Captive Plant High Capacity Boiler Manufacturers in India
Raj Boilers is a genuine name among captive plant high capacity boiler manufacturers, suppliers, traders, and dealers in India. Our organisation is involved in designing and supplying highly efficient boilers to meet captive power plants, Co-Generation Power Plants, captive coal power plants, and other power sector solutions. We specialise in designing better boiler solutions for EPC power plants, high-pressure industrial boilers, thermal power plants, package boilers, multi-fuel AFBC boilers, and captive thermal power plants with better technology. Our area of innovation is to ensure that every system supports captive power generation, high-pressure boiler operation, and trouble-free integration with steam turbine generators for industrial power plants.
Working Principle of Captive Plant High Capacity Boilers
The main operation mode of a captive plant high capacity boiler is water being transformed into high-pressure steam aided by heat energy generated through the combustion of fuel. The generated steam drives steam turbine generators, which generate electricity for captive power production in industries irrespective of the grid. Latest-tech boilers now feature waste heat recovery in cement facilities and the latest multi-fuel technology to provide maximum efficiency, lower fuel consumption, and cause less environmental harm. Captive Plant High Capacity Boiler Types
Types of our Captive Plant High Capacity Boilers
Being one of the top captive plant high capacity boiler manufacturers in India, we provide the best captive plant high capacity boilers such as:
- Circulating Fluidised Bed Combustion (CFBC)
CFBC boilers utilise a fluid bed to burn fuel at reduced temperatures with maximum efficiency and low NOx and SOx emissions. Emerging CFBC technology makes multi-fuel AFBC boilers more versatile to burn coal, biomass, and waste fuel. The boilers are suitable for captive thermal power plants because they are energy-efficient and environmentally friendly.
- Pulverised Fuel-Fired Boilers
Pulverised fuel-fired boilers pulverise coal to very fine dust, which is highly combustible and hence has higher thermal efficiency. New designs have waste heat recovery in cement plants to utilise wastage of heat for waste heat recovery and improvement in overall energy production. They are applied on a large scale in thermal power stations and industrial power stations where high-pressure steam requires turbines.
- Single Drum/Bi-Drum Boilers
Single drum and bi-drum boilers can be utilised for high-pressure applications with stable and consistent performance. They have modern designs with automated control systems and digital controls for energy efficiency and optimisation of combustion. They are used in captive coal power generation and co-generation power plants for round-the-clock energy supply.
Features of Captive Plant High Capacity Boilers
- High Efficiency Combustion
Our boilers use the latest combustion technology, which gives maximum utilisation of heat and loses minimal fuel. Multi-fuel AFBC boiler compatibility gives maximum combustion of coal, biomass, and alternative fuels. It ensures low emissions and stable generation of power for industrial power plants.
- Automated Control Systems
High-pressure boilers today are sophisticated, with smart control systems monitoring temperature, pressure, and fuel. This technology reduces the involvement of man, is safer, and increases efficiency utilisation to the fullest. It also reduces integration with steam turbine generators for producing electricity more efficiently.
- Waste Heat Recovery
Our boilers capture waste heat from flue gases, thereby improving energy conservation and cost benefit. Waste heat recovery within the cement and other industries saves considerable energy. This support towards sustainability also adds another dimension to the captive power generation sustainability factor.
- Strong Construction
Raj Boilers' high-capacity heavy-duty boilers are designed in such a way with high-grade material that they can resist maximum temperature and pressure. Heavy-duty design keeps them running for a long term and requires less maintenance. These are the conditions which are favourable to captive thermal power plants which are run continuously.
- Flexible Fuel Options
Our co-generation power plants may be designed to operate with fuel of various types such as coal, biomass, and industrial wastes. High-efficiency fuel management systems and burners facilitate a seamless switch-over. This provides uninterrupted captive power with a lower ecological burden.
Technical Specifications
| Parameter |
Specification / Description |
| Boiler Type |
High-Pressure Water Tube Boiler (CFBC / PF / HRSG type depending on fuel) |
| Steam Generation Capacity |
150–250 TPH (Tons per Hour) |
| Operating Pressure |
110–150 bar(g) |
| Steam Temperature |
540–565°C (Superheated) |
| Fuel Type |
Imported / Indian Coal, Petcoke, Biomass, or Multi-fuel Capability |
| Efficiency (Gross) |
86–90% (with air preheater & economizer) |
| Feed Water Temperature |
105–130°C (with deaerator system) |
| Flue Gas Exit Temperature |
140–160°C |
| Boiler Drum Material |
ASTM A516 Gr.70 / ASME SA-299 (High Strength Carbon Steel) |
Advantages of Captive Plant High Capacity Boilers
- Stable and Uninterrupted Power Supply
Captive boilers offer round-the-clock power to industries, which allows for continuous operation of production processes. Through their linkage with steam turbine generators, they offer round-the-clock power regardless of the national grid. It is especially useful in captive coal power plants and co-generation power plants.
- Cost Efficiency
High-capacity boilers reduce fuel consumption due to improvements in high-pressure boiler technology. Waste heat recovery in industry and cement plants also conserves operating costs. It provides economical captive power generation for sustainable long-term growth.
- Environmental Compliance
Advanced multi-fuel AFBC next-generation boilers have been conceptualised with a vision of achieving the lowest emissions and complying with strict environmental regulations. The lowest emissions of NOx and SOx are ensured by utilising best-class combustion control and flue gas treatment technology. It is an extension of green policy in thermal power plants as well as industrial power plants.
- Operational Flexibility
These boilers can be switched between fuels according to availability, and uninterruptible power supply is obtained through this. Integration with EPC power plants gives greater responsiveness and agility in operations. This is highly important for organisations handling dynamic energy requirements in captive power generation.
Applications of Captive Plant High Capacity Boilers
- Cement Industry
Waste heat recovery in cement plant high capacity boilers enhances energy efficiency. The generated steam is utilised for power generation and process heat. It reduces fuel consumption and operating costs in cement plants.
- Sugar and Agro-Based Industries
Biomass and bagasse of sugar mills are utilised as fuel by captive boilers to produce co-generation power plants. High-end multi-fuel AFBC boilers with ultra-high technology harness renewable inputs in the most effective way possible. This helps in environmentally friendly captive power generation without any environmental impact.
- Chemical and Pharmaceutical Industries
Our boilers supply industrial high-pressure steam, which is a vital source of process heat as well as chemical reactions. Automatic control ensures precise pressure and temperature control. This ensures the safety, efficiency, and productivity of industrial power plants.
- Textile and Paper Industry
High-pressure industrial boilers generate process, dyeing, and drying steam, etc. Through captive power plants on coal, we ensure process and power stability. Wastage of energy is kept at a minimal level with maximized plant efficiency through the latest designs.
Raj Boilers is a leading captive plant high-capacity boiler manufacturers, suppliers, dealers, and traders in India. Our boilers are equipped with the most modern technologies such as multi-fuel AFBC units, waste heat recovery in cement, and automation control systems for optimal efficiency and sustainability. Used in captive power plant utilisation of coal, co-generation power plant utilisation, thermal power plant utilisation, and industrial power plant utilisation, we offer safe, efficient, and eco-friendly energy solutions. Our association with Raj Boilers guarantees a twenty-four-hour power supply, lower operating costs, and long-term environmental equilibrium, establishing us as the first choice of the Indian industrial boiler industry. Contact us today for more information!
