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Thermax Chillers Installed At A Food & Beverages Major In Saudi Arabia

The deployment of Thermax chillers in the potato frying process for a Food & Beverages major is one of the pathbreaking applications developed by the Absorption Cooling team.

After tasting success at its pilot manufacturing facility in India, the customer has partnered with Thermax to replicate this technology at several of its locations across the globe, the latest one being in Saudi Arabia. Here, Thermax successfully commissioned two ultra-low pressure vapour driven absorption chillers of 1000 TR each. These chillers help conserve water wastage by capturing the vapour released during the process of potato frying through a fan and further channelised through a duct for providing chilled water at 7ºC. This water is used for both process and comfort cooling requirements of the customer, such as air conditioning and refrigeration.

Being the largest capacity chiller supplied in the ultra-low category by Thermax, to date, this technology has resulted in significant power savings of 4500 MW and reduction of carbon footprint by 9,830 tonnes per year, equivalent to planting 5,22,240 trees.

Power EPC scores a century

The Power EPC division recently commissioned a four-megawatt cogeneration power plant for Godrej Agrovet’s palm oil production facility at Chintampalli, Andhra Pradesh. The plant is designed to run on a fuel mix of shredded empty fruit bunch, palm fibre and palm kernel shell to generate power and steam simultaneously; making this the first EPC project by Thermax that is fueled by 100% palm waste. Apart from a 50 TPH pusher grate boiler, Thermax has also supplied air pollution control system, water treatment plant and other auxiliary equipment for this plant. The successful completion of this turnkey project has helped the Power division achieve a significant milestone of commissioning its 100th power plant.

Thermax’s sunshine spreads to the Philippines

The Solar Power business commissioned its first ever international project comprising a 152 KWp rooftop solar photovoltaic system for one of the packaging giants in the Philippines. This captive power system from Thermax is slated to reduce the client’s dependence on the grid and meet 12% of their electricity demand while bringing down 137 tonnes of CO2 e annually. Collaborative efforts between the Solar Power and International Business Group led to this modest beginning in the global solar arena. 

Thermax and Bataan 2020, a decade of partnership

 It was a decade ago when Thermax received its first overseas power plant order of 12.5 megawatt (MW) from Bataan 2020, a leading manufacturer of fine paper, board and tissues in the Philippines. Through the years, Thermax’s on-time delivery, industry accolades received by the customer for the plant and continuous service support resulted in a repeat order of a 25 MW captive cogeneration plant. 

The Power division recently commissioned the captive cogen plant for Bataan 2020’s paper unit located in Samaal, the Philippines on an EPC basis. Inaugurated on 24th September this year, the plant generates power and steam for the process using a 145 TPH AFBC boiler that fires either 100% Indonesian coal or with 20% rice husk / wood chips / pelletised biomass. Apart from the boiler, the scope of supply includes a steam turbine generator (STG) with water cooled condenser, ESP for the AFBC boiler, water treatment plant, main cooling tower and various material handling as well as control systems.

Danstoker commissions boilers in Abu Dhabi

Thermax’s European subsidiary, Danstoker has made inroads into the Middle Eastern markets. In June 2017, it commissioned two 40 TPH boilers at a manufacturing plant of the Al Dhafrah Paper Manufacturing Company LLC, in Abu Dhabi. The boilers which use natural gas as fuel generate steam at 12 bar each. They were manufactured at Danstoker’s facility in