FORM - 2
THE PATENTS ACT, 1970
(39 OF 1970)
AND
THE PATENT RULE, 2003
COMPLETE SPECIFICATION
"SOLID FUEL FIRED SMALL INDUSTRIAL BOILER AND IBR EXEMPTED BOILER AND SYSTEMS THEREOF"
TRANSPARENT ENERGY SYSTEMS PRIVATE LIMITED A COMPANY REGISTERED UNDER THE PROVISIONS OF COMPANIES ACT, 1956 HAVING ADDRESS AT "PUSHPA HEIGHTS", 1ST FLOOR, BIBWEWADI CORNER, PUNE-SATARA ROAD, PUNE-411 037, MAHARASHTRA, INDIA.
THE FOLLOWING SPECIFICATION DESCRIBES THE NATURE OF THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED

FIELD OF THE INVENTION:-
Present invention relates to the solid fuel fired boiler and system thereof exempted from definition of the boiler (referred as Non IBR boiler as per Sub-section (2) of section 3 of IBR (amended act 2007)) as per Indian Boiler Regulations, 1950 (IBR). It also relates to the solid fuel fired boiler and system thereof defined as small industrial boiler (Referred as SIB As defined in Regulation 619 of Chapter XIV of Indian Boiler Regulations Act) as per Indian Boiler Regulations, 1950 (IBR).
PRIOR ART:-
The boilers exempted from definition of the boiler and the small industrial boilers as per Indian Boiler Regulations, 1950 (IBR) currently in use are Furnace oil, HSD, Natural Gas or LPG fired. These boilers have burner type fuel combustion system. Also, these boilers have coil type construction with a jacket of boiler quality steel surrounding the coil. The said jacket is exposed to high temperature flue gases in conditions when coil gets scaling on its inner surface resulting in to reduced rate of heat transfer. Due to this it is subjected to overheating resulting in to failure of shell strength.
LIMITATIONS OF PRIOR ART AND NEED OF THE PRESENT INVENTION:-
1. Rising fuel prices
Prices of petroleum derived fuels such as Furnace Oil, HSD, Natural Gas or LPG used currently in Non IBR boilers and SIBs have increased to the extent that operating these boilers for fulfilling heating requirements of a small process industry has become unaffordable. Also, the availability of gaseous fuels like Natural Gas or LPG is becoming scarce in certain regions of India. Therefore, there is a need to develop a non IBR boiler and SIB which could be operated on cheaply and easily available solid fuels such as Coal or Biomass.
2. Overheating of boiler
As said in the prior art, the currently used Non IBR boilers and SIBs have a coil carrying water inside a shell. Hot flue gas after combustion flows over the

coil from inner side of the shell. It is commonly observed that the quality of boiler feed water used in current Non IBR boilers and SIBs is not critically maintained which results in to scaling of coil from inside affecting rate of heat transfer. Due to this insufficient heat recovery, temperature of flue gases flowing over coil does not drop sufficiently to maintain the strength of shell. Shell subjected to high temperature over prolonged period of operation under these conditions, fails losing its strength. Therefore, there is a need to have an improved construction of Non IBR boiler. 3. Wet steam (Low Dryness) of steam at outlet
As said in prior art, there are no specific devices such as flash vessel & moisture separators for separation of droplets from the steam. There is no controlled feeding of boiler water with respect to moisture separated from the steam. This results in delivery of steam containing water droplets which reduces enthalpy of steam.
OBJECT OF THE INVENTION:-
Present invention relates to the solid fuel fired boiler and system thereof exempted from definition of the boiler (referred as Non IBR boiler) as per Indian Boiler Regulations, 1950 (IBR). It also relates to the solid fuel fired boiler and system thereof defined as small industrial boiler (Referred as SIB) as per Indian Boiler Regulations, 1950 (IBR).
Embodiment 1 of the present invention relates to the solid fuel such as coal / biomass fired automatic boiler defined in IBR as exempted from definition of boiler with description that reads, ".....a pressure vessel,
(i) with volumetric capacity less than 25 liters (such capacity measured from the feed check valve to the main steam stop valve);
(ii) with less than 1 kg/cm2 design guage pressure and working gauge pressure; or
(iii) in which water is heated below 100 °C;"

