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Energy boost for RCF

Thermax commissioned a 50 MW gas based cogeneration plant at the Thal (Maharashtra) facility of Rashtriya Chemicals and Fertilizers Limited (RCF). Power division executed this project to upgrade the energy efficiency of the urea and ammonia plants on a turnkey basis – from design to commissioning. The scope of supply included two gas turbines (25 MW each) and 2 X 100 TPH heat recovery steam generators, besides civil work. 

The CMD of RCF, in the presence of personnel from both the organisations, was briefed about the working of the cogen plant. Back in Pune, Power division’s project team celebrated the Performance Award from RCF for Thermax’s contribution. 

Wins Rs. 503 crore order for three cogeneration plants

Thermax will set up three natural gas based EPC cogeneration plants (each of 20 MW capacity) for National Fertilisers Limited (NFL). The public sector company has placed an order worth Rs. 503 crore with Thermax for the plants to be commissioned at its facilities in Haryana and Punjab. 

The project is the outcome of NFL’s initiative to bring down its dependence on fossil fuel and to save energy. The three cogen plants through a combination of GTGs (Gas-Turbine-Generators) and HRSGs (Heat Recovery Steam Generators) will generate power for captive use and steam for process simultaneously. Says Unny, “The thrust on cogeneration for saving energy costs has increasingly gained importance among our customers where we have secured recent orders.” Thermax’s proven expertise in EPC cogen plants positions it well in pitching for new business across sectors. 

The scope of supply includes design, engineering, manufacturing, construction and commissioning of the cogeneration plants. The project is to be completed in 22 months.

Thermax wins Rs. 327 crore order for a co-generation power plant

Thermax Group bagged a Rs. 327 crore order from a public sector company based in western India for its up-coming chemical plant. The project is for a BTG (BoilerTurbine-Generator) package on EPC basis for its captive cogeneration power plant of 2×65 MW capacity.

The order is an affirmation of Thermax’s expertise in cogeneration that provides optimal energy solutions to industries that need both power and steam to support processes. M.S. Unnikrishnan, Thermax MD & CEO stated that “as one of the pioneers of this energy efficient option,Thermax is confident of meeting such challenges and anticipates similar opportunities.” 

The scope of supply includes design, engineering, manufacturing, construction and commissioning of the solid fuel based BTG package consisting of two CFBC boilers, steam turbines and generators. Thermax also would be supplying emission control equipment and other auxiliaries for the BTG package. The project is to be completed in 24 months.

Construction chemicals for industrial flooring

Thermax’s construction chemicals are finding several new customers. Recently, the Chemical business bagged an order to supply construction chemicals to SRF, Indore tor industrial flooring. SRF, a leading manufacturers of specialty chemicals, technical textiles and engineering plastics, required flooring done for its newly constructed manufacturing facility at Indore – that would withstand the weight of heavy equipment and abrasion due to continuous movement of heavy machineries. In the face of stiff competition, the Chemical and CMG team could persuade SRF to try Thermax’s construction chemicals- Tecfloor PR, Tecfloor UL and Tecfloor ET. The job was successfully executed to the satisfaction of the customer

Repeat order from Chambal fertilizers and chemicals

Thermax’s WWS division bagged an order from Chambal Fertilizers & Chemicals Ltd. (CFCL), Rajasthan. The scope of this job includes pre-treatment and demineralisation plants, condensate polishing unit, side stream filtration plant for ammonia and urea units, and water recycling facility. This is a repeat order from CFCL which caters to the expansion of its urea and ammonia fertiliser complex at Gadepan, Kota. Toyo Engineering from Mumbai is the EPC consultant for CFCL and they awarded the job to Thermax after due diligence following the bidding process.

