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Powering the Future with Sustainable Energy

Advanced thermal solutions for reliable, efficient, and sustainable power generation. From cogeneration to captive power plants, we deliver customized energy solutions for industrial needs.

The Evolving Power Landscape

The global power industry is in the midst of a significant transformation. As climate goals, technological advancements, and growing energy demands reshape the sector, the shift from centralized, fossil-fuel-based generation to cleaner, more flexible, and decentralized systems is gaining momentum.

In India, this evolution is being driven by aggressive targets, including achieving net-zero carbon emissions by 2070 and significantly increasing the use of renewable and agro-residue-based energy sources.

Despite these changes, thermal power remains indispensable, especially for energy-intensive industries that require a reliable and consistent supply of electricity and steam. At Urja-Disha, we understand the balance between traditional and future-ready energy.

Advanced Power Generation Systems

We specialize in designing both Cogeneration (Combined Heat and Power) systems that produce electricity and process steam simultaneously, and Captive Power Plants (CPPs) built to supply power exclusively for industrial operations. One of our strongest differentiators is our expertise in fuel-flexible system design which allows clients to switch between a wide range of fuels. This flexibility enables operational continuity and cost optimization, regardless of seasonal or market fluctuations.

System Capabilities

  • Power Generation - Up to 40 MW capacity
  • Steam Capacity - Up to 200 TPH
  • Pressure - Up to 120 kg/cm²
  • Temperature - Up to 540°C

Fuel Flexibility

  • Coal & Lignite
  • Biomass: Bagasse, rice husk, wood chips, wood variants, sawdust, palm Empty Fruit Bunches (EFB), paddy straw, wheat straw, mustard husk, corn cobs, etc.
  • Municipal Solid/Liquid Waste (MSW/MLW)
  • Multi-fuel switching capabilities

Our Comprehensive Approach

At Urja-Disha, we design with practicality and longevity in mind. Our systems feature compact, modular layouts and are engineered for ease of maintenance and robust performance. Whether it’s a new build or a plant upgrade, we ensure the highest standards of reliability, performance, and cost-effectiveness.

Our Services Include

  • Boiler system design and optimization
  • Turbine-generator selection and integration
  • Fuel and ash handling systems
  • Water-steam cycle optimization
  • Pollution control technologies (ESPs, scrubbers, bag filters)
  • Greenfield and brownfield projects
  • Feasibility studies and system audits
  • Regulatory compliance and optimization

Success Story

How we helped a leading company achieve sustainable power generation.

7.5 MW Cogeneration Plant for Indophil, Philippines

A 7.5 MW cogeneration plant designed and delivered for Indophil in the Philippines. Fueled by bagasse and biomass, this plant supports the company’s electricity needs sustainably and efficiently, showcasing our expertise in sustainable power generation solutions.

  • Sustainable Power - Utilizes renewable biomass and bagasse for clean energy production
  • Cost Efficiency - Significant reduction in energy costs through cogeneration
  • Reliable Operation - Consistent power supply with minimal downtime

Ready to Transform Your Power Generation?

As the world moves toward decentralization and carbon neutrality, we empower industries to lead this change. Our systems are built to be sustainable, regulation-ready, and future-proof.

Our design team will assess your power requirements and identify optimization opportunities.

Case studies

Projects we have delivered

Plant we engineered, supplied and commissioned in this sector.

Fired Boiler for Jind Bio Energy LLP

Client
LGS Industrial Works
End user
Jind Bio Energy LLP, Fatehabad, Haryana
Year
2024

Key specifications

Rating
63 TPH, 91 Kg/cm²(g), 525°C
Fuel
100% Paddy Straw
Furnace
Bottom-supported, multi-pass furnace
Fuel feeding
Twin-screw bale fuel feeding system
Combustion
In-house vibratory grate combustion system
Superheater
Pendant type superheater (radiation + convection)
Heat recovery
Flue gas cooler instead of traditional APH
Air heating
Maintenance-free SCAPH (plain tube design)
Construction
Single drum, membrane panel construction
Installation
Outdoor installation ready
Scope
Complete design and detail engineering
Dedusting
ESP (Electrostatic Precipitator) for dedusting
63 TPH paddy straw fired boiler with bale feeding system at Jind Bio Energy

A 63 TPH, 91 Kg/cm²(g), 525°C boiler firing 100% paddy straw, engineered for Jind Bio Energy LLP, Fatehabad, Haryana, through LGS Industrial Works in 2024.

