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Energy | The power that moves the world

Since its foundation, Sermatec Zanini® has carried out major undertakings. In the last 15 years the company has supplied more than 160 steam generators for burning several fuels, thus serving varied market segments.

In 2009, 22 new projects for bioelectricity generation were delivered, accounting for supplying an average of 150 MWh to the Brazilian energy matrix. Sermatec Zanini® experience and tradition have made it one of the main players in the supply of steam generators to Latin American companies.

Energy,our business

IACO AgrícolaWater-tube Boiler

Capacity: 200.000 kg/hPressure: 65 kgf/cmTemperature: 520 oC

Zanini / Sermatec, more

than 500 boilers in operation

in Brazil, the Americas,

and Angola

Markets where it operates• Sugar and ethanol• Paper and pulp• Mining• Oil and gas• Chemical and petrochemical• Foods• Steelmaking• Energy generation

Sermatec Zanini® projects for steam and energy generation contemplate different conceptions of systems for burning solid, liquid or gaseous fuels in rotary grates, pin-hole, tilting or through modern, efficient systems of bubbling or circulating fluidized bed, thus offering the best cost-benefit ratio available in the market.

Manufactured to produce process steam or generate electric power at thermoelectric plants, Sermatec Za-nini® water-tube boilers are designed to provide high operational availability based on burning conven-tional fuels or such process waste as biomass residue, STP sludge, coal-mine tailings, petroleum coke, etc.

100 kgfcm2

EquipavWater-tube BoilerCapacity: 200.000 kg/hPressure: 67 kgf/cmTemperature: 490 oC

São Fernando PlantWater-tube BoilerCapacity: 250.000 kg/hPressure: 100 kgf/cmTemperature: 540 oC

ETH Bioenergia | Unit Rio ClaroWater-tube BoilerCapacity: 260.000 kg/hPressure: 67 kgf/cmTemperature: 520 oC


Fully automated, Ser-

matec Zanini® water-tube boilers can reach a capacity of 500 TSH or higher, and steam-operation pressure of up to 150 kgf/cm², and steam temperatures higher than 530 °C.

Tradition and competence

Adecoagro Group | Angélica PlantWater-tube Boiler ICapacity: 200.000 kg/hPressure: 68 kgf/cmTemperature: 480 oC

Water-tube Boiler IICapacity: 320.000 kg/hPressure: 68 kgf/cmTemperature: 480 oC

ETH Bioenergia | Conquista do Pontal UnitWater-tube Boiler


ETH Bioenergia | Santa Luzia UnitWater-tube Boiler


ZACI - Zanini Comércio Internacional is one of the most important trading companies in Brazil, specializing in mar-keting, importing and exporting capital goods. With over 30 years’ experience and more than 50 projects implemented in several countries in the Americas and Africa, the company operates with local offices in several countries to meet the needs and requests of the international market.

The versatility and experience of ZACI – Zanini Comércio Internacional in managing complex projects, most of which of the turnkey type, allows it to offer its clients differentiated services which provide an excellent cost-benefit ratio.

Differentiating features

• Project Finance made feasible for the development of financial engineering and in structuring the legal procedures with domestic and international bodies in a proper manner to meet the specific requirements of each project.

• Specializing in technical solutions with engineering teams experienced in sugar cane and biomass processes available to serve the interests of the clients to carry out technical and economic feasibility studies, optimization of manufacturing processes, upgrading of plants and boilers and provision of engineering services to repower boilers and equipment.

• Drawing up international legal contracts to comply with the legal requirements and provisions of each country’s legislation.

• The after sales team performs the logistics side of project engineering, supervision, assembly, commissioning and start-up of the plant.

