FBC involves suspending solid fuel (like coal or husk) in a bed of hot sand or ash using high-pressure air. This creates a "fluid-like" state that ensures turbulent mixing and uniform temperature, leading to almost 100% combustion of even low-grade fuels.

Most standard heaters use three passes. Our Fourth Pass adds an extra layer of heat recovery, significantly reducing the exit flue gas temperature and boosting overall thermal efficiency by 3–5% compared to traditional designs.

The FBC furnace is incredibly versatile. It is optimized for "free-flow" fuels such as:

• Agro-waste: Rice husk, sawdust, and coffee flakes.
• Coal: Pulverized coal, lignite, or imported coal.
• Biomass: Small wood chips and crushed briquettes.

The vertical orientation has a significantly smaller footprint than horizontal units. It is ideal for factories with limited floor space but available vertical height, allowing for a compact utility area.

Thanks to the Four Pass design and FBC technology, these heaters achieve an overall thermal efficiency of 82% to 85% (NCV). Efficiency can be further increased with an Air Pre-Heater (APH).

Standard units at indianboilers.com are designed for temperatures up to 300°C. For specialized high-temp processes, we can engineer units capable of reaching 350°C using synthetic thermal oils.

No. Like all thermic fluid systems, it provides high heat (300°C+) at very low pressures (typically 2–5 bar). This makes it much safer than a high-pressure steam boiler.

We offer capacities from 4 Lac kcal/hr to 100 Lac kcal/hr (10 Million kcal/hr), catering to both mid-sized plants and massive industrial complexes.

We provide automated Under-bed (Pneumatic) or Over-bed (Screw Feeder) systems. These systems are synchronized with the temperature controller to increase or decrease fuel flow automatically.

• Rice Mills: Using their own husk as free fuel.
• Plywood & Laminates: For high-temperature presses.
• Textile Processing: For stenters and curing ranges.
• Chemical & Edible Oil: For distillation and refining.

No. Thermic fluid heaters are generally Non-IBR, which means you do not need an IBR-certified attendant or annual government inspections of the pressure vessel, though safety norms still apply.

FBC technology maintains a uniform bed temperature (typically 850°C–900°C), which is below the ash fusion temperature of most fuels. This prevents the formation of "clinkers" (hard ash lumps) that can clog grate-fired heaters.

• Bed Temperature Monitor: Prevents furnace overheating.
• Differential Pressure Switch: Shuts down the system if oil flow drops.
• High Stack Temp Alarm: Indicates if heat is being lost or if coils need cleaning.

No. We include an easy-access ash discharge system. Since the fuel burns completely in the fluidized bed, the volume of unburnt carbon is virtually zero.

The "Four Pass" path is designed with sufficient velocity to prevent soot buildup. However, we recommend a monthly inspection and cleaning of the convection passes to maintain peak efficiency.

By using SA210 Grade boiler tubes and ensuring high oil velocity, our coils are designed to last 15 to 20 years with proper oil quality management.

Pricing is capacity-dependent. Estimated rates for 2025 at indianboilers.com are:

• 4 Lac to 10 Lac kcal/hr: ₹2,000,000.
• 20 Lac to 50 Lac kcal/hr: ₹25,00,000 – ₹55,00,000.
• High Capacity (100 Lac kcal/hr): ₹90,00,000+.
• Note: Prices vary based on automation (PLC/SCADA) and pollution control (Bag filters).

Manual heaters have low efficiency (60-70%) and high labor costs. FBC heaters offer 15% higher efficiency and use cheaper, low-grade fuels. The fuel savings alone usually pay back the price difference within 8 months.

Visit indianboilers.com, navigate to the VFF-Series, and click "Request a Quote." Please provide your required kcal/hr, fuel availability, and site location for a detailed proposal.