BOILERS DIVISION
CATALOG CONTENTS
2
1. GROUP............................................................................................. 4 2. About the company .................................................................... 6 3. Innovative production................................................................. 8 4. Quality standards........................................................................12 5. Production program...................................................................16 6. Fire-tube hot water boilers.......................................................18 6.1 Two-pass fire-tube hot water boilers, Duotherm series.................................................................. 20 6.1 Three-pass fire-tube hot water boilers, Unitherm series.................................................................... 26 7. Water-tube gas and oil fired hot water boilers..................30 7.1 Eurotherm series...................................................................32 7.2 Novotherm series................................................................40 7.3 Megatherm series................................................................46 8. Fire-tube steam boilers............................................................50 8.1 Two-pass fire-tube steam boilers, Vapotherm series .................................................................52 8.2 Three-pass fire-tube steam boilers, VTF series..........56 9. Project geography and production growth.......................63
3
GROUP
4
HIGH TECHNOLOGY FOR INNOVATIVE SOLUTIONS Polyimpex is a Swiss distributor of European heavy industrial equipment, such as industrial steam boilers, bioenergy boilers, burners and power generation engines and is one of the largest systems integrators in worldwide markets in heat and power engineering. OUR PARTNERS ARE WORLDWIDE LEADERS IN THE FIELD OF ENGINEERING AND CONSTRUCTION OF POWER FACILITIES. Weather your plant needs steam, hot or superheated water, power, you must rely on a competent and experienced partner. At Polyimpex our engineers will take care of your needs and study for you the best solution. Fast delivery, large amounts of products in stock, attractive prices, and quality control at every manufacturing step make our products highly competitive and suitable for world market for power systems.
4 MAIN DIRECTIONS COMBUSTION DIVISION Supplies burners for domestic use and for all industrial applications operated on traditional fuels, liquefied natural gas, biogas, diesel, oil and crude oil, as well as coal and wood dust
POWER GENERATION DIVISION OFFERS COMPLETE RANGE OF POWER GENERATION SOLUTIONS FOR ALL TYPES OF FUEL. In the world market of energy, we act as the Energy System Integrator and offer a broad choice of equipment and integrated turnkey solutions Our equipment includes gas and dual-fuel turbines, dual-piston biogas installations, CHP & CCHP plants, thermal turbines based on ORC, cogeneration & trigeneration plants, energy systems, waste hear recovery boilers.
BOILERS DIVISION Supplies boilers for all applications, namely: our range of power for hot water boilers is from 150 kW to 140 MW, for steam boilers - up to 50,000 kg/h, for the biomass boilers - up to 6 MW, for domestic wall hung gas boilers - from 24 kW to 36 kW.
BIOENERGY DIVISION Offers effective solutions in biomass field, such as agriculture, wood processing and forest industry to generate steam, hot water and electricity.
5
ABOUT BOILERS DIVISION POLYKRAFT GmbH (Austria) is an industrial energy holding that works in the field of investment in international manufacturing and design projects for thermal energy conservation equipment, and is opening a new era in the heat and power industry. • Today, POLYKRAFT is a successful, innovative manufacturer with developed infrastructure and highly skilled employees, and a powerful industrial cluster in Russia. • Modern energy-efficient and flexible solutions, and the high quality and reliability of products are the result of development and implementation of new methods for obtaining efficient energy, integration of innovative industrial technologies, and development of infrastructure. • POLYKRAFT industrial energy holding has its own innovative technological clusters within the territory of Russia and Europe, which include modern high-tech production lines. In 2013, on the basis of the first enterprise for manufacturing licensed European industrial boiler equipment in the territory of Russia, OJSC "WOLF Energy Solution" (Russia), a broad scientific and manufacturing infrastructure is being created. 350 highly skilled specialists 25 design engineers are involved in the development of advanced boiler models 17,000 sq.m. of production area • 2008 – the year of foundation of high-tech production in Russia • Location: Safonovo, Smolensk region, Russian Federation • Quality management system ISO 2001:2008 • TUV Certificate
6
7
INNOVATIVE PRODUCTION 8
“POLYKRAFT” industrial cluster is an advanced scientific and manufacturing infrastructure which includes the highest state-of-the-art equipment of the world's leading manufacturers:. • C LOOS Portal Robotic Welders (Germany) for welding of firetube boilers. Robotic welding allows a considerable increase in quality and productivity. • M ulticam plasma arc cutting unit (USA). The precision and high-quality of plasma arc cutting eliminate mechanical processing of parts and reduce the manufacturing cycle in general. • C LOOS robotic unit for 3D plasma arc cutting and welding of manifolds materially improves both the efficiency of furnace tube orifice preparation operations and quality of the “manifold-bottom” welding joints. • K UKA robotic welding of gas-proof panels (Germany). Robotic welding provides a significant increase in welding rate and quality, and decreases panel post-processing time due to heat input reduction during the welding process. • E rcolina automatic tube bender (Italy), which allows a fully automated bending cycle with adjustable bending parameters according to the mechanical properties of the material. • C ertified welding equipment by the world's leading manufacturers: Esab, Kemmpi, Cloos, and Lincoln Electric. • A Rosler through-type shot-blast unit (Germany) for processing the flat and tubular steel products allows the overall time for welding joint preparation (deseaming) to be reduced and the quality of welding works to be improved. • 4 -roller bending rolls with an NC controller that allows processing of sheet material up to 35 mm thick. • E SAB unit for automatic welding under a layer of flux (Sweden). Making the critical circular welds for firetube and steam boilers. • C LOOS tandem welding unit for making longitudinal boiler shell welds (Germany). Gas-shielded tandem welding extends the production capabilities of the plant. The welding rate and quality are consistent with those of flux welding, but the cost per weld running meter is smaller. • The plant's load handling equipment allows work with loads up to 100 tons.
