01. Turnkey EPC & Balance of Plant (BOP) Utility Scope
What complete scope is delivered under an Uttamenergy turnkey EPC power contract?
Uttamenergy assumes single-point contractual responsibility encompassing thermodynamic heat-balance optimization, complete civil foundations and structural engineering, automated fuel logistics (yard storage, conveyors, screens, magnetic separators), high-pressure water-tube boiler islands, steam turbine-generator (STG) sets, water treatment (DM/RO) and deaeration systems, flue gas treatment (ESP/baghouse), balance of plant piping, plant-wide DCS automation, and high-voltage grid switchyard interconnection.
What performance guarantees are standard in your EPC contracts?
We provide formal contractual performance guarantees for gross electrical megawatt output, net heat rate (kJ/kWh or kcal/kWh), boiler thermal efficiency on gross and net calorific value (GCV/NCV), guaranteed continuous steam flow rate, auxiliary power consumption limits, and stack particulate emissions (typically <30 mg/Nm³ or project-specific norms).
02. Fuel Thermodynamics & Combustion Systems Feedstock Engineering
How do Uttamenergy boilers handle 50%+ moisture Palm Empty Fruit Bunches (EFB)?
Empty Fruit Bunches (EFB) combine high moisture (50–60%), low bulk density, volatile alkali metals, and chlorine salts. We utilize our in-house Reciprocating Servo Grate (RSG) with multi-step hydraulic tumbling that continuously agitates the fuel bed to evaporate moisture without blanketing. Multi-tier staged overfire air injects oxygen precisely where volatile pyrolysis occurs, maintaining furnace temperatures above ignition while avoiding localized slagging eutectics.
How do you achieve Zero Liquid Discharge (ZLD) with spent wash in bio-distilleries?
Concentrated distillery effluent (vinasse / slop) at 55°–60° Brix is atomized via multi-lance spray nozzles into the high-temperature zone of our specialized incineration boiler. The organic content is 100% burned out alongside supporting biomass (bagasse or coal), generating continuous high-pressure process steam while the inorganic potash ash is precipitated and recovered as commercial potassium fertilizer.
How is severe tube erosion prevented when burning silica-heavy rice husk or paddy straw?
Rice husk and paddy straw fly ash contains up to 90% abrasive silica. Uttamenergy designs furnaces with generous volumetric heat-release envelopes that keep convective gas velocities conservatively below 9 m/s. We employ inline tube pitching, heavy stainless steel wear shields over the leading tube surfaces, and motorized sootblowing systems to avoid abrasive erosion channels.
03. High-Pressure Boiler Design Envelope Parameters
What are the maximum boiler steam outputs and thermal parameters available?
We manufacture single-boiler steam generators up to 200 TPH (tonnes per hour) capacity. Our high-pressure steam parameters reach 125 ata (barg) pressure and 545°C superheated steam temperatures, supporting both modern high-efficiency multi-stage power turbines and industrial extraction cogeneration demands.
When do you recommend Traveling Grate Stokers versus Atmospheric Fluidized Bed (AFBC)?
Traveling Grate Stokers are the optimal selection for fibrous, coarse, or unevenly sized feedstocks (palm EFB, sugarcane bagasse, wood waste) where fuel processing and sizing costs must be minimized. AFBC is recommended for dense, high-ash fuels, coal blends, or multi-fuel regimes where uniform fluidized bed combustion and in-situ desulfurization (using limestone) are required.
04. Manufacturing Quality, Tooling & ASME Certification Shop Works
What authorized ASME stamps and regulatory quality standards do you hold?
Our captive heavy manufacturing complex in Chhatrapati Sambhajinagar (Aurangabad), India holds active ASME 'S' (Section I Power Boilers) and 'U' (Section VIII Div 1 Pressure Vessels) authorization, the National Board NBIC 'R' stamp for repairs and alterations, and Indian Boiler Regulations (IBR) Special Class maker certification. All pressure parts carry 100% mill test report (MTR) material traceability.
What is your in-house heavy fabrication tooling capacity?
Our Aurangabad complex is equipped with hydraulic plate rolling cells capable of rolling SA-516 Gr 70 plate up to 150 mm (5.9 in.) thickness for steam drums, twin automated multi-torch submerged arc welding (SAW) membrane panel lines producing 50 ft continuous watertube panels, CNC gantry multi-spindle drum/header drilling lines, and multi-axis cold booster tube benders.
Need Specific Project Calculations or Consultant Data?
Our thermal applications team provides detailed mass & heat balance calculations, fuel combustion models, and general arrangement (GA) drawings for tender specifications.
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