Embodiment 2 of the present invention relates to the solid fuel such as coal/biomass
fired automatic small industrial boiler defined as below (" ") in Indian Boiler
Regulations, 1950
"(a) a shell type boiler generating steam for use external to itself under pressure up to 7 kg/cm2 and having volumetric capacity exceeding 25 liters (such capacity measured from the feed check valve to the main steam stop valve) but not exceeding 500 litres including the volumetric capacity of all pressure parts being heated from the same heating source and connected to the boiler or
(b) a coil type boiler or a once through boiler or a water tube boiler having conditions specified in above except that -
(i) the limitation of pressure shall be 12 kg/cm2, and (ii) the capacity shall be not exceeding 150 litres:
PROVIDED that in case of boilers having combined features of clauses (a) and (b),
the working pressure shall be restricted to 7 kg/cm2 and the volumetric capcity of
particular pressure parts shall not exceed the limits specified in the respective
clauses above subject to an aggregate of 500 litres."
It is also object of present invention to eliminate limitations or drawbacks of the prior
art.
STATEMENT OF INVENTION:-
Accordingly the invention provides solid fuel fired small industrial boiler and IBR exempted boiler and systems thereof comprises an outer body formed by a pair of co-axial cylindrical jacket bodies (35,36) to form jacketed body with tubesheets (44) connected at upper and lower end of the jacket such that the annular space of which has number of vertical smoke tubes (12) running parallel to each other and mounted distant radially connecting the said tubes sheets; a furnace, with primary air and secondary air supply means , at bottom, provided with a water cooled oscillating grate; an evaporator coil (11), made of coiled tube, formed in cylindrical shape mounted coaxially above the said furnace in such a way that the flue gas exhaust through the said smoke tube (12) having path to heat inner(33) and outer surface(34) of said evaporator coil/coils and inner jacket wall; a flue gas cleaning system (14) provided between the said smoke tube outlet and exhaust chimney

(16); a first outlet from deareator tank (17) connected through pump (50) to inlet of oscillating grate (5) to supply cooling water; the jacketed body annular space having inlet to receive heated water from the grate and having an outlet (41) connected to the said de-aerator tank; heat recovery heat exchanger (62) to recover heat of flash steam from the said deaerator and another heat recovery heat exchanger (60) to recover heat from blowdown water by heating make up water, a mixer (61) to mix heated make-up water in to the hot water through outlet (41) which flows in to deaerator (17); a second out let from the said deareator tank(17) connected the inlet of said evaporator coil through a feed pump (21); an outlet of evaporator coil connected to inlet of flash tank (18) through the water pressure transmitter(28) and an out let provided to the said flash tank to take out steam.
BRIEF DESCRIPTION OF THE SCHEMATIC DRAWING:-
The invention is described with reference to the accompanying drawing wherein, Figure.1a Embodiment 1 of the present invention that describes simplified fuel combustion & flue gas circuit diagram of the solid fuel fired boiler and system thereof exempted from definition of the boiler as per Indian Boiler Regulations, 1950 (IBR) Figure. 1b Embodiment 1 of the present invention that describes simplified water/steam flow circuit diagram of the solid fuel fired,boiler and system thereof exempted from definition of the boiler as per Indian Boiler Regulations, 1950 (IBR) Figure.2a Embodiment 2 of the present invention that describes simplified fuel combustion & flue gas circuit diagram of the solid fuel fired boiler and system thereof defined as SIB as per Indian Boiler Regulations, 1950 (IBR) Figure.2b Embodiment 2 of the present invention that describes simplified water/steam flow circuit diagram of the solid fuel fired boiler and system thereof defined as SIB as per Indian Boiler Regulations, 1950 (IBR)
DETAILED DESCRIPTION OF THE PRESENT INVENTION:-
As described in the object, present invention relates to the solid fuel fired boiler and system thereof exempted from definition of the boiler (referred as Non IBR boiler) as per Indian Boiler Regulations, 1950 (IBR). It also relates to the solid fuel fired boiler