9
1
2
3
4
5
1, 2. Water-tube boiler production units 3, 5. Section for assembling and coating of finished products 4.
Fire-tube boiler production area.
10
7
6
8
9
10
5.
Rosier shot-blast unit (Germany)
7.
Multicam plasma arc cutting unit (USA)
8.
4-roller bending rolls with an NC controller that allow processing of sheet material up to 35 mm thick.
9.
CLOOS robotic welding of fire-tube boilers (Germany)
10.
ESAB unit for automatic welding under a layer of flux (Sweden).
11
QUALITY STANDARDS
12
Non-destructive testing service is equipped with the most state-of-the-art equipment for a thorough testing and quality control of weld seams on the product and carries out strict control of finished products shipped to customers, as well as of all incoming to the plant materials and components. Polykraft trademark on the company’s products is the warrantor of impeccable quality and reliability. The company’s products have exceptional reputation not only in Europe and CIS but also in the whole territory of the Russian Federation. The products supplied are all accompanied by CE, TUV and GOST certificates. The company management actively implements quality assurance policies such as production line modernization, introduction of new energy saving technologies, strict observance of technological discipline, selection of reliable suppliers of the best raw materials and available components, reducing production costs and the environmental footprint, and promoting professionalism. The policies are supported by the quality management system in place which is ISO 9001:2008 compliant.
13
1
2
3
4
5
1.
CLOOS robotic unit for 3D plasma arc cutting and welding of manifolds (Germany)
2.
The precision and high quality of plasma arc cutting eliminate mechanical processing of parts
3.
KUKA robotic welding of gas-proof panels (Germany)
4.
Thorough testing and quality control of finished products shipped to customers
5.
The highest quality weld seams of products6. 14
6
7
8
9
6.
10
Multicam plasma arc cutting unit (USA)
7, 8. Thorough testing and quality control of finished products shipped to customers 9.
Precision and high-quality of plasma arc cutting eliminate mechanical processing of parts
10. Certified equipment used to perform pressure testing
15
PRODUCTION PROGRAM FOR THE MANUFACTURING OF THE INDUSTRIAL BOILERS EQUIPMENT 16
THE BOILER EQUIPMENT OF VARIOUS TYPES AND MODELS WITH THE WIDE RANGE OF POWER IS BEING PRODUCED UNDER THE TRADEMARK POLYKRAFT FOR THE MARKETS OF RUSSIA, CIS AND EUROPE:
FIRE-TUBE STEAM BOILERS VAPOTHERM 500-5000 kg of steam/h VTF 5000-25000 kg of steam/h
WATER-TUBE GAS AND OIL FIRED HOT WATER BOILERS EUROTHERM 1,1 – 5,8 MW MEGATHERM 35 – 140 MW NOVOTHERM 35 – 140 MW
WATER-HEATING FIRE-TUBE BOILERS DUOTHERM 150 – 6000 kW UNITHERM 1000 – 20 000 kW
17
FIRE-TUBE HOT WATER BOILERS
18
POLYKRAFT FIRE-TUBE HOT WATER BOILERS
Two-pass fire-tube hot water Polykraft boilers, Duotherm series DUOTHERM 150 – 6000 kW
Three-pass fire-tube hot water Polykraft boilers, Unitherm series UNITHERM 1000 – 20 000 kW
19
TWO-PASS FIRE-TUBE HOT WATER POLYKRAFT BOILERS, DUOTHERM SERIES
POWER 150–6,000 kW • • • • •
18 standard sizes Operates on natural gas or light fuel oil GOST R certified Intended service life of at least 25 years 2 year warranty 20
FEATURES • B oilers are ultimately tailored for the Russian market. • C onvenient model series for application in block-module boiler houses. • Modern appealing design. • C ompact dimensions and weight for allocating in industrial and block-module boiler houses. • S ymmetrical structure for optimal distribution of thermal stress. • H eating surfaces are made of smoothwalled pipes in order to decrease the possibility of their contamination. • O perating overpressure is up to 6 bar. • The reversed chamber can be opened either to the left or to the right for convenient cleaning and servicing of the boiler.
STRUCTURE AND FUNCTION One special structural feature is a firetube with reverse flow of combustion products. The firetube is centrally located. In order to intensify heat-exchange processes, turbulence stimulators are inserted into the flue tubes. • I n the front part of the boiler there is an opening uncooled reversed chamber (front cover), onto which a burner device is mounted. • T he boiler structure provides the required resistance for any possible "bursts," which eliminates the need for the installation of explosion safety valves. • I n the back of the boiler there is a detachable gas duct cap necessary for boiler maintenance and servicing. • I n the cap there is a door for draining combustion products from the gas duct.
21
DUOTHERM BASIC SPECIFICATIONS AND DIMENSIONS 22
DUOTHERM
BASIC SPECIFICATIONS AND DIMENSIONS 115째C kW Rated power
150 200 250 300 350 430 500 750 1000 1500 2000 2500 3000 4500 5200 6000
kcal/ 129 h
172
215
260 300 370 430 645 860 1290 1720 2150 2500 3870 4470 5160
Weight
kg
960 975 990 1200 1280 1340 1370 1950 2150 2955 4100 6150 7685 9210 11400 11800
Efficiency factor gas / light oil
%
92/91
Water volume
l
Water supply and drainage, PN6 Safety valve connections, PN16
330 320
310
550
510
490 460
910
850 1490 2000 2190 4270 5410 7400 6500
DN
65
65
65
80
80
80
80
125
125
125
150
150
150 200 250 250
DN
50
50
50
50
50
50
50
50
65
65
80
80
80
Boiler condensate drain, inch male thread
1/2
3/4
Drain connection, male inch thread
1/2
100
125
100
3/4
1 1/4
L (length)
mm 2303 2303 2303 2370 2405 2468 2468 3120 3120 3085 3720 4175 4515 5195 5653 5825
B (width)
mm 950 950 950 1047 1082 1050 1097 1260 1260 1526 1690 1642 1927 2117 2192 2192
H (height)
mm 1125 1125 1125 1225 1225 1280 1340 1475 1475 1027 1940 1940 2225 2375 2467 2450
L1
mm 1608 1600 1688 1756 1793 1650 1653 2500 2500 2480 3010 3450 3775 4425 4052 5025
B1
mm 800 800 800 900 950 900 1000 1100 1100 1300 1450 1485 1770 1920 1995 1995
H1
mm 10B6 10B6 1086 1185 1268 1240 1300 1390 1390 1767 1855 1855 2140 2290 2365 2450
23
DUOTHERM
150; 200; 250; 300; 350; 400; 500; 750; 1,000; 1,500; 2,000; 2,500; 3,000; 4,500; 5,200; 6,000 KW General boiler view Top view
7
6
7
L
H1
Rear view
4
5
9
24
.
