Korach Industry Company Limited, a Thai sugar major, trusted Thermax for achieving its pollution control mark. The Enviro team installed two Electrostatic Precipitators (ESPs) for 2 x 200 TPH travelling grate boilers, thereby maintaining emission levels well below the stipulated regulatory norms. The boilers were commissioned by the Boiler & Heater division of Thermax in 2018, being its largest installation in Thailand till date.
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40 MW cogen plant at the Philippines
Victorias Milling Company Inc., a publicly listed company in the Philippines, produces integrated raw and refined sugar. Founded in 1919, they enjoy the repute of being among the earliest modern sugar mills in the country.
Thermax has successfully commissioned a Boiler Turbine Generator (BTG) cogeneration biomass power plant for the customer comprising a 200 TPH, 110 ata, 540°C bagasse fired travelling grate boiler along with Balance of Plant. The plant supplies steam and power to the sugar and refinery factory and also provides clean green energy to the grid. The scope of the project included design, engineering, manufacturing, supply, civil works, construction and commissioning of the 40 MW cogeneration biomass plant.
Biomass fired boiler supplied by B&H to Thailand
Thermax’s B&H business has consolidated its presence in the South East Asian market with 140 units supplied to region’s sugar industry. Recently, it commissioned 2 x 200 TPH high-pressure boilers at the Thai sugar major, Korach Industry Company Limited. The boilers are the highest capacity units that Thermax has supplied in Thailand. The scope of contract comprised design, engineering, manufacturing, commissioning and supervision of construction done by a Thai contractor.
The single drum top-supported travelling grate boilers use bagasse and wood chips as fuel. Along with auxiliaries, they are installed at Korach’s 65 MW cogeneration plant located at Nakornsawan Province,Thailand, generating steam for the sugar mills and captive power for the entire complex. Excess electricity produced will be sold to the national grid (EGAT) under a power purchase agreement.
Emission control in Thailand
In January 2018, the Enviro team of Thermax commissioned an Electrostatic Precipitator (ESP) for checking the emissions at a boiler installation site of Thailand’s Mitr Phol group, Asia’s leading sugar and bioenergy producer. The ESP was part of an order that Thermax won in 2016 for design, supply, erection and commissioning of a 175 TPH high pressure traveling grate boiler and auxiliaries. The boiler had been commissioned earlier, and the ESP handles a gas volume of 4,89,000 m3 /day. This is the sixth ESP order that Thermax has won from Mitr Phol.
Cogen boiler in the Philippines
Thermax supplied and commissioned a 45 TPH, travelling grate boiler at a greenfield distillery of ProGreen Agricorp. The distillery situated in the Balayan area was inaugurated on 14th March 2018.
The distillery is designed for the production of 2,00,000 litres of ethanol per day. The boiler will supply steam for both process and 6 MW of captive power. The multi fuel boiler is designed to fire bagasse (sugarcane waste), coal and biogas. Thermax has also supplied emission control and ash handling systems.
Keeping pollution under check
Another ESP was commissioned for Greenply Industries Limited, a renowned player in India manufacturing high-quality MDF (Medium Density Fibre) boards, a material commonly used in making furniture. This is a unique application where the ESP captures particulate matter in heat streams used in drying and binding process of MDF boards. The heat streams are required to have least possible particulate matter as they are recirculated to improve the quality of the boards. In this application, the ESP is operated at elevated temperatures and handles flue gas with multiple fuel combinations like board trims, screen rejects, sander dust, etc., fired in the boiler. In addition to meeting all critical operating parameters and regulatory norms, the ESP has been providing optimum efficiency till date.
This project also reinstates our commitment to a lasting partnership with customers as we have been associated with Greenply for more than a decade and commissioned a 97 MW energy plant for them last year, which is the largest in Asia.
Getting on the wheels of sustainability
To reduce its dependence on coal while retaining efficiency, Goodyear South Asia Pvt. Ltd., a leading tyre company, reached out to Thermax for adopting sustainable heating solutions. The Heating business commissioned a 28 TPH Bi-Drum reciprocating grate boiler at its tyre manufacturing unit located in Waluj, Aurangabad. Capable of providing uninterrupted operation even on highly choking fuels, the boiler is designed to run on soya briquettes, biomass pellets as well as Indonesian coal to supply high steam pressure of 25 kg/cm2 for moulding, cleaning and drying of rubbers.
The project was completed on an EPC basis where apart from the boiler, material handling systems for fuel, dry ash and fly ash; ESP and chimney were also supplied, installed and commissioned by Thermax. The project was handed over to the customer for continuous operation within ten months.
Thermax commissions second integrated energy plant for Greenply
Thermax successfully commissioned a 97 MW energy plant for Greenply Industries Ltd. at Shrikalahasti, Andhra Pradesh.
The plant will help Greenply manufacture MDF boards, which is made by breaking down wood into fibres which are again combined with adhesives and the end product is formed into panels by applying heat and pressure.
For the manufacturing process, the plant provides multiple heat streams in the form of steam, thermal oil and hot gas, achieving a thermal efficiency of 94% from the process. Nearly 50% of the plant’s fuel requirements are met by utilising process wastes such as board trims, screen rejects and sander dust.
This is a repeat order from Greenply. In 2009, Thermax had commissioned a 49 MW energy plant at its Rudrapur unit in Uttarakhand. For both projects, Dieffenbacher GmbH, the German OEM, is the technology supplier.
Process cooling bags orders from Coca-Cola
For the beverage major CocaCola, the essential prerequisite was to save electrical energy for inter-stage cooling of the compressor used for their pet bottle filling. Thermax delivered an energy conserving solution of evaporative cooling with the help of Closed Loop Cooling Tower (CLCT). An additional advantage of CLCT is that it avoids contamination and scaling inside the compressor
Thermax installs a fully automated water treatment plant in Bangladesh
Thermax has commissioned a water treatment plant with a capacity of three million litre per day (150 m3 / hour). The fully automatic plant is for a global beverage company’s manufacturing facility at Mymensingh, Bangladesh, about 90 km from Dhaka.
This comprehensive project treats the inlet water (drawn from the ground) through a combination of systems for aeration, filtration and ultrafiltration. These help in the removal of TDS (total dissolved solids) and iron from the water. The system also comprises dealkaliser, softening and double stage reverse osmosis (RO) plants and a backwash recovery system.
In water treatment systems,the backwash process that cleans up the filters at specific intervals, essential for optimum performance, consumes large quantities of water. The WWS team has designed a backwash recovery process to recycle 87% of the water. The wastewater reject from the RO plants also is recycled. As a result of such integrated design and automation (operated through SCADA offered with PLC) the plant, compared to conventional ones, operates at an overall 5% higher efficiency.
Through an appreciation letter, the customer expressed his satisfaction with the performance of the Thermax plant. It is now a reference project for peer companies in Bangladesh. Thermax has also supplied two Shellmax boilers with BOP to the same customer.