and system thereof defined as small industrial boiler (Referred as SIB) as per Indian Boiler Regulations, 1950 (IBR).
As shown in figure 1a, Embodiment 1 of the present invention, the fuel combustion & flue gas circuit in Non IBR boiler and system thereof comprises of, A fuel hopper (1) equipped with a fuel feeder (Screw or Rotary type) (2) to supply fuel to the water cooled oscillating grate (5) of boiler with cylindrical construction (30) through chute (29). The feeder is connected to Variable Frequency Drive (37) to control the fuel feed rate in response to signal from pressure transmitter (28) mounted on outlet of boiler. The FD fan (4) supplies primary combustion air to the underlying compartments of the water cooled oscillating grate as described in the already applied patent application 1113/MUM/2005. The Secondary air fan (3) supplies secondary air above, the water cooled oscillating grate surface to aid complete combustion of fuel through air distribution nozzles (6). The ash formed as a result of fuel combustion travels along the length of grate due to oscillating movement of grate as described in the patent application 1113/MUM/2005 and resulting ash falls on the ash removal system (7) which conveys ash outside the boiler (30). The furnace (8) holding th.e grate (5) is lined with two layers of refractory (9) and (10). An evaporator coil (11), made of coiled tube, formed in cylindrical shape mounted coaxially above the said furnace. The said evaporator coil consists of single coiled tube, made in cylindrical shape, and mounted coaxially having an inlet at one end of the said tube coil and an outlet to the other end of the said tube coil.
The combustion flue gas from furnace (8) enters the first pass (31) of flue gas in which it flows on the inner side of the evaporator coil (11) over inner wall (33) of coil. The said evaporator coil has volume less than 25 liters. As shown in figure, the flue gas exits the first pass, turns in 180 degrees and enters second pass (32) formed by outer wall (34) of coil and inner wall of inner jacket (35) in which it flows on the outer side of the evaporator coil over outer wall (34) of coil. The flue gas exits the second pass by turning again in 180 degrees and enters third pass formed by smoke tubes (12) radially arranged with respect to axis of boiler connected to tubesheet (44) connecting inner jacket (35) and outer jacket (36). The flue gas then enters the smoke box (13) connected at outlet of third pass and is conveyed to flue gas cleaning system (14) by duct (45) due to the negative draft maintained by I.D. Fan

