HISTORICAL NOTES AEROTO INDIA. Interactive table of contents. historical notes. Boldrocchi Group operations. R&D, process engineering and service

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2 HISTORICAL NOTES On the rd of March 909 LUIGI BOLDROCCHI established the activity with the first orders for the supply of ten centrifugal fans. In 9 the Officine Termo Meccaniche BOLDROCCHI was set up in Milano with an operating area of 000 square meters. In 9 the first plant for air pollution control was produced. The company offered a wide range of products including radial and axial fans, fire-tube boilers, coolers, dryers, ventilating and heat-exchange units and plants. In 9, the licence for the manufacture of finned tubes was acquired in the USA and the manufacture of extended surface heat-exchangers was developed. From then on, the product range has been enlarged, above all as regards air coolers and steam condensers, heavy duty lng. Luigi Boldrocchi (880-99) and process fans, gas turbine ancillaries and diverters. Founder of the Boldrocchi Company The recent acquiring and incorporation of several companies (Aeroto, Marelli Ventilazione, De Cardenas) allowed Boldrocchi to enter new market opportunities as supplier of air intake and exhaust gas systems for gas turbine and large fans for any industrial application. In 00 a J-V manufacturing Company has been setup in India. In 00 a Boldrocchi Ecologia India office has been setup in Pune to manage air pollution business. historical notes operations Fans and service Engineered fans Main applications After sale service Direct main customers Contacts D.I. high head centrifugal fan supplied in 9 Te chnical drawing of centrifugal fan

3 BOLDROCCHI GROUP OPERATIONS Historical notes operations Fans In Italy, there are four separate workshops with total of,000 SQM manufacturing area. Boldrocchi in Italy employs 00 staff, among which 0 are qualified engineering staff. Boldrocchi production in Italy is divided into four main lines-heat exchange (exchanger and coolers), fans, industrial noise protection and air pollution control. Aeroto Boldrocchi India Private Limited was set up on th September 00, with a total 000 SQM manufacturing area. Boldrocchi India employs 80 staff, among which 9 are qualified engineering staff. Boldrocchi India production is dedicated to manufacturing of Industrial fans and heavy duty dampers. Production is featured by highly specialised technical contents of Boldrocchi Italy, many decades of on site experiences, flexibility in design and in production together with high quality C.A.D. Workstation in technical office standards. Supplies are tailor made to fulfill all Customer specific requests. Boldrocchi Quality system is as per ISO 900 edition 008 and according to ASME code. A wide range of materials are usually utilised: steel and copper alloys, aluminium,titanium and plastic materials; welding processes have been qualified. The products are subject to intermediate and final testing, witnessed by the Customers. Boldrocchi shops are equipped with acoustic and aeraullic test facilities. Boldrocchi Italy has additional facility to conduct thermal test. and service After sale service Product portfolio of EXCHANGERS Air coolers for refinery service and for other industrial purpose Shell and tube heat exchangers and feedwater heaters Surface condensers Steam vacuum condensers Gas heaters and coolers Air preheaters Finned tube coolers and heaters COOLERS FOR POWER TRANSFORMERS Air-oil and water-oil coolers Low noise fans Axial and radial pumps COOLERS FOR ELECTRIC MOTORS AND GENERATORS Air-air coolers and air-water coolers Explosion proof and special equipment Complete equipment with coolers, hoods, fans, filters and silencers Hydrogen coolers Oil bearing coolers Heavy duty axial fans RADIAL FANS For industrial application Flow rate : up to 00 m Pressure : up to 80kpa Shaft power : up to 8000kw 0 Temperature : up to 80 C Tip speed : up to 00 M/S Use of special Materials Gas tightness for special fluids Wear and corrosion design /s AXIAL FANS Variable pitch blades High efficiency Use of special Materials AEROTO DIVISION Gas turbine air intakes Gas turbine exhaust systems with diverters, silencers and stacks. Absorption and resonance silencers Silencers for gas exhaust of internal combustion engines Acoustic enclosures complete with auxiliary plants ECOLOGIA DIVISION Fabric filters Electrostatic precipitators Scrubbers Mechanical collectors Gas coolers and conditioning towers Hot gas ducts Dust handling Bag filters and ESP revamping Gas cleaning plants enhancement Planned maintenance services SERVICE DIVISION Problem solving Field measurements Rebuilds and upgrades Revamping of existing equipment Component upgrade and overhaul Commissioning and erection supervision Periodic and preventive maintenance