- Water drainage
.
- Water supply
.
- Safety valve pipe
.
- Condensate drain connection
.
- Blow-off and drain pipe
.
- Inspection and heating surface cleaning door
.
- Pressure gauge connection
.
- Thermometer connection
.
- Door for cleaning the gas duct chamber
DUOTHERM
150; 200; 250; 300; 350; 400; 500; 750; 1,000; 1,500; 2,000; 2,500; 3,000; 4,500; 5,200; 6,000 KW General boiler view
H
Frontal view
B1 B
Right-side view
8
2
3
1 8
L1 L
25
THREE-PASS FIRE-TUBE HOT WATER POLYKRAFT BOILERS, UNITHERM SERIES
POWER 1,000–20,000 kW • • • • •
17 standard sizes Operates on natural gas or fuel oil GOST R certified Intended service life of at least 25 years 2 year warranty 26
FEATURES • The boilers are ultimately tailored for the Russian market. • Convenient model series for application in boiler houses. • Symmetrical structure with the firetube offset to the bottom. • Heating surfaces are made of smoothwalled pipes in order to decrease the possibility of their contamination. • The temperature chart for the heat-carrying agent is 115–70° C, 150–70° C. • Efficiency factor of at least 92% • Operating overpressure is up to 12 bar.
STRUCTURE AND FUNCTION One special structural feature of the boiler is a three pass combustion products flow scheme. The firetube is offset to the bottom. In order to intensify heat exchange processes, turbulence stimulators are inserted into the flue tubes. • In the front part of the boiler there is an opening uncooled reversed chamber (front cover), onto which a burner device is mounted. • The boiler structure provides the required resistance for any possible "bursts," which eliminates the need for the installation of explosion safety valves. • In the back of the boiler is a detachable gas duct cap necessary for boiler maintenance and servicing. • In the cap is a door for draining combustion products from the gas duct.
27
UNITHERM
150; 200; 250; 300; 350; 400; 500; 750; 1,000; 1,500; 2,000; 2,500; 3,000; 4,500; 5,200; 6,000 KW Basic Specifications and Dimensions Rated Power
Model
kW
Rated water temperature
at inlet °C
at outlet °C
Gas Rated Total exhaust water water duct repressure volume sistance
at chart 70115 (150)°C Mpa
Boiler efficiency
at chart 70-115°C, not less m
3
at chart 70-150°C, not less
Water flow
Fuel flow
at chart 70-115°C, not less
at chart 70-150°C, not less
mbar Gas, Light Gas, Light Gas, oil, oil, 3 3 m3/h kg/h m /h kg/h m /h
Light oil, kg/h
Gas, m3/h
Light oil, kg/h
Dimensions
at chart 70-115 (150)°C Mpa
H, mm
B, mm
ØD gas duct, mm
L, mm
1000
1000
70
115(150) 0,6(1,2)
3,1
5,2
108,4
92,8
109,6
93,8
19,1(10,8)
1750 2700 1450
300
1250
1250
70
115(150) 0,6(1,2)
3,0
5,6
135,5
116,0
137,0
117,3
24,0(13,5)
1850 3300 1550
300
1500
1500
70
115(150) 0,6(1,2)
3,7
5,8
162,6
139,2
164,4
140,8
28,7(16,2)
2000 3700 1700
320
2000
2000
70
115(150) 0,6(1,2)
4,8
6,5
216,8
185,6
219,2
187,8
38,2(21,)
2350 4050 2050
320
2500
2500
70
115(150) 0,6(1,2)
5,7
6,8
271,2
232,0 274,0 234,6
47,8(27,0)
2420 4180
2120
400
3500
3500
70
115(150) 0,6(1,2)
7,4
7,6
379,5 325,0 383,7 328,5
66,9(37,6)
2550 4830 2250
500
4000
4000
70
115(150) 0,6(1,2)
9,2
8,2
433,8
371,3
438,5 375,4
76,4(43,4)
2610 5070 2310
500
4500
4500
70
115(150) 0,6(1,2)
9,7
8,2
488,0
417,8
493,3 422,3
86,0(48,4)
2780 5920 2480
500
5000
5000
70
115(150) 0,6(1,2)
12,5
9,6
542,1
464,1
548,1
469,2
95,6(53,8)
2910 6450 2610
650
6000
6000
70
115(150) 0,6(1,2)
14,2
9,4
650,5 556,9
657,7
563,1
114,7(64,5)
3400 6805 2850
650
8000
8000
70
115(150) 0,6(1,2)
16,8
10,6
867,4
877,0
750,9 153,0(86,0) 3280 7120 2980
900
10 000
10 000
70
115(150) 0,6(1,2)
20,4
11,2
1084,2 928,2 1096,2 938,5
12 000
12 000
70
115(150) 0,6(1,2)
30,2
11,6
1301,1
15 000
15 000
70
115(150) 0,6(1,2)
34,8
17 500
17 500
70
115(150) 0,6(1,2)
70
115(150) 0,6(1,2)
92,0 91,0
200 000 200 000
91,0 90,0
742,5
191,1(107,5) 3520 7480 3220
900
1113,8 1315,4 1126,2 229,3(129,0) 3800 7905 3350
900
12,2
1626,4 1392,3 1644,2 1407,7 286,6(161,3) 3900 8240 3510
1100
37,8
12,8