Leaving a ‘green’ impression at Hero MotoCorp

By installing Thermax’s 1400 kW natural gasfired absorption heat pump at their facility in Neemrana, Rajasthan, the two-wheeler automobile major – Hero MotoCorp is saving nearly 40% of natural gas used for heating hot water; thereby reducing their carbon footprint. The heat pump recovers waste heat from the cooling tower which is then used to cool the air compressors at their plant. The hot water generated by the heat pump is used to heat paint at their booth. With the success of this project, the concept is currently being replicated in the company’s other manufacturing facility at Haridwar

 

Process cooling bags orders from JCB India

Another multinational, primarily into earth moving equipment and heavy machinery, JCB India had the requirement for cooling water at their engine testing facility, with the lowest possible water consumption. Thermax offered an adiabatic cooling tower solution that conserves 70% to 80% water as compared to the conventional cooling towers. This cooler makes the best use of wet and dry technology to optimise and save water, thus leading to lower maintenance and higher operating efficiency.

‘Oorja’ forays from kitchens to cars

Taking the sustainable heating solutions from their brand ‘Oorja’ to newer avenues, First Energy Pvt. Ltd. (FEPL), Thermax’s subsidiary has partnered with Refreshed Car Care (Revive Labs Private Limited), an eco-friendly car care company to introduce a first-of-its-kind steambased car cleaning solution. The scope includes the supply and erection of a pellet-fired non-IBR type boiler of 100 kg capacity and its integration with the car washing system. This steam-based application provides superior cleaning and more importantly, a significant reduction in water consumption up to 90%. It is estimated that one car requires 10 kg of steam above 150°C and 120°C for exterior and interior cleaning respectively. 

“For FEPL, this is a step in the right direction, leveraging our leadership in the energy and environment space by foraying into the consumer segment with green solutions,” says Sriram Vishwanathan, Director at FEPL. 

The business operates on a unique model where the capital investment, commissioning and maintenance concerning the boilers are managed by FEPL. The customer only pays for the pellets used as fuel for the boiler, that are manufactured at FEPL’s plant in Islampur and Dharwad using agrowaste. 

The first such cleaning station in India has been set up by Landmark Group at Ahmedabad, one of the largest automotive networks in India.

MÖllergroup, Germany partners with Thermax for tri-generation cooling system

Thermax’s chiller that works on hot water is a key component in the combined heat, power and cooling (CHPC) package that the Möllergroup in Germany is deploying at a client’s site. The 220 TR (780 kW) chiller is handy for cooling robots and for the customer’s plastic manufacturing process. The Möllergroup is a leading global manufacturer who develops modules for the automotive industry and construction parts for various industrial applications. The CHPC plant helps client industries to save energy and cost. The choice of Thermax as a preferred vendor reflects the careful choice that industrial manufacturers like Möller make today to balance energy requirements and environment sanity.

Low-carbon solution for Trelleborg

Trelleborg Wheel Systems is a global supplier of tyres and complete wheels, having one of its facilities in Sri Lanka. Addressing the customer’s need of switching from fossil fuel to biofuels – to reduce their plant’s environmental footprint as well as improve production efficiency – Thermax’s Heating division commissioned a 12 TPH Combipac boiler with a reciprocating grate combustor on a turnkey basis. 

The unit is designed to fire rubber wood chips with high moisture content, a byproduct of their production process, available abundantly. At its full capacity under standard operating conditions, the boiler will use nearly 2,700 kg/hour of feedstock, equivalent to 830 litres of diesel, for generating 12,000 kg/ hour of steam, which is equal to 7.5 MW of effective heat delivered to the process. 

Use of biomass in place of fossil fuel such as diesel will result in a reduction of 15,000 tons of CO2 emissions per year.

 Speaking on the project, Paolo Pompei, President of Trelleborg Wheel Systems quoted in Biomass magazine, an international trade journal, “This is a key milestone project in achieving a reduction in the carbon footprint within the whole organisation—something where we have put huge investment.” He further added, “Energy is a ‘significant element’ in manufacturing costs, and the new boiler and wood chips as fuel will bring a ‘significant reduction’ to the cost of steam generation.”

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