4 Historical notes operations Fans and service After sale service FANS Today Boldrocchi spans over a wide range of fan types, used in all industrial applications. The growing importance of these machines marked the steps of a continuous and quick technical evolution, to which Boldrocchi has perfectly adapted in terms of design and manufacturing capabilities. For instance, with the recent acquisition of the technical and production knowhow of Aeroto, De Cardenas and Marelli Ventilation Companies, Boldrocchi became an outstanding supplier, not only in Europe, in the heavy duty fans field. Synergies with Aeroto Dept. for acoustic treatment and with Boldrocchi Ecologia for gas dedusting are another strength point of Boldrocchi fan production. DESIGN, CONSTRUCTION AND TESTS The high performance fans, as requested nowadays, involve strict procedures throughout all stages of design, manufacturing and testing. As regards fans materials and in particular for the rotating parts, Boldrocchi foresees high-yield materials and corrosion/abrasion protecting coatings. Impeller and steel works calculations are performed on stress analysis for a proper sizing of all the details. Moreover the rotating parts are designed to avoid any resonance with the supporting structures. Boldrocchi manufactures its fans using certified materials. All weldings are carried out according to proper specifications by pre-qualified welders and with pre-qualified procedures. Stringent dimensional and ND tests are performed on all the portions and on the whole assembled fan. Impellers are carefully balanced on high-sensitivity balancing machines. Large Fan Heavy duty process fan for industrial application Performance test Test room in Biassono workshop as per AMCA 0

5 Historical notes operations Fans and service R & D A deep search based on software finite element calculations allows Boldrocchi to choose the proper size and materials of designed fan, in order to match the customers requirements. In our test room tests are carried on in compliance with international standards, even on fan prototypes, in order to point out their performance curves: flow rate-pressure,flow rate-power,flow rate-noise level. The experimental data are processed by the Engineering Department to optimize the fans series. Special tests are performed, on case by case basis, to verify the fans performances, even assembling specific test rigs. PROCESS ENGINEERING AND SERVICE Thanks to an extended experience in the ventilation business, Boldrocchi is able to supply to customers a valuable and reliable engineering consultancy service, on already installed fans, to increase performances, to comply with environmental rules, and to save energy, either on own production fans or on fans supplied by other manufacturers. This service integrates the after sales service, dedicated mainly to periodic and predictive maintenance, mechanical troubles diagnostic and solution, dynamic balancing of rotors on site and erection /supervision. After sale service Finite Element Analysis In specific requirements, casing stress analysed with shell and brick element Special test Hot gas test for chlorination blower Test performed at 00 C for hours and hour without lubrication unit New products Mechanical vapour recompression blower Double stage blower with duplex steel Ø 0 mm Speed 00 rpm

6 ENGINEERED FANS We specialise in Engineered Industrial Fans for process and heavy duty applications, which are supplied with the following features: Rotating part dimensioning and material selection is done using Stress & Frequency Analysis (FEA) Historical notes operations Fans and service Rolled and profiled Inlet cone and shroud manufactured on special purpose spinning machine After sale service Forged steel shaft having integral hub, for high torsional rigidity, uniform thermal expansion and easy maintenance Machined impeller I.D & O.D. and machined ring at impeller eye for close manufacturing and dimensional tolerances.