1897,4 1624,3 1918,3 1642,4 334,4(188,1) 3970 8560 3670
1100
43,2
12,6
2168,5 1856,4 2192,3 1877,0 382,2(215,0) 4100 8905 3800
1100
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UNITHERM
150; 200; 250; 300; 350; 400; 500; 750; 1,000; 1,500; 2,000; 2,500; 3,000; 4,500; 5,200; 6,000 KW
H
General boiler view
B
L
29
WATER-TUBE GAS AND OIL FIRED HOT WATER BOILERS 30
POLYKRAFT WATER-TUBE GAS AND OIL FIRED HOT WATER BOILERS
Water-tube gas and oil fired hot water Polykraft boilers, Novotherm series NOVOTHERM 35–140 MW
Water-tube gas and oil fired hot water Polykraft boilers, Eurotherm series EUROTHERM 1.1–58.2 MW
Water-tube gas and oil fired hot water Polykraft boilers series MEGATHERM 35–140 MW
31
WATER-TUBE GAS AND OIL FIRED HOT WATER POLYKRAFT BOILERS, EUROTHERM SERIES POWER 1,1–58,2 MW • • • • • •
12 standard sizes Operate on natural gas or fuel oil GOST R certified RosTekhNadzor approved Intended service life of at least 25 years 2 year warranty
32
FEATURES • Boilers of this series are ultimately tailored to be used in Russian heat networks. • A broad product range allows us to offer customers appropriate equipment selection. • Ready for installation and assembly. • Possibility of highly efficient operation in networks with open draw-off. • Operating overpressure is up to 13 bar. • Heating surfaces are made of smooth-walled pipes in order to decrease the possibility of their contamination. • The temperature chart of the heat-carrying agent is 95– 70° C, 115–70° C, 150–70° C. • The efficiency factor is at least 92% • Low NOx level in flue gas. • Energy savings due to absence of smoke exhaust. • High maintainability.
STRUCTURE AND FUNCTION Eurotherm series include a boiler that is unique to the Russian market with 17,440 kW (15 Gcal) of power, which was included in the production program due to persistent recommendations from many heat network operating companies. • The broad range of boiler sizes in this series allows easy adaptation to customers' needs for boilers of any capacity. • Eurotherm boilers were initially designed for use with modern automatic burners. • Gas-tight construction provides for boiler operation under excessive pressure or vacuum, depending on the type of burner and boiler plant design. • The high flow rate of the heat-carrying agent in the boiler convection section makes these boilers indispensable for use in heat networks with an open water draw-off scheme. • In terms of their dimensions, Eurotherm series boilers are adjusted for installation in district and module boiler plants, as well as for reconstruction of facilities with previously installed boilers from other domestic manufacturers. • A self-supporting boiler, which has sliding bearings. The boiler's sliding bearings are mounted on a frame made of double t-iron. • In the cap is a door for draining combustion products from the gas duct.
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EUROTHERM BASIC SPECIFICATIONS AND DIMENSIONS 95째C Rated calorific value
MW
1,1
1,6
2,0
2,5
Range of adjustment of calorific value
%
30-100
30-100
30-100
30-100
Operating water pressure at boiler outlet
MPa
0,35
0,35
0,35
0,35
Rated pressure at boiler inlet
MPa
0,6
0,6
0,6
0,6
Test pressure
MPa
0,9
0,9
0,9
0,9
Rated water temperature at water inlet/outlet
째C
Rated fuel flow: natural gas
m3/h
116
170
137
265
Boiler efficiency factor, at minimum, using natural gas
%
93,0
93,0
93,0
93,0
Max rated air-flow resistance
Pa
190
Water flow
t/h
Rated water resistance, not more than
MPa
0,12
Boiler weight without water
kg
2900
3800
4300
5775
L (length)
mm
4030
4545
4750
5335
B (width)
mm
1230
1255
1230
1490
H (height)
mm
2095
2360
2610
3160
L1
mm
3800
4340
4500
5050
L2
mm
1967
2560
2870
3315
L3
mm
1056
2447
2760
3175
B1
mm
1160
1150
1160
1122
B2
mm
997
997
997
1022
B3
mm
81B
818
755
1022
H1
mm
2040
2144
2280
2845
H2
mm
1765
2020
1250
2845
H3
mm
965
1095
1222
1500
H4
mm
220
240
240
240
KV
DN (mm)
100
100
100
125
KR
DN (mm)
100
100
100
125
KK
DN (mm)
25
25
25
25
KE