Trading Company

Ingenio Pantaleón | NicaráguaWater-tube BoilersCapacity: 150.000 kg/hPressure: 63,3 kgf/cmTemperature: 510 oC

Termoelétrica Enersa | Honduras14 Recorery BoilersCapacity: 6,437 kg/h*Pressure: 19 kgf/cm*Temperature: 320 oC** values per unit

Ingenio Santa Matilde | HondurasWater-tube BoilerCapacity: 150.000 kg/hPressure: 63,3 kgf/cmTemperature: 510 oC

Ingenio Ledesma | ArgentinaWater-tube BoilerCapacity: 150.000 kg/hPressure: 63,3 kgf/cmTemperature: 510 oC


Sermatec’s recognized competence in manufacturing and assembling boilers, together with Zanini’s tradition and technology, allow it to provide the market with competitive projects for the production of process steam and electric energy generation in thermoelectric plants, according to international quality norms and standards such as ASME I and ISO 9001:2008.

Fully automated, the ZS – Zanini Sermatec® boilers are designed for applications requiring high reliability and availability, meeting all the pressure, temperature, and production needs required by the market.

High-pressure boilers

THE NEW ERAOnly a traditional supplier can offer:

ProjectManufacturingAssemblyElectrical & AutomationRetrofit & RepoweringTechnical ServiceCommissioning & Start-upOperation trainingMaintenance


The ZS – Zanini Ser-matec® boilers can be installed in industrial plants and/or thermoelectric power plants, since they can burn the most varied types of fuels.

Identification of the ZS line

with a refractory belt that increases the furnace tempera-ture in that area, allowing for the burning of bagasse with a higher moisture content.

Tube bundleThe tube bundle or evaporators are designed taking into

account: heat exchange and the gas passage area, in order to work with speeds suitable for the type of fuel used, are conceived as a cross-flow, single gas passage, transverse to the tubes and allowing for effective cleaning through soot blowers.

SuperheatersThe ZS - Zanini Sermatec® boilers primary and secondary

steam superheaters are predominantly of the convection type, non drainable and properly sized for the conditions required by the boiler.

CondenserThe condenser operates as a shell-tube type heat exchanger,

having as cold fluid the boiler feed water and as hot fluid the

Sermatec Zanini® is positioned to offer boilers with 1 or 2 drums, either bottom-supported or supported by a metallic frame and struts, the latter type being the most indicated one for regions subject to seismic tremors.

FuelsZS - Sermatec Zanini® boilers are designed to burn

several types of fuels, among which: sugarcane bagasse, chopped wood, forestry waste and other biomass by products that can be burned alone or in combination with coal, oil and/or natural gas.

Combustion systemsDepending on the type and quality of fuels to be burned,

Sermatec Zanini® engineering can provide the best solu-tion for combustion systems, that is, to offer boilers with suspended burning or under a grate, thus ensuring maxi-mum reliability and thermal efficiency with the lowest cost of steam generated.

ZS - Zanini Sermatec® boilers can be supplied with fixed or moving grates. The system to spread fuel over the grate allows for the combustion process stages to take place in a sequential manner, causing the equipment to attain maximum thermal efficiency.

FurnaceIn ZS - Zanini Sermatec® boilers, the furnace is designed

taking into account the following assumptions: dwell time, gas speeds, ash softening point and circulation They are to-tally finned, ensuring equipment gas tightness, thus avoiding leakage of the gases generated during combustion, and fitted

Leading-edge technology

proprietary

ZS-2B

ZS-2T

ZS-1B

ZS-1T

until 200

until 225

until 200

>225

Bottom-supported

Top-supported

Bottom-supported

Top-supported

02

02

01

01

until 67

until 67

until 120

until 120

until 520

until 520

until 540

until 540

Boilers Production (t/h) Supporting Drums Pressure (bar) Temperature (oC)


saturated steam from the steam drum, and essentially has the function of supplying high-purity condensate to the steam temperature control system (desuperheater).