7 METALLURGY Combustion air fans, boosters, exhausters for: EAF, LD converter, sinter plant, stockhouse, continuous casting, Coluper, etc. Turn key plants and filters can be supplied in cooperation with Boldrocchi Ecologia. Historical notes operations Fans and service Metallurgy Power 8 Incinerators 9 Chemical, fertilisers and petrochemical 0 Cement Marine applications After sale service Sinter Plant exhauster at JSW Ø00mm Rating 800 kw Speed 000 rpm Exhaust fans for SMS Installed power 00 kw Speed 000 rpm Ball mill fan at Essar steel PP Ø00 mm Rating 800 KW Speed 000 rpm

8 POWER Forced draft fans, primary and secondary air fans, gas recirculation fans, induced draft fans for power boilers, deno x /deso x systems. Historical notes operations Fans and service Metallurgy Power 8 Incinerators 9 Chemical, fertilisers and petrochemical 0 Cement Marine applications After sale service 8 ID Fan for CFB Boiler 00 MW ENEL power plant, Sulcis (Italy) Ø 00mm Rated power 00KW FD Fan for 0MW Boiler ENEL power plant, Montalto di Castro (Italy) Ø 0mm Rated power 800KW FD Fan for Auxiliary Boiler NODCO Refinery expansion Qatar Contractor Macchi Double drive : Electric motor + Steam turbine

9 INCINERATORS Forced draft fans, primary and secondary air fans, induced draft fans for incinerating plants. Historical notes operations Fans and service Extraction fan For water saturated flue gas from refuse incinerator Rubber lined casing with Uranus B impeller Flow rate. m /s Static pressure. kpa Shaft power kw Metallurgy Power 8 Incinerators 9 Chemical, fertilisers and petrochemical 0 Induced draft fan For deso x application in an incineration plant Flow rate. m /s Static pressure kpa Installed power 00 kw Speed control by hydraulic coupling Cement Marine applications After sale service Induced draft fan Welding of titanium impeller for waste refusal gas Ø 00 mm Static pressure kpa Flue Gas fan Impeller in AVESTA SMO, Flue Gas fan for incineration unit Ø 00mm Rated power 00KW 9

10 CHEMICAL, FERTILISERS AND PETROCHEMICAL Fans for hydrocracking, ethylene, ammonia-urea, chlorination, methanol, Formaldehyde, sulphuric acid, granulation, fluidization, alumina plants, etc. Historical notes operations Fans and service Engineered fans Main applications Metallurgy Power 8 Incinerators 9 Chemical, fertilisers and petrochemical 0 Cement Marine applications After sale service Direct main customers Contacts Flue Gas Fan Flue Gas fan for Hydrogen plant Combustion Air Fan Combustion Air fan with are intake for Hydrogen plant 0 Ethylene Cracking Furnace Fan Flue gas fan for Ethylene Cracking Furnace Chlorination Blower Chlorination Blower for CCR Unit Operating Temperature 8 0C Impeller in Inconel 00 Specification UOP

11 CHEMICAL, FERTILISERS AND PETROCHEMICAL Double stage blower for L&T Rating 0 KW Speed 000 rpm Pressure kpa Historical notes operations Granulator scrubber Rating 800 KW Speed 00 rpm Material AVESTA 0 Fans and service Flue Gas for Ammonia Plant at ENGRO Chemical Pakistan Dual Drive : Electric Motor / Turbine Rating 800 KW Speed 000 rpm Metallurgy Power 8 Incinerators 9 Chemical, fertilisers and petrochemical 0 Cement Marine applications 8 Two Fans in series for UHDE Formaldehyde plant at SAFCO. Rating x0 KW Speed 00 rpm Pressure. kpa After sale service 8 9 Customer: GE Oil & Gas Rating 0 KW Speed 00 rpm Direct drive impeller mounted on motor shaft Gravity louvre dampers. 9

12 CEMENT Raw mill fans, kiln primary air fans, kiln exhausters, filter exhausters, final exhausters, grate cooler fans, clinker grate exhausters, cement mill fans, coal mill fans, separator fans. Turn key plants and filters can be supplied in cooperation with Boldrocchi Ecologia. Historical notes operations Fans and service Metallurgy Power 8 Incinerators 9 Chemical, fertilisers and petrochemical 0 Separator fan Ø900mm Rated power 0 KW Speed 0 rpm MCL Kenya Cement Marine applications After sale service Raw Mill Fan Buzzi USA Ø0 mm Rating 00 KW Speed 000 rpm Pre Heater Fan JAL- GACL SP II Ø0mm Rating 80 KW Speed 000rpm