DN (mm)
25
25
25
25
70/115
70/95
21
38
34
70/115
70/95
70/115
70/95
70/115
70/95
270
250
290
280
170
30
55
38
69
48
90
0,17
0,08
0,135
0,12
0,105
0,06
EUROTHERM BASIC SPECIFICATIONS AND DIMENSIONS 115째C Rated calorific value Rated pressure at boiler inlet Test pressure Rated water temperature at water inlet/outlet Rated fuel flow: - natural gas - light oil - heavy oil Boiler efficiency factor, at minimum - using natural gas - using light oil - using heavy oil Max rated air-flow resistance Water flow Rated water resistance, not more than Boiler weight without water Water volume of boiler L (length) B (width) H (height)
MW MPa MPa
3,15 1,6 2,0
4,65 1,6 2,0
7,65 1,6 2,0
11,65 1,6 2,0
17,44 1,5 2,0
23.26 1,6 2,0
35,00 1,6 2,0
째C
70/115
70/115
70/115
70/115
70/115
70/115
70/115
m3/h kg/h kg/h
336,8 282,5 326,0
495,5 414,0 474,0
797,0 667,0 772,0
1 229,0 1 093,0 1 196,0
1 041,5 1 546,0 1 734,0
2 432,0 2 078,0 2 350,0
3 657,0 3130,0 3 542,0
%
93 92 90 361 60,0 0,25 6 500 1,48 5 930 2 205 2 645
93 92 90 388 88,6 0,25 8 500 2,41 7 000 2 800 3 100
93 92 90 544 144,0 0,25 10 000 3,00 7 490 2 090 3 065
93 92 90 631 220,0 0,25 14 500 3,55 9 030 2 890 3 050
93 92 90 923 332,0 0,25 20 000 5,60 10 855 3 910 3 970
93 92 90 1150 440,0 0,25 27 000 6,02 11 370 3 910 5 005
93 92 90 1330 667,0 0.25 33 000 9,2 11 445 4 390 7 460
Pa t/h MPa kg m3 mm mm mm
150째C Rated calorific value Rated pressure at boiler inlet Test pressure
MW MPa MPa
3,15 1,6 2,0
4,65 1,6 2,0
7,65 1,6 2,0
11,65 1,6 2,0
17,44 1,6 2,0
23.26 1,6 2,0
35,00 1,6 2,0
58,2 1,6 2,0
Rated water temperature at water inlet/outlet
째C
70/150
70/150
70/150
70/150
70/150
70/150
70/150
70/150
m3/h kg/h kg/h
337,7 233,0 325,0
496,0 415,0 474,0
798,0 680,0 775,0
1 230,0 1 842,5 2 469,0 3 699,0 6 210,0 1 049,0 1 547,0 2 092,0 3 150,0 5 183,0 1 196,0 1 735,0 2 371,0 3 574,0 5 763,0
%
93 92 90 350 33,5 0,25 6 500 1,40 5 930 2 205 2 645
93 92 90 372 49,5 0,25 8 500 2,41 7 000 2 800 3 100
93 92 90 548 00,5 0,25 10 000 3,00 7510 2 090 3 400
93 93 93 93 93 92 92 92 92 92 90 90 90 90 90 676 870 1220 1410 1102 123,5 186,0 246,0 370,0 620 0,25 0,25 0,25 0,25 0,25 14 500 20 000 27 000 33 000 57 000 3,55 5,68 6,02 8,8 15,5 9 030 10 865 11 370 11 445 11 840 2 090 3 910 3 910 4 390 5 665 3 500 3 970 5 085 7 460 7 890
Rated fuel flow: - natural gas - light oil - heavy oil Boiler efficiency factor, at minimum - using natural gas - using light oil - using heavy oil Max rated air-flow resistance Water flow Rated water resistance, not more than Boiler weight without water Water volume of boiler L (length) B (width) H (height)
Pa t/h MPa kg m3 mm mm mm
35
EUROTHERM 1.1; 1.6; 2.0; 2.5 MW
General boiler view
Left-side view
KR
60 – 120
KK
KE
L1 L Frontal view
H4
H H1 H2
B2 B3
B1 B
36
165
EUROTHERM 1.1; 1.6; 2.0; 2.5 MW
General boiler view
Top view
L2 L3
Rear view
H3
KV
37
EUROTHERM
3.15; 4.65; 7.65; 11.65; 17.44; 23.26; 35.0; 58.2 MW General boiler view
Left-side view
L
H
38
EUROTHERM
3.15; 4.65; 7.65; 11.65; 17.44; 23.26; 35.0; 58.2 MW General boiler view
H
Frontal view
B
Top view
39
WATER-TUBE GAS AND OIL FIRED HOT WATER POLYKRAFT BOILERS, NOVOTHERM SERIES
POWER 35–140 MW • 4 standard sizes • U-type configuration • O perates on natural gas or fuel oil • GOST R certified • RosTekhNadzor approved • Intended service life of at least 20 years • 2 year warranty 40
FEATURES • Used in municipal and industrial heating systems and hot water supply systems, as well as at thermal power plants. • The boilers are GOST R certified and approved by RF RosTekhNadzor. • Operated using natural gas, light fuel oil, heavy oil/residual oil, depending on the type of burner installed. • The temperature chart of the heat-carrying agent is 150–70° С. • The efficiency factor is at least 92%. • The warranty term, on the condition of compliance with transportation, storage, assembly and operation requirements, is 2 years from the day of commissioning.
STRUCTURE AND FUNCTION Novotherm series boilers have a U-type configuration.