Internals of steam drumThe internals of the steam drums are designed to efficiently

perform two essential functions that must be fully accom-plished to ensure an efficient performance. One of them is to separate the steam from the water so that the downward tube system receives steam-free water, thus providing an adequate, safe natural circulation. The other function is to separate moisture from the steam, in order to ensure that it leaves the boiler extremely pure and dry.

EconomizersThe economizers (smooth or finned tubes) are designed

to increase the unit’s efficiency, through heat exchange between the feed water and the boiler outlet gases.

Specific projectfor each application

Air preheatersThe use of the tubular-type of air preheater is also made

to increase the unit’s efficiency, through heat exchange between the combustion air and the boiler outlet gases.

Supporting structuresThe equipment structures are designed and manufactured

according to required conditions, always in compliance with ABNT and AISC standards, having staircases, platforms and catwalks for normal access to all access and inspection doors, valves, and instruments.

ManufacturingThe ZS - Zanini Sermatec® boilers items are designed

aiming at maximum prefabrication, that is, the purpose is to send the equipment to the field as fully assembled as possible. Items that may not be sent assembled due to dimensional and/or transportation reasons are preassembled at the factory. Thus, assembly is faster and consequently with a lower cost, besides ensuring a high final quality level of the product.

EngineeringDue to the various alternatives and technologies available

for combustion systems, gas treatment, ash removal, etc., Sermatec Zanini® engineering can provide its clients with the best solution and thus obtain the best efficiencies in any type of project.

MaintenanceZS - Zanini Sermatec® boilers are designed aiming to

facilitate assembly, maintenance and operating processes. The use of refractories is restricted as much as possible.

BevapWater-tube Boilers


2 unitsFully automated

ETH Bioenergia | Alcídia UnitWater-tube Boilers


Ester PlantWater-tube Boiler



The circulating and bubbling fluidized bed boilers repre-sent the most modern, recent and effective technologies for burning solid fuels, with low emission of pollutants.

With 100% of their manufacture carried out in Brazil by Sermatec Zanini®, the BFB/CFB fluidized bed boilers are made available in the market in the 15 t/h to 300 t/h pro-duction range, with no steam pressure or temperature limits, for application to all types of biomass, including for supple-mentary fuels such as tire strips, coal, petcoke and others.

Circulating fluidized bed

Representing the current state of the art in power boilers,

the circulating fluidized bed (CFB) boilers are characterized by the following main applications:

Broad range of fuel applications: - Volatile matter: 4% to 40% - Ashes: 0% to 60% - Calorific power: Greater than 1,500 kcal/kg - Moisture: lower than 65% - Use of process waste; - Flexibility of fuels: minimizing supply uncertainties; - Capable of burning low-cost fuel due to their low appli-

cation in conventional boilers.

CFB boilers provide accurate temperature control, allow-ing temperature variation along the furnace to be 15% at maximum. Thus, CFB-type boilers provide low emissions of nitrogen oxides (NOx), CO and, together with the exclusive lime injection system, low emissions of sulfur oxides (SOx), thus generally not requiring the extremely high investments in gas desulfurization systems.

With steam generation capacities starting from 30 t/h, the CFB boilers have no limits as to steam production, as well as operating pressure, being widely utilized in thermal generation units where pressures above 120 bar are recom-mended.

Alunorte - Alumina do Norte do BrasilBubbling fluidized bed boilerCapacity: 340.000 kg/hPressure: 93 kgf/cmTemperature: 490 oC

Bubbling fluidized bed boiler operating in Catanduva-SP

Fluidizedbed boilers

With 100% of their manu-facture being carried out in Brazil by Sermatec Zanini®, CFB boilers represent the state of the art in steam generators.

Bubbling fluidized bed

The combustion carried out in BFB-type boilers is characterized by the injec-tion of fuel into a sand bed, kept there until it is totally burned, which accounts for a combustion efficiency of more than 99%.

With a controlled tem-perature in the range of 850 °C, through control of the primary and secondary air ratio, as well as through recirculation of inert gases, the boilers present low emissions of particulates into the atmosphere, nitro-gen oxides (NOx), as well as CO.