13 CEMENT Cooler Exhaust Fan JAL - GACL SP II 00mm Rated power 00 KW Speed 0 rpm Ø Historical notes operations Fans and service Coal Mill Fan MCL Kenya Ø0mm Rated power 80 KW Speed 000 rpm Metallurgy Power 8 Incinerators 9 Chemical, fertilisers and petrochemical 0 Cement Marine applications After sale service Other Fans Primary Air Fans Airslide Fans Cooler Fans

14 MARINE APPLICATIONS Supply and exhaust fans for compressor room, for evaporators room, for purifier room (combustion and cooling air), for diesel generator (combustion air), for propulsion electric motor, for battery room. Historical notes operations Fans and service Metallurgy Power 8 Incinerators 9 Chemical, fertilisers and petrochemical 0 Cement Marine applications After sale service Exhaust fans for P.E.M. room Axial type with variable pitch blades (at rest) Ø 00 mm Flow rate.m /s Static pressure 0.8 kpa Installed power 8 kw Speed 00 rpm Main engine combustion air service Hot deep galvanised centrifugal fans Flow rate.m /s Static pressure. kpa Installed power 0 kw Speed 800 rpm Main engine combustion air service Fans for P&O Cruise Vessel Contractor : Mitsubishi Heavy Industries

15 AFTER SALES SERVICE Problem solving, field measurements, rebuilds and upgrades. Revamping of existing equipment, component upgrade and overhaul, Commissioning and erection supervision. Periodic and preventive maintenance. Historical notes operations Fans and service On site supervision during erection Mill exhauster for Cement Calcia Ø 0mm Rating X00 KW Speed 000 rpm After sale service Bearing Installation & Alignment At Saudi Kayan Petrochemical complex, Al-Jubail KSA Replacement of Wear Liners Photograph shows wear liner replacement done at our workshop Revamping Solutions Methods used to revamp are: Speed increase Impeller blades tipping Impeller change

16 Aeroto India - Direct main customers Historical notes operations Fans and service After sale service ABB Lummus Ansaldo ARM Cement BHPV Bangladesh Fertilizer BJCIL Cement Satna BSES Chambal Fertilizer Engineers India Limited Essar Refineries Essar Steel Fouress F L Smidth Techint Hypertherm Indo Gulf Fertilizer IFFCo IOCL (Haldia, Gujarat & Panipat) Jacobs Netherland Jaypee Sidhi Cement Jaypee Super Cement JNK Heaters Korea JSW Stell Jaiprakash Associates Limited Jindal Steel & Power Kanoria Chemical Krupp Polysius Kutch Chemical Larsen & Toubro Process Larsen & Toubro Cement Maithan Ispat Mangalore Refineries Metso Power Mombassa Cement MSPL Steel Mukund Steel Nagarjuna Fertilizer National Sulphur, KSA NTPC National Fertilizer PDIL Punj Lloyd Raipur Alloys Reliance Jamnagar Refinery RCF Shivam Cement Nepal Snamprogetti Shriram Fertilizer SISCOL Sterlite Tata Steel Tata Chemical Technimont Technip KT India Thermax Tororo Cement Uhde India Uttam Sugar

17 Viale Trento e Trieste 9-08 Biassono (MB) - Italy Historical notes operations Fans Group Headquarters Viale Trento e Trieste 9, 08 Biassono (MB) - Italy Phone Fax [email protected] Indian Headquarters & Factory B - &, SIPCOT Industrial Area, Irrungatturkottai, Kancheepuram - 00 (TN) Phone +9 - Fax [email protected] Boldrocchi India and service Engineered fans Main applications Corporate Sales Office - Gurgaon - India [email protected] Branch Office Kolkatta - India [email protected] Branch Office Mumbai - India After sale service Direct main customers Representative Office North America Contacts Boldrocchi Ecologia India Office - Pune [email protected] [email protected] [email protected]