(15). After particulate removal in flue gas cleaning system, the gas is exhausted to atmosphere through chimney (16). The variable speed drive (57) modulates the fan speed to control the furnace pressure shown by furnace pressure transmitter (58). The Steam pressure transmitter (28) modulates the fuel feed rate by changing speed of VFD (37) of feeder (2) and primary air flowrate by changing speed of VFD (59) of primary air fan (4) to maintain the evaporator coil pressure.
As shown in figure 1b, Embodiment 1 of the present invention, the water/steam flow circuit in Non IBR boiler and system thereof comprises of,
The water from Deaerator tank (17) is pumped from outlet (46) of the Deaerator tank by circulation pump (50) and it is supplied to the grate (5) through its inlet header (38). The water circulates through the grate absorbs heat of combustion and exits the grate from outlet header (39) and flows in to the annular space between inner jacket (35) and outer jacket (36). The said water carrying annular space provides water cooling to the jackets (35) and (36). The water gets heated further by absorbing heat from flue gases flowing through tubes (12) and exit the annular space through outlet (41) and flow in to the Deaerator tank (17). The level in the Deaerator tank is maintained by level transmitter (49) by modulating the make-up water control valve (48). The make-up water passes through shell and tube type flash steam heat recovery heat exchanger (62) in which water flows through the tubes and flash steam from deaerator flows through shell. At the outlet of the said heat exchanger (62), the heated water is supplied to tube side of shell and tube type blowdown water heat recovery heat exchanger (60) in which the preheated make up water flows through tubes and the blowdown water flows through shell. The make-up water is heated further in the said heat exchanger (60). The outlet of heat exchanger (60) is connected to inlet of mixer (61) which mixes the hot water flowing through outlet (41) and supplies the mixed hot waters to deaerator (17). The water from Deaerator tank (17) is pumped from outlet (47) by feed pump (21) and it is supplied to the evaporator coil (11) through inlet (42). The flowrate of feed water is recorded by flow transmitter (20) and the total dissolved solid content is measured by TDS sensor (22). The saturated water exits the evaporator coil through outlet (43) and enters the flash tank (18) where steam is released from outlet (51). The steam flow is measured by flow meter (19). The total dissolved solids content in. the boiler blowdown water drained from flash vessel is measured by TDS (Total Dissolved Solids ) meter (52).

Level transmitter (25) maintains the level in the flash tank (18) by controlling speed of pump (21). There is continuous blowdown from flash vessels which maintains the TDS of boiler water within desired limits. A part of the steam from flash tank is supplied to the Deaerator by pipeline (27) for heating the water in deaerator tank. As shown in figure 2a, Embodiment 2 of the present invention, the fuel combustion & flue gas circuit in SIB and system thereof comprises of,
A fuel hopper (1) equipped with a fuel feeder (Screw or Rotary type) (2) to supply fuel to the water cooled oscillating grate (5) of boiler with cylindrical construction (30) through chute (29). The feeder is connected to Variable Frequency Drive (37) to control the fuel feed rate. The FD fan (4) supplies primary combustion air to the underlying compartments of the water cooled oscillating grate as described in the already applied patent application 1113/MUM/2005. The secondary air fan (3) . supplies secondary air above the water cooled oscillating grate surface to aid complete combustion of fuel through air distribution nozzles (6). The ash formed as a result of fuel combustion travels along the length of grate due to oscillating movement of grate as described in the patent application 1113/MUM/2005 and resulting ash falls on the ash removal system (7) which conveys ash outside the boiler (30). The furnace (8) holding the grate (5) is lined with two layers of refractory (9) and (10). An evaporator coil (11), made of coiled tube, formed in cylindrical shape is mounted coaxially above the said furnace. The said evaporator coil consists of two or more coiled tube, made in cylindrical shape, mounted coaxially and connected serially so as to form inlet of outer most of the said tube coil and an outlet to the inner most of the said tube coil. The combustion flue gas from furnace (8) enters the first pass (31) of flue gas in which it flows on the inner side of the first evaporator coil (11) over inner wall (33) of coil. The said first and second evaporator coils cumulatively have volume more than 25 liters and less than 500 liters. As shown in figure, the flue gas exits the first pass, turn in 180 degrees and enters second pass formed by outer wall (34) of first evaporator coil (11) and inner wall (54) or second evaporator coil (56). As shown in figure, the flue gas exits the second pass, turns in 180 degrees and enters third pass (53) formed by outer wall (55) of second evaporator coil (56) and inner wall of inner jacket (35) in which it flows on the outer side of the evaporator coil over outer wall (34) of coil. The flue gas exits the third pass by turning again in 180 degrees and enters fourth pass formed by smoke

