stop Valves

Will be motorized and will have bypass arrangement for start up and fitted with
indicators, so that percentage of valve opening can be seen.

Start Up Valves
There will be one motorized start up valve and silencer will be fitted.

Direct Reading Water Gauge Glass

There will be 2 units connected to the drum on each end with isolating valves.

Other valves as required will be provided.

INSULATION
All parts of the boiler with hot surface exposed to atmosphere will be suitably
insulated with high grade mineral wool and will be cladded with aluminum sheets.

As this activity is in site after erection - excluded from our scope.

REFRACTORY
The use of refractory will be minimum as boiler walls are of membrane
construction. The hearth will be lined with 200 mm thick Basic Chrome Ore
Castable.

As this activity is in site after erection - excluded from our scope.

Contd……P/10-

: 10 :
DUCTING FOR AIR AND FLUE GAS

All air ducts will be made from 3.15 mm thick. M.S. Sheets and all flue gas ducts
from 5 mm M.S. Plates. Required expansion below as required will be provided.
Necessary regulating and isolating dampers at suitable points will be provided.

INSTRUMENT & CONTROLS

Control and monitoring instruments are required for proper operation of the boiler.
These will mainly consist of the following ;

- Drum level control.

- Steam temperature control.
- Feed water control.
- Level control for MDT and cascade evaporators.
- Density control of MDT.
- Pressure Regulators for B/L and Oil.
- Black Liquor Flow.
- Temperature, Pressure & Draft Gauges, Steam, Water, Air, Black Liquor
and Flue Gas.

BLACK LIQUOR HANDLING

Black liquor at 48% solids will be received in two cascade evaporators where the
combustion will be increased to 60%.

The concentrated black liquor will be taken to FLT fitted with steam jacketing and
agitator.
Contd…..P/11-

: 11 :
The firing black liquor will be heated to about 120 oC. in two stages. The first stage
will be by indirect heaters in which the temperature will be raised to about 115 oC.
The indirect heaters will be of shell and tube design with L.P. Steam and heating
media. There will be 3 heater bodies – two in operation in parallel and the 3 rd for
cleaning mode. We will provide a dedicated cleaning arrangement for indirect
heater and the black liquor piping from FLT to heater. In this arrangement there
will be storage tank for weak wash and a pump. In the cleaning mode weak wash
will be a circulated in the heater body or the pipe line until the inside surfaces are
clean. The contaminated weak wash after use will be discharged to dump tank.

There will be 4 liquor firing nozzles, two each on front and rear walls. The spray
guns will be of fixed nozzle design. There will be a ring header from which liquor
will be supplied to individually spray guns. The excess quantity will flow back to
the FLT. A control valve located on the return line will ensure the desired firing
pressure.

Black Liquor handling equipments like pumps and indirect heater needs regular
draining and cleaning. We have installed these equipments at an elevation so that
the wash can be discharged into the dump tank on ground floor. This will facilitate
to keep the working place clean.

SMELT AND GREEN LIQUOR

There will be two spouts for discharge of smelt into the main dissolving tank
(MDT). The MDT will be approximately 4 M dia and 3 M height with two side
agitators and two vents. The vents will be taken beyond roof and fitted with
demisters to arrest fumes. A booster pump will be provided to wash and clean the
demister pads periodically with weak wash.
Contd…..P/12-

: 12 :
There will be two transfer pumps and two circulating pumps – one working and
other standby. Instruments will be provided for level and density center in the
MDT. Two agitator will be provided for mixing.

Spout cooling will be done with DM water with arrangement for temp controls.

CHEMICAL ASH COLLECTION

There will be two ash hoppers in the boiler. Ash from the hopper will be carried by
screw conveyor and rotary air lock valve below the hoppers. The ash from the
conveyors will be discharged to MDT.

AUXILIARY OIL FIRING SYSTEM

For start up and to meet unstable furnace condition auxiliary oil firing equipment
will be provided. The system will consists of oil day tank of 5 M 3 capacity, duplex
oil pumping and heating, oil pressure control, oil ring main, oil firing nozzles.
There will be four oil firing guns located two on each side walls.

