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‘SUPER’
HEATERS
THE WORLD’S MOST EFFICIENT
SOLID FUEL BASED INDIRECT FIRED HEATERS FOR THE TEA INDUSTRY

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Introduced to the
Tea Industry in the mid-eighties and subsequently evolved into
the revolutionary Phase – II design at the beginning of the
new millennium, the ‘SUPER’ heater remains AARKAY’s
biggest contribution to the Industry at large. In an industry
plagued with high manufacturing costs, the ‘SUPER’ heater
guarantees coal ratios as low as 0.4 per kg. of made tea. With
close to 150 installations in
North India
alone, the ‘SUPER’ has found industry - wide acceptance
with both the corporate sector as well as the private bought
leaf / plantation sector.
The
SUPER heaters can be fired with either coal - lump
or dust, leco, firewood, gas or oil. They come with AARKAY’s
hassle-free COMPOSITE GUARANTEE and SINGLE POINT SERVICE since
AARKAY is also a leading manufacturer of Chain Grate Stokers
with more than 200 installations.
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THE 'SUPER' CONCEPT |
It
was in the mid-eighties that Aarkay launched its range of
‘SUPER’ – Phase I heaters, coining the term ‘PASS’
in the process. The SUPER heaters sought to seek a balance
between the flow of the process air and the path of the flue
gas within the heater. The 4 - stack Tube Bank structure of
the fourth-Generation ‘Special’ Heaters was retained. A
unique cross- path was evolved for the flow of process air.
The
SIX
PASS
was
coined to denote this new flow-design of process air. Coupled
with automated coal stoking (Aarkay remains, to date, the only
heater manufacturer to offer the complete single-point heating
solution with automated stoking), the result was phenomenal
– a range of super-efficient heaters which could take upon
any Dryer, Conventional or Fluidized, and was capable of
giving unheard-of fuel economies. The chimney temperature was
brought down much below the targeted 115 degree mark and the
Dryer Inlet Temperature would remain rock-steady in any
climatic conditions.
Continuous
on-site R&D and the undying commitment to pioneering and
excellence finally led to the evolution of the Phase – II
design, a revolutionary new heating system for the new
Millennium. The Phase –II design has a unique 6-stack
structure. The robust simplicity of the Phase – I design has
been retained. The flow of the process air has been
re-designed to include initial passage through the new
in-built heat recovery unit which recycles the spent heat from
the exiting flue gas before discharging it through the
chimney. The Phase –II design employs a staggering figure of
nearly 400 tubes of different shapes, sizes and design.
It
may be noted here that the ‘SUPER’ theory does not
advocate the replacement of C.I. tube stacks with fabricated
M.S. tubes in the main heater body as the rough-surfaced oval
CI Tubes promise better heat absorption and a much higher life
span as compared to their smoothened round fabricated
counterparts.
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TECHNICAL
SPECIFICATIONS |
MODEL |
10 |
12 |
14 |
16 |
18 |
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Phase-I |
Phase-I |
Phase-I |
Phase-II |
Phase-I |
Phase-II |
Phase-I |
Phase-II |
Hot Air Output Capacity (Kgs./hr. at 140º C) |
9,000 |
14,000 |
22,000 to 24,000 |
32,000 to 33,000 |
38,000 to 39,000 |
Heat Generation Capacity (K. Cal./hr. at 5000 K. Cal / kg. of coal) |
4,00,000 |
6,00,000 |
7,00,000 to 8,00,000 |
9,00,000 to 10,00,000 |
11,50,000 to 12,50,000 |
Fuel Consumption (per hour)
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Lump / Dust
Coal (kgs.)
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60-70 |
80-100 |
100-120 |
85-100 |
130-150 |
110-130 |
190-210 |
160-180 |
Leco (kgs.)
|
45-55 |
60-70 |
75-85 |
65-70 |
100-110 |
85-95 |
140-150 |
120-130 |
Fire
Wood (m3) |
0.3 |
0.4 |
0.6 |
0.5 |
0.75 |
0.7 |
1.0 |
0.9 |
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'SUPER' FEATURES |
VERSATILE
The SUPER
comes in varying sizes to suit various Dryer capacities and can be fired with either coal, leco, firewood, gas or oil.
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FUEL ECONOMY & HEAT TRANSFER
The SUPER
Phase – I (
SIX
PASS
) and Phase- II (
EIGHT
PASS
) models optimize the heat
transfer process between the flue gas and the process air and
thereby offer unprecedented fuel economies as low as 0.4 –
0.5 kg. of coal / kg. of made tea.
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BETTER HEAT RETENTION & ROCK STEADY
DRYER INLET TEMPERATURE
The
‘SUPER’ design optimizes heat retention inside the heater
and reduces heat loss. The Dryer Inlet temperatures remain
rock-steady even in the most adverse climatic conditions.
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CASTING LIFE & MAINTENANCE
All Cast
Iron parts are made from superior quality Graded Castings for
better durability and heat resistance. As there are no moving
parts, very minimal maintenance is required on a regular basis
except for cleaning of tube banks. Provision of conveniently
placed Cleaning and Soot removal doors at the front and rear
ends facilitate easy tube cleaning, soot removal and casting
inspection.
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EASY & QUICK INSTALLATION
‘SUPER’
Heaters can be erected on a firm and rigid 9” thick concrete
base set on solid Earth. No excavation and no foundation bolts
are required.
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INDUCED DRAFT SYSTEM
The
‘SUPER’ heaters are designed to handle both Induced and
Forced Air. ‘SUPER’ Induced Draft fans operate on
relatively low RPM, thereby enhancing impeller life and
reducing risk of back-pressure. Inlet and bypass dampers are
provided in the fan for better control.
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TUBE BANK STACKS
All
the Tube Bank Stacks in the Main heater body are made from
Cast Iron. The single-cast CI Tube Bank with rough-surfaced
oval CI Tubes promise better heat absorption and a much higher
life span as compared to its fabricated MS counterpart with
smoothened round tubes.
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HEAT RECOVERY SYSTEM
‘SUPER’
Phase-II Heaters are fitted with unique built-in Heat Recovery
Units that pre-heat the process air with recycled waste heat
with the result of giving unprecedented and unmatched fuel
economies.
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MECHANICAL STOKING & A COMPOSITE
GUARANTEE
Aarkay remains, to-date, the only heater manufacturer
to offer a complete heating system with built-in mechanical
stoking capability. Hence,
our composite guarantee also covers the entire heating system
in toto without the room for any conflict or controversy as
regards the quality and performance of the ‘SUPER’ heating
system.
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