tubes (12) radially arranged with respect to axis of boiler connected to tubesheet (44) connecting inner jacket (35) and outer jacket (36). The flue gas then enters the smoke box (13) connected at outlet of fourth pass and is conveyed to flue gas cleaning system (14) by duct (45) due to the negative draft maintained by I.D. Fan (15). After particulate removal in flue gas cleaning system, the gas is exhausted to atmosphere through chimney (16). The variable speed drive (57) modulates the fan speed to control the furnace pressure shown by furnace pressure transmitter (58). The Water pressure transmitter (28) modulates the fuel feed rate by changing speed of VFD (37) of feeder (2) and primary air flowrate by changing speed of VFD (59) of primary air fan (4) to maintain the evaporator coil pressure.
As shown in figure 2b, Embodiment 2 of the present invention, the water/steam flow circuit in SIB and system thereof comprises of,
The water from Deaerator tank (17) is pumped from outlet (46) of the Deaerator tank by circulation pump (50) and it is supplied to the grate (5) through its inlet header (38). The water circulates through the grate absorbs heat of combustion and exits the grate from outlet header (39) and flows in to the annular space between inner jacket (35) and outer jacket (36). The said water carrying annular space provides water cooling to the jackets (35) and (36). The water gets heated further by absorbing heat from flue gases flowing through tubes (12) and exit the annular space through outlet (41) and flow in to the Deaerator tank (17). The level in the Deaerator tank is maintained by level transmitter (49) by modulating the make-up water control valve (48). The make-up water passes through shell and tube type flash steam heat recovery heat exchanger (62) in which water flows through the tubes and flash steam from deaerator flows through shell. At the outlet of the said heat exchanger (62), the heated water is supplied to tube side of shell and tube type blowdown water heat recovery heat exchanger (60) in which the preheated make up water flows through tubes and the blowdown water flows through shell. The make-up water is heated further in the said heat exchanger (60). The outlet of heat exchanger (60) is connected to inlet of mixer (61) which mixes the hot water flowing through outlet (41) and supplies the mixed hot waters to deaerator (17). The water from Deaerator tank (17) is pumped from outlet (47) by feed pump (21) and it is supplied to the second evaporator coil (56) through inlet (42). The water flows through second evaporator coil (56) and then enters the first evaporator coil (11) connected to it. The flowrate of

feed water is recorded by flow transmitter (20) and the total dissolved solid content is measured by TDS sensor (22). The saturated water exits the first evaporator coil (11) through outlet (43) and enters the flash tank (18) where steam is released from outlet (51). The total dissolved solids content in the boiler blowdown water drained from flash vessel is measured by TDS (Total Dissolved Solids) meter (52). Level transmitter (25) maintains the level in the flash tank (18) by controlling speed of pump (21). There is continuous blowdown from flash vessel which maintains the TDS of boiler water within desired limits. A part of the steam from flash tank is supplied to the Deaerator by pipeline (27) for heating the water in deaerator tank.
ADVANTAGES AND FEATURES OF THE PRESENT INVENTION:-
1. The embodiments 1 and 2 of the present invention does not require employment of certified boiler attendant therefore, has less operating hassles.
2. The embodiments 1 and 2 of the present invention are both fully automatic boilers therefore they can be operated independent of operator.
3. The embodiments 1 and 2 of the present invention are solid fuel fired boilers therefore they have lesser operating cost than the boilers mentioned in prior art.
4. The water cooled jacket prevents overheating of coil thereby maintaining its strength.
5. Automatic Water Level Control System for De-aerator Tank
6. Automatic Water Level Control System for Flash Vessel
7. Online monitoring and control of Boiler Water and Feed Water parameters
8. Automatic Steam Pressure Control
9. Skid mounted DM Water plant with chemical dosing system may be included in the system.
10. Skid Mounted Assembly of Boiler and Water Treatment Plant
a. The Boiler system explained above can be mounted on a compact
transportable skid with pre-fabricated and assembled piping, cabling,
insulation, etc.
b. The Water treatment package including DM plant, chemical dosing
system can be mounted on same or separate skid.