Construction
element
strength was calculated according to the standards in RD 10-249-98 • The heating part is shielded with vertical pipes, on the front waterwall there are burner throats, and on the rear ones – manholes for inspection and servicing of heating surfaces. • The convection part is located in the downtake gas duct. • When working with heavy oil, boilers can be equipped with gas-pulse cleaning (GPC) systems. The pulse cleaning system is designed for cleaning convection heating surfaces from contamination with heavy oil combustion products. • The pipeline system is supported by a carrying frame, which is rigidly fixed in a special base. • The boiler can be equipped with gas, fuel oil, and dual-fuel automatic burners from domestic and foreign manufacturers. • Boilers are furnished with tube coating, a thermal insulation made of mineral pads, and a decorative coating made of demountable metal panes. 41
NOVOTHERM BASIC SPECIFICATIONS AND DIMENSIONS 150째 C Calorific value
MW (Gcal/h)
35 (30)
56,2 (50)
116,3 (100)
139,6 (120)
Operating water pressure (at boiler outlet)
MPa (kgf/cm3)
135 (13,5)
1,35 (13,5)
1,35 (13,5)
1,35 (13,5)
Rated water temperature at inlet, main (peak) operation mode
째C
70 (150)
70/110 (150)
70/110 (150)
70 (150)
Water flow (main/peak mode),
t/h
370
618/1230
1238/2460
1410
- natural gas Qph=8620
kcal/m3, m3/h
3830
6250
12449
14852
- heavy oil Qph=9240
kcal/m3, kg/h
3650
5750
11856
14255
Boiler efficiency factor, rated using gas (heavy oil)
%
92,2 (89,6)
93,3 (90,8)
93,2 (90,7)
93,7 (90,5)
Rated air-flow resistance, not more than
Pa
600
800
1000
1000
Rated water resistance
MPa (kgf/cm2)
0,25 (2,5)
0,25 (2,5)
0,35 (3,5)
0,25 (2,5)
Range of adjustment of calorific value, against rated
%
30-100
30-100
30-100
30-100
Flue gas temperature
째C
155
145
144
139
L (length)
mm
7980
11650
15830
15830
B (width)
mm
8025
10130
10110
10110
H (height)
mm
13300
13215
14920
14920
Weight
kg
71500
95000
165000
175000
Rated fuel flow
42
NOVOTHERM 35; 58.2; 116.3; 139.6 MW General boiler view
Right-side view
H
Gas outlet
L
43
NOVOTHERM 35; 58.2; 116.3; 139.6 MW General boiler view
Frontal view Place for burner unit installation
B
44
NOVOTHERM 35; 58.2; 116.3; 139.6 MW General boiler view
Rear view
45
WATER-TUBE GAS AND OIL FIRED HOT WATER POLYKRAFT BOILERS, MEGATHERM SERIES
POWER 35–140 MW • • • • • •
4 standard sizes Vertical configuration Operates on natural gas or fuel oil GOST R certified Intended service life of at least 20 years 2-year warranty
46
FEATURES • Used in municipal and industrial heating systems and hot water supply systems, as well as at thermal power plants. • The boilers are certified according to the GOST system. • Operated using natural gas, light oil, heavy oil/residual oil, depending on the type of burner installed. • The temperature chart of the heatcarrying agent is 150–70° С • The efficiency factor is at least 92%. • The warranty term, on the condition of compliance with transportation, storage, assembly and operation requirements, is 2 years from the day of commissioning.
STRUCTURE AND FUNCTION • The pipeline system is connected to a boiler frame with hanger rods on upper manifolds and freely expands downwards. • Construction element strength was calculated according to standards in RD 10-249-98. • When working with heavy oil, boilers can be equipped with gas-pulse cleaning (GPC) systems. The pulse cleaning system is designed for cleaning convection heating surfaces from contamination with heavy oil combustion products. • The boiler can be equipped with gas, fuel oil, and dual-fuel automatic burners from domestic and foreign manufacturers. • Boilers are furnished with tube coating, thermal insulation made of mineral pads, and a decorative coating made of demountable metal panes.
47
MEGATHERM 35; 58.2; 116.3; 139.6 MW
Basic Specifications and Dimensions Description
Model
Megaterm-58
Megaterm-70 Megaterm-100 Megaterm-140
MW
58,2
69,8
116,3
139,6
Gcal/h
50
60
100
120
Range of adjustment
%
30…100
30…100
30…100
30…100
Water rated pressure at boiler inlet
MPa
1,6
1,6
1,6
1,6
Water operating pressure at boiler outlet
MPa
1,35
1,35
1,35
1,35
Water resistance
MPa
0,25
0,25
0,25
0,25
C
70
70
70
70
Rated calorific value
Water temperature at boiler inlet
0
Water temperature at boiler outlet
0
C
150
150
150
150
Water flow through boiler
t/h
618
743
1238
1485
Rated air-flow resistance, not more than
mbar
2,5
2,5
2,5
2,5
- natural gas
%
92
92
92
92
- heavy oil
%
91
91
91
91
- natural gas
m3/h
7050
8400
14100
16900
- heavy oil
kg/h
6200
7500
12500
15000
C
155
145
103
133
Sound pressure level in the working range, not more than
dBa
80
80
80
80
L- length
mm
9350
10350
10925
10925
B- width
mm
8750
8980
11530
11530
H- height
mm
14170
14670
14450
14450
kg
104000
140000
240000
246000
Efficiency factor, at minimum
Fuel flow
Flue gas temperature
Boiler dimensions:
0
Boiler weight without water
48
MEGATHERM 35; 58.2; 116.3; 139.6 MW General boiler view
H
L
B 49
FIRETUBE STEAM BOILERS
50
POLYKRAFT FIRE-TUBE STEAM BOILERS
Two-pass fire-tube steam Polykraft boilers, Vapotherm series VAPOTHERM 500–5,000 kg steam/h
Three-pass fire-tube steam Polykraft boilers, VTF series VTF 5,000–25,000 kg steam/h
51
TWO-PASS FIRE-TUBE STEAM POLYKRAFT BOILERS, VAPOTHERM SERIES
STEAM OUTPUT 500–5,000 kg steam/h • • • • • •
5 standard sizes Compact sizes Operates on gas fuel and light fuel oil Completely ready for installation GOST R certified 2 year warranty
52
FEATURES • A broad product range allows us to offer customers appropriate equipment selection. • Complete set of parts supplied, which allows assembly time to be minimized. • Operating overpressure is 8, 12, 15 bar. • The efficiency factor is at least 92%. • T he
reversed
chamber
can
be
opened either to the left or to the right for convenient cleaning and servicing of the boiler. • High maintainability.
STRUCTURE AND FUNCTION The firetube steam boiler is designed to receive steam with pressure above atmospheric level. This boiler series is designed as two pass on the flue-gas side with a cooled firetube, and one pass flue-gas tubes. • The boiler is supplied fully equipped with safety and control devices. • The water level in the boiler is maintained automatically. • The boiler can be equipped with gas, oil fuel and dual-fuel automatic burners from domestic and foreign manufacturers. • In the rear part of the boiler there is a detachable gas duct cap, which facilitates access to the tube sheet for boiler inspection, cleaning, and maintenance. • The boiler is supplied with thermal insulation and a decorative coating.