With 100% of their manu-facture carried out in Brazil by Sermatec Zanini®, the BFB/CFB fluidized bed boilers are made available in the market in the 15 t/h to 300 t/h production range, with no steam pressure or tem-perature limits, for applica-tion to all types of biomass, including for supplementary fuels such as tire strips, coal, petcoke and others.

Rigesa Celulose, Papel e EmbalagensBubbling fluidized bed boiler


Technological innovation


Sermatec Meppam® engineering has been researching materials and developing projects for fire-tube projects since 1979, with a track record of more than 500 boilers installed. Our products stand out for the quality of the materials utilized, besides the projects developed aiming at maximum heat exchange based on the fuel used.

Welded equipment undergo heat treatment, is x-rayed and subjected to hydrostatic testing

under the surveillance of the quality control depart-ment in accordance with specific ASME I standards for boilers.

Sermatec Meppam® fire-tube boilers are compact, horizontal, with models with two or three gas passages, for burning solid fuels, especially waste such as: cane bagasse, vegetable husks, wood chips and high-ash coal, in addition to liquid and/or gaseous fuels through burners manufactured by companies specializing in

Model: MDS

Model: MCP Model: MZL / MZG

Fire-tube boilers

industrial combustion.With working pressures

up to 21 kgf/cm², the Ser-matec Meppam® boilers cover a capacity range from 250 kg/h to 35,000 kg/h of steam.

The company has a staff specialized in all stages of boiler manufacturing, from design to start-up, with technical expertise to offer the most efficient solutions for steam generation.

The Sermatec Meppam® boilers operate in virtually all domestic and foreign re-gions in industries such as foodstuffs, vegetable oils, juices, textiles, tobacco, paper, slaughterhouses, tanning facilities, tire recap units, clubs, hospi-tals, and kitchens, among others, and are a concrete evidence of the efficacy of our projects and quality of such equipment.

As a natural conse-quence of the good results obtained, Sermatec Meppam® has assumed for more than 30 years the leading position in the steam generator segment, with more than 500 boilers installed.

Fire-tube Boiler Sermatec Meppam®Model: MZL / MZG

Unileaf - Joinville/SC Capacity: 20.000 kg/hPressure: 10.5 kgf/cm

Fire-tube Boiler Sermatec Meppam®Model: MDSFrigorífico Friboi - Andradina/SP Capacity: 20.000 kg/hPressure: 12 kgf/cm

Zanini / Meppam over

500 boilers installed

FlexibleOperation

ReducedInstallation

Costs

MinorMaintenance

CostsMinor

OperatingCosts

EnergySaving

HighReliability

Greatercontinuity in

OperatingResults

IncreasedEquipment Life

GreaterOperational

Combustion

Phone: 16 2105 4422 | Fax: 16 2105 4450

[email protected]

Rod. Armando de Salles Oliveira, km 341Sertãozinho-SP | Zip Code 14176-500

Energy The power that moves the world

The world’s energy consumption can be summed up, in large part, by such tradi-tional energy sources as oil, coal and natu-ral gas. These are polluting, non-renewable sources but in the future they will inevita-bly be replaced. There are controversies as to how long fossil fuel reserves will last, but because of clean and renewable energy sources like biomass, wind power, and ocean mechanical energy, and sanctions like those of the Kyoto Protocol, which demands from industrial nations a lower level of pollutant emissions (CO2) into the atmosphere, alternative energy sources are a new model for producing economical and healthy energy for the environment.

Energy consumption can reflect both a nation’s degree of industrialization and its population’s degree of development and well being on average terms. Energy con-sumption in more industrialized nations is approximately 88 times higher than in developing nations

Developing high-tech equipment to process renewable energy sources by con-verting sugarcane into sugar, ethanol and energy has been Sermatec’s work for years.

Serm

atec

‘s M

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QualityManagement System

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