11. Flash tank removes droplets from steam ensuring delivery of dry steam; the steam outlet of which is provided with flow meter to measure flow of steam.
VARIATIONS POSSIBLE TO BE COVERED AND PROVIDED WITHIN THE PRESENT INVENTION:-
1. The number / dimensions of evaporator coils shall vary depending on the volumetric capacity required for the said boiler.
2. The solid fuels fired in the boilers in the present invention could be but not limited to coal, biomass, petcoke etc.
3. The gas cleaning equipment on the exhaust flue gas from the said boiler can be cyclone / multiclone / bag filter.
TYPICAL APPLICATION AREAS:-
Small process industries having steam requirements that fall in range of Non IBR and SIB type boilers

WE CLAIM:-
1. Accordingly the invention provides solid fuel fired small industrial boiler and IBR exempted boiler and systems thereof comprises an outer body formed by a pair of co-axial cylindrical jacket bodies (35,36) to form jacketed body with tubesheets (44) connected at upper and lower end of the jacket such that the annular space of which has number of vertical smoke tubes (12) running parallel to each other and mounted distant radially connecting the said tubes sheets; a furnace, with primary air and secondary air supply means , at bottom, provided with a water cooled oscillating grate; an evaporator coil (11), made of coiled tube, formed in cylindrical shape mounted coaxially above the said furnace in such a way that the flue gas exhaust through the said smoke tube (12) having path to heat inner(33) and outer surface(34) of said evaporator coil/coils and inner jacket wall; a flue gas cleaning system (14) provided between the said smoke tube outlet and exhaust chimney (16); a first outlet from deaerator tank (17) connected through pump (50) to inlet of oscillating grate (5) to supply cooling water; the jacketed body annular space having inlet to receive heated water from the grate and having an outlet connected to the said de-aerator tank; heat recovery heat exchanger (62) to recover heat of flash steam from the said deaerator and another heat recovery heat exchanger (60) to recover heat from blowdown water by heating make up water, a mixer (61) to mix heated make-up water in to the hot water through outlet (41) which flows in to deaerator (17); a second out iet from the said deareator tank(17) connected the inlet of said evaporator coil through a feed pump (21); an outlet of evaporator coil connected to inlet of flash tank (18) through the water pressure transmitter(28) and an out let provided to the said flash tank to take out steam.
2. The boiler system as claimed claim Iwherein the said furnace is lined with two layers of refractory.
3. The boiler system as claimed in claims 1 and 2 wherein a fuel hopper (1) equipped with a fuel feeder (Screw or Rotary type) (2) to supply fuel to the

said water cooled oscillating grate (5) of boiler with cylindrical construction (30) through chute (29).
4. The boiler system as claimed in claims 1 to 3 wherein the said evaporator coil consists of single coiled tube, made in cylindrical shape, mounted coaxially having an inlet at one end the said tube coil and an outlet to the other end of the said tube coil.
5. The boiler system as claimed in claims 1 to 4 wherein the said evaporator coil consists of two are more coiled tube, made in cylindrical shape, mounted coaxially and connected serially so as to form inlet of outer most of the said tube coil and an outlet to the inner most of the said tube coil.
6. The boiler system as claimed in claims 1 to 5 wherein a first Variable Frequency Drive (37), controlled by the said water pressure transmitter provided to drive the said feeder and a second variable frequency drive, controlled by the said water pressure transmitter to drive primary air force draft (FD.)fan.
7. The boiler system as claimed in claims 1 to 6 wherein the said flash tank is provided with level transmitter to maintain water level.
8. The boiler system as claimed in claims 1 to /wherein a TDS (Total Dissolved Solids) meter is provided to the said flash tank and feed pump pipeline.
9. The boiler system as claimed in claims 1 to 8 wherein, to control the pressure, a pressure sensor provided in the furnace to control the variable speed drive of exhaust chimney fan.
10. The boiler system as claimed in claims 1 to 9 wherein the said flash tank removes droplets from steam ensuring delivery of dry steam; the steam outlet of which is provided with flow meter to measure flow of steam.