53
VAPOTHERM BASIC SPECIFICATIONS AND DIMENSIONS 8, 12, 15 bar Steam output
kg/h
500
750
1000 1250
1500 2000 2500 3000 3500 4000 5000
Rated power
kW
340
510
680
1020
Temperature of feed water
째C
Natural gas consumption (Hi 8620 kcal/m3)
m3/h
40
60
87
101
121
Light oil consumption (Hi 10200 kcal/kg)
kg/h
34
51
68
85
102
Flue gas temperature without an economizer Air-flow resistance
850
1701
2041
23S1
2721
3401
161
201
241
282
321
402
136
170
204
238
272
340
8,0
8,2
9,0
10,0
12,0
104
째C Mbar
1361
210-220 4,2
4,5
6,0
6,5
6,8
7,0
Boiler efficiency factor using natural gas, at minimum
%
90,1
Boiler efficiency factor using natural gas with an economizer, at minimum
%
95
Connection of gas duct A
mm
250
250
250
300
300
350
350
400
400
450
550
Connection of safety valves C
Dn
25
25
25
25
25
32
32
32
32
40
40
Connection of steam valve D
Dn
40
40
50
65
65
80
80
80
100
100
125
Connection of drain E
Dn
25
25
25
25
25
40
40
40
40
40
40
Length (L)
mm
2280 2500 2960 2150 3270 3450 3700 4010 4360 4760 5050
Width (B)
mm
1670
1750
1050 1900 2000 2240 2300 2410 2500 2550 2750
Boiler housing width B1
mm
1400
1400
1580
Height (H)
mm
1930 2030 2130
Transportation weight
kg
2090 2375 2660 3135 3420 4465 5510 6365 6650 8445 9300
Transportation weight
kg
2200 2500 2000 3300 3600 4700 5000 6700 7000 0900 9850
Transportation weight
kg
2530 2875 3220 3795 4140 5405 6670 7705 8050 10023 11300
1600
1730
1930 2050 2190 2270 2350 2550
2190 2200 2480 2510 2570 2690 2805 2950
0,7 bar Steam output
kg/h
500
750
1000
1250
1500
2000
2500
3000
Power
kW
370
560
690
900
1080
1380
1730
2070
Efficiency factor
%
L (length)
mm
2220
2360
2490
2660
2820
3090
3310
3480
B (width)
mm
1570
1690
1760
1920
1920
2000
2160
2240
H (height)
mm
1440
1560
1630
1780
1010
1890
2050
2130
Weight
kg
1620
1980
2250
2670
2980
3650
4360
5030
90
54
VAPOTHERM 8, 12, 15 BAR
H
General boiler view
L
B
VAPOTHERM
H
0,7 bar
B
L 55
THREE-PASS FIRE-TUBE STEAM POLYKRAFT BOILERS, VTF SERIES
STEAM OUTPUT 5,000–25,000 kg steam/h • • • • • •
10 standard sizes Operates on gas fuel, light fuel oil Fast transition to operating mode GOST R certified RosTekhNadzor approved 2 year warranty
56
FEATURES • C omplete fuel combustion due to optimal boiler construction. • T he operating overpressure is 9, 12, 15 bar. • The efficiency factor is at least 92%. • L ow thermal stress due to external and internal beaded bottoms. • Fast transition to operating mode. • H igh combustion efficiency allows the level of nitrogen oxide emissions to be reduced. • S uitable for any type of industrial use which requires saturated high-pressure steam. • T he boiler controller regulates the entire boiler unit system and allows changing operating parameters.
STRUCTURE AND FUNCTION The firetube steam boiler is designed to obtain steam with pressure above atmospheric level. This boiler series is designed as three-pass on the flue-gas side with a cooled firetube, and twopass flue-gas tubes. • The boiler is supplied fully equipped with safety and control devices. • The water level in the boiler is maintained automatically. • The boiler can be equipped with gas, fuel oil, and dual-fuel automatic burners from domestic and foreign manufacturers. • In the front and in the rear parts of the boiler there are manholes, which provide access to tube sheets for boiler
inspection,
cleaning,
and
maintenance. • The boiler is supplied with thermal insulation and a decorative coating.