FLASH STEAM AND CONDENSATE RECOVERY

An appreciable quantity of steam is used at different pressure in heating air and

black liquor in the recovery boiler system. We will provide the equipments to
recover flash steam for higher pressure condensate for use as heating source at
lower pressure application and recover all uncontaminated condensate.

Contd…..P/13-

: 13 :
THE DETAILED LIST OF OUR SCOPE OF SUPPLY IS GIVEN BELOW.

- Boiler Pressure Parts with Valves & Mountings.

- 2 Nos. Cascade evaporator .
- B/L indirect heaters.
- B/L direct heater.
- B/L spray system.
- Spout and spout cooling systems.
- Ash collection & disposal.
- Auxiliary oil firing system.
- Soot Blowers – 18 nos. with PRDS Sequencer, Valves, Air sealing
arrangement, piping etc.

- Main dissolving tank, Agitator, Vent, Demister & Boosting Pumps.

- Dump Tank.
- Firing liquor tank with agitator.
- B/L Pumps.
- B/L Valves.
- Primary, Secondary, Tertiary Fans, With Drive & VFD.
- I.D. Fan with Driove & VFD.
- Primary & Secondry Air Preheater.
- Instruments (Field Instruments only)
- Chemical Dozing.
- Condensate & Flash steam Recovery.
- IBD & CBD Valves.
- Misc. pipes for B/L & Steam.
- Structurals.
- Platform Gratings,
Contd…..P/14-

: 14 :
- Ductings, Casing etc.
- Vents & MDT Chimney.
- Painting (Factory only).

EXCLUSIONS
The offer does not include the following:-
- All civil works, grouting of equipments, roof and canopy of boiler structure.
- DM boiler feed water.
- Black liquor at 48% concentration and with adequate free alkali. (Min. in
Weak Black Liquor).
- Deaerator.
- Feed Pumps.
- Insulation.
- Refractory.
- L.P. Steam supply at 3 kg.
M.P. Steam supply at 9 kg.
- Compressed air for instrument and sealing of soot blower openings.
- Supply of WWL, WBL, Hot Water, Cooling Water in the boiler house.
- MCC and electrical wiring and connections.
- In case of PLC control all wiring beyond instrument junction box in the boiler
house.
- Chemical for boiling out.
- ESP
- Chimney.
- Ducting from cascade to ESP and from ESP to chimney – cascade and ESP
by pass ducts with DTPA Valves.

Contd…..P/15-

: 15 :
POINTS OF TERMINATION

Steam - at 5 m from the outlet header, stop valves.

Flue Gas - at outlet of cascade.
Green liquor - at outlet of transfer pumps.
48% black liquor - at inlet to cascades.
Electricals - at motor, terminal boxes.
L.P. & M.P Steam,
Cooling Water,
Compressed air - at one point in boiler house.
Weak wash

PRICE
Ex-our works and exclusive of all duties and taxes. - Rs.14,10,00,000.00
( Rupees Fourteen Crore Ten Lacs only )

DUTIES & TAXES

The above prices are ex-works and exclusive of excise duties and VAT (CST)
which will be extra at the rates prevalent at the time of delivery.

PACKING & FORWARDING

1 ½% of cost of equipment

All the equipments will be transported by truck and trailers which you will arrange
at your cost.

PAYMENTS
20% with order.
25% on submission of load data, GA drawings.
45% against Proforma invoice on readiness of material on pro rata basis
plus full taxes and duties.
10% on complete of last dispatch along with a B/G for 10% of cost of material
and performance valid for 18 months from date of last dispatch or 12
months from date of commissioning whichever is earlier.
Contd…..P/16-

: 16 :
ERECTION OF THE BOILER AT SITE
You may arrange for erection of the equipment at site. If desired we will provide
technical assistance. Our charges will be as below.

For Engineer in Charge - Rs. 3,000.00 per day.

For Erection Engineers - Rs.15,000.00 per day.
For Instrument Engineers - Rs. 5,000.00 per day.
For Commissioning Engineer - Rs. 5,000.00 per day.
Plus all expenses in lodging & boarding at your site.

DELIVERY
To be completed within 20 months from the date of your commercially and
technically clear order.

VALIDITY - 30 days.

FOR PRESSELS PVT. LTD.

Encl : As above Drg.

( S. C. MULLICK )

scm/pkb.