The challenge

  • Difficulty in achieving complete combustion with paddy straw
  • Wear and tear of traditional grate systems
  • Environmental impact due to carbon emissions
  • High structural load from conventional top-supported boilers
  • Limited reliability and shorter continuous run cycles
  • High APH fouling risk

Our solution

  • 63 TPH high-pressure boiler tailored for paddy straw
  • Bottom-supported, multi-pass outdoor-ready design
  • Vibratory grate and twin-screw bale feeding system
  • Custom combustion system optimized for agro-waste
  • Flue gas cooler replacing traditional APH
  • Durable, low-maintenance components

The results

  • Reliable combustion of 100% paddy straw
  • Minimal grate maintenance
  • Lower carbon emissions
  • 25% lighter structure via bottom support
  • >60 days continuous operation
  • Improved reliability by replacing APH with flue gas cooler

Fired Boiler for Sahabat Biomass Power Plant (Felda)

Client
Mechmar
End user
Sahabat Biomass Power Plant (Felda), Malaysia
Year
2013

Key specifications

Rating
55 TPH, 45 Kg/cm²(g), 435°C
Fuel
100% EFB (Empty Fruit Bunches)
Furnace
Tail-end type multi-pass furnace
Combustion
Reciprocating grate combustion system
Fuel feeding
Pusher-type fuel feeding system
Construction
Single drum, membrane panel, girth-supported design
Heat recovery
Superheater, evaporator, and economizer in 3rd pass
Air heating
No SCAPH - simplified air heating system
Installation
Outdoor installation ready
Scope
Complete design and detail engineering
Dedusting
ESP (Electrostatic Precipitator) for dedusting
55 TPH EFB-fired boiler with tail-end multi-pass furnace at the Sahabat Biomass Power Plant, Malaysia

A 55 TPH, 45 Kg/cm²(g), 435°C boiler firing 100% empty fruit bunches, supplied through Mechmar for the Sahabat Biomass Power Plant (Felda), Malaysia, in 2013.

The challenge

  • Inconsistent combustion performance with EFB
  • High particulate load and emissions
  • Difficulty in achieving long continuous operation
  • Complex air heating systems requiring frequent maintenance
  • Structural challenges for accommodating tail-end furnace configuration

Our solution

  • Optimized reciprocating grate for reliable burn
  • Pusher-type feeding system for EFB
  • Tail-end type multi-pass furnace design
  • Compact, girth-supported single drum construction
  • Eliminated SCAPH for reduced maintenance

The results

  • Efficient combustion of 100% EFB
  • Reduced emissions and clean burn operation
  • Over 60 days continuous run without troubleshooting
  • Low maintenance due to simplified air heating (no SCAPH)
  • Compact and stable structure for outdoor use

Fired Boiler for Saraff Global Power Plant

Client
Bajaj Power Equipment Pvt. Ltd.
End user
Saraff Global Power Plant, Surat Thani, Thailand
Year
2015

Key specifications

Rating
55 TPH, 45 Kg/cm²(g), 450°C
Fuel
100% EFB (Empty Fruit Bunches)
Furnace
Tail-end type multi-pass furnace
Combustion
Travelling grate
Fuel feeding
Pusher-type fuel feeding system
Construction
Single drum, membrane panel, girth-supported design
Heat recovery
Superheater, evaporator, and economizer in 3rd pass
Air heating
No SCAPH - simplified air heating system
Installation
Outdoor installation ready
Scope
Complete design and detail engineering
Dedusting
ESP (Electrostatic Precipitator) for dedusting
55 TPH EFB-fired boiler with travelling grate at the Saraff Global power plant in Surat Thani, Thailand

A 55 TPH, 45 Kg/cm²(g), 450°C boiler firing 100% empty fruit bunches, supplied through Bajaj Power Equipment Pvt. Ltd. for the Saraff Global Power Plant at Surat Thani, Thailand, in 2015.

The challenge

  • Inconsistent combustion performance with EFB
  • High particulate load and emissions
  • Difficulty in achieving long continuous operation
  • Complex air heating systems requiring frequent maintenance
  • Structural challenges for accommodating tail-end furnace configuration

Our solution

  • Travelling grate
  • Pusher-type feeding system for EFB
  • Tail-end type multi-pass furnace design
  • Compact, girth-supported single drum construction
  • Eliminated SCAPH for reduced maintenance

The results

  • Efficient combustion of 100% EFB
  • Reduced emissions and clean burn operation
  • Over 60 days continuous run without troubleshooting
  • Low maintenance due to simplified air heating (no SCAPH)
  • Compact and stable structure for outdoor use

Talk to the team that sizes the plant

Send us your fuel, steam parameters and site constraints. Our design team will work through the heat balance and come back with a feasibility view.

Request a feasibility study