57
VTF
BASIC SPECIFICATIONS AND DIMENSIONS 9 , 12, 15 bar Steam output of the boiler Rated (absolute) steam pressure
1/4
5,0
5,0
7,0
MPa (kgf/cm2) 1,0 (10) 1,3 (13) 1,6 (16) 1,0 (10) 1,3 (13) 1,6 (16) 1,0 (10) 1,3 (13) 1,6 (16)
Temperature of feed water
°C
104
Steam temperature* [rated]
°C
Flue gas temperature**
°C
220±5 230±5 240±5 220±5 230±5 240±5 220±5 230±5 240±5
rated gas at Qph=8620 kcal/m3, light oil (rated at Qph=10180 kcal/m, not more than m3/h)
kcal/m3
398,5 401,2 403,0 470,2 401,3 483,5 557,8 561,5 564,0 (337,4) (339,6) (340,5) (405,1) (407,6) (409,4] (472,3) (475,5) (477,6)
Air-flow resistance (rated), not more than
Pa
950
1050
1100
Boiler efficiency factor, at minimum
%
91 90,4 90
91 90,4 90
91 90,4 90
Steam volume of the boiler
m
2,6
3,2
3,0
Water volume of the boiler
m
10,2
11,1
13,5
Allowed number of startups during service life, not more than
times
2500
Modularity factor, at minimum
%
100
Service life between major overhauls, at minimum
years
3,5
Mean time between failures, at minimum
h
4500
Full intended service life, at minimum
years
20
Equivalent sound pressure level in the working range, not more than
dBA
80
Total hardness of feed water, not more than
mkg-equivalent/ kg
100
Specific emission of nitrogen oxide at burning rated fuel volume, not more than
g/m3
0,23
°C
55
points
9
179±2 191±2 201±2
179±2 191±2 201±2
179±2 191±2 201±2
Fuel flow
Temperature of outer (isolated) boiler surface, not more than Seismic stability pursuant to SNiP 11-A, 12-69 not more than Overall boiler dimensions: - L (length)*** - B (width) - H (height) Boiler weight****
3 3
mm t
6025 2565 2975 16,5 18,0 19,0
* At feed water temperature of 104° C ** Without economizer *** Length without burner unit **** Weight without burner unit, water inside the boiler and fittings 58
6305 2710 3140 17,8 19,0 21,0
6500 2760 3310 20,0 21,5 23,0
VTF
BASIC SPECIFICATIONS AND DIMENSIONS 9 , 12, 15 bar 8,0
10,0
12,0
15,0
10,0
1,0 (10) 1,3 (13) 1,6 (16)
1,0 (10) 1,3 (13) 1,6 (16)
1,0 (10) 1,3(13) 1,6 (16)
1,0 (10) 1,3 (13) 1,6 (16)
1,0 (10) 1,3 (13) 1,6 (16)
104 179±2 191±2 201+2
179+2 191+2 201±2
179±2 191±2 201±2
179±2 191±2 201±2
179±2 191±2 201±2
220±5 230±5 240±5
220±5 230±5 240±5
220±5 230±5 240±5
220±5 230±5 240±5
220±5 230±5 240±5
637,5 642,0 644,6
797,0 802,2 805,0
856,3 962,6 967,0
1195,4 1203,3 1208,6
1434,4 1444,0 1450,4
(809,7) (815.1) (823,6)
(1012,2) (1020,0) (1029,5)
(1214,6) (1222,8) (1235,4)
(539,8) (543,4) (545,6) (674,8) (679,3) (682,3) 1200
1350
1450
1640
1380
91 90,4 90
91 90,4 90
91 90,4 90
91 90,4 90
91 90,4 90
4,3
5,1
5,5
5,5
7,6
14,5
16,2
21,2
25
31,6
2500 100 3,5 4500 20 80 100 0,23 55 9
6835
7345
7010
7905
0755
2775
3025
3275
3400
3750
3590
3620
3710
3800
4080
23,0 25,0 27,0
26,8 27,5 29,5
26,6 29,0 31,0
30,0 33,0 36,0
43,4 45,6 48,0
59
VTF
BASIC SPECIFICATIONS AND DIMENSIONS 9 , 12, 15 bar Steam output of the boiler
t/h
20,0
25,0
Rated (absolute) steam pressure
MPa (kgf/cm2)
1,0 (10) 1,3 (13) 1,6 (16)
1,0 (10) 1,3 (13) 1,6 (16)
Temperature of feed water
°C
Steam temperature* (rated)
°C
179±2 191±2 201±2
179±2 191±2 201±2
Flue gas temperature**
°C
220±5 230±5 240±5
220±5 230±5 240±5
rated gas at Qph=8620 kcal/m3, light oil (rated at Qph=10180 kcal/m, not more than m3/h)
kcal/m3
1594,0 1604,4 1611,5 (1349,6) (1358,5) (1372,7)
1992,3 2005,5 2014,4 (1687,0) (1698,2) (1715,8)
Air-flow resistance (rated), not more than
Pa
1500
1600
Boiler efficiency factor, at minimum Steam volume of the boiler Water volume of the boiler
% m3 m3
91 90,4 90 8,4 33,1
91 90,4 90 12,3 39,8
Allowed number of startups during service life, not more than
times
2500
Modularity factor, at minimum
%
100
Service life between major overhauls, at minimum
years
3,5
Mean time between failures, at minimum
h
4500
Full intended service life, at minimum
years
20
Equivalent sound pressure level in the working range, not more than
dBA
80
Total hardness of feed water, not more than
mkg-equivalent/kg
100
Specific emission of nitrogen oxide at burning rated fuel volume, not more than
g/m3
0,23
104
Fuel flow
Temperature of outer (isolated) boiler surface, not more than Seismic stability pursuant to SNiP 11-A, 12-69 not more than
55 points
9
Overall boiler dimensions: L (length)*** B (width) H (height)
mm
8950 3875 4080
9240 3975 4200
Boiler weight****
t
44,4 46,6 49,0
52,0 55,0 59,0
60
VTF
5; 6; 7; 8; 10; 12; 15; 18; 20; 25T/H General boiler view
Right-side view
L
B
Top view
61
VTF
5; 6; 7; 8; 10; 12; 15; 18; 20; 25T/H General boiler view
H
Frontal view
Rear view
B
62
PROJECT GEOGRAPHY AND PRODUCTION GROWTH DYNAMICS FROM 2008 TO 2013 Latvia
133.7 MW
Italy
15 t
of steam/h
25.0 MW
1135 MW
Abkhazia
4.0
112.2
603.6
Belarus
428.7
MW
MW
218.4
271.3 MW
MW
Russia
139.2 MW
MW
MW
After 5 YEARS of work we have supplied boiler equipment with a total capacity of over 3500 MW in the markets of Russia, CIS, and Europe. 2013 — our company reached an unprecedented level of production volume and growth rate. 1000 PCS. Total number of products produced since 2008.
63
SOLUTIONS
BOILERS COMBUSTION
POWER GENERATION GAS & OIL
BIOENERGY
Polyimpex Trading AG Industriestrasse 7, P.O. Box, CH-6300 Zug, Switzerland Tel.:+41 (0) 41 725 05 95 Fax: +41 (0) 41 725 05 96 info@polyimpex.ch