DDFC (Pvt.) Ltd. is a leading engineering and fabrication company, renowned for manufacturing high-quality steam boilers to British standards BS 2790 (latest addendum). With decades of expertise, DDFC specializes in smoke tube boilers, available in various capacities and pressure ratings, designed to meet the needs of industries requiring efficient and reliable steam generation solutions.
Key Specifications:
- Capacity: From 1 ton per hour (TPH) to 32 TPH. Boilers with capacities beyond 20 TPH utilize a twin-furnace design for improved performance.
- Pressure Rating: Up to 25 bars (depending on capacity), making it suitable for a wide range of industrial applications.
Design Verification:
- DDFC’s boiler designs are verified by a UK-based consultant, ensuring international compliance and performance standards.
- The final design is also checked and approved by the Royal Sun Alliance Insurance Co. of UK, as required by the customer.
Design Features:
- 3 Pass Wet Back Design: The proven, time-tested 3-pass wet-back design with a fully submerged reversal chamber is widely regarded as the industry standard.
- Customization: DDFC offers full customization to meet the specific requirements of each customer, ensuring maximum efficiency and minimal downtime.
- No Proprietary Components: The majority of the boiler’s controls and instrumentation are standard items sourced from international manufacturers, eliminating the need for proprietary parts and reducing downtime in case of control malfunctions.
Product Features:
- European Design: The boiler is designed using European engineering practices for enhanced efficiency and performance.
- Maximum Efficiency: High operational efficiency ensures energy savings and cost reduction for the customer.
- Minimum Maintenance: Designed for easy maintenance, reducing downtime and operational costs.
- Multi-Fuel Firing: Capable of firing multiple types of fuel, offering versatility to meet different operational needs.
- Quality Assurance: All components are sourced from certified international manufacturers to guarantee reliability and long-lasting performance.
Instrumentation and Control:
- The boiler comes with a fully integrated electric control panel that includes all necessary controls for the boiler and burner, equipment starters, circuit breakers, and isolating switches.
- The panel is constructed to IP42 standards, with higher enclosure ratings available.
- A PLC-based control system is available as an option for advanced automation and monitoring.
Ease of Inspection:
- Fire Side Inspection: The front and rear doors of the boiler are hinged, providing full access to the fire side tube surfaces for inspection and cleaning, without the need to disconnect the burner and fuel piping.
- Water Side Inspection: A manhole on top and sedimentation holes on the lower part of the shell provide easy access for inspection of the water side surfaces.
Blow Down System:
- Each boiler is equipped with a blowdown connection, allowing for manual or automatic blowdown to maintain proper Total Dissolved Solids (TDS) levels in the boiler water.
Combustion Systems:
- DDFC provides a wide range of single and dual-fuel burners, including nozzle and rotary cup designs, to meet customer needs and budgets.
- Low NOx and SOx burners are available for customers with stringent environmental requirements.
- Oxygen Trim System: Large boilers can be fitted with an oxygen trim system, reducing excess air in the exhaust gases, which minimizes heat losses and improves fuel efficiency.
Ancillary Equipment:
- Feed Water Tank & Deaerator: A non-pressurized system with a feed water tank equipped with heating coils, spargers, temperature control systems, and optional level control probes. Pressurized tank configurations are also available.
- Feed Water Pumping System: Includes operational and standby pumps, along with necessary valves and controls.
- Fuel Oil Storage & Pumping System: Designed for heavy fuel oil or diesel oil, available upon customer request.
- Economizers: Improve thermal efficiency by capturing additional heat from exhaust gases, which is used to heat feed water, thereby reducing boiler fuel consumption. Economizers are included as standard for natural gas-fired boilers with capacities of 2 TPH or larger and are also available for HFO-fired boilers.
- Measuring Instruments: Optional instruments for measuring steam, water, and fuel oil parameters, available for both local and remote monitoring.
The DDFC Advantage:
- Warranty: DDFC provides a warranty against defects in design, material, and workmanship for a specified period.
- Quality Assurance: DDFC’s quality management system is certified to ISO 9001:2008 by Lloyd’s Register of Quality Assurance, ensuring that the company meets international quality standards.
- After-Sales Service: DDFC offers prompt and responsive after-sales support, ensuring that customer needs are met quickly and efficiently.
- Turnkey Service: DDFC provides complete turnkey services, including concept development, engineering, installation, and commissioning of the steam generation system, along with detailed engineering for the steam distribution network.
- Proven Track Record: DDFC has a strong track record of manufacturing, installing, and commissioning steam boilers for national and multinational companies in industries such as textiles, power generation, chemicals, petrochemicals, pharmaceuticals, cement, and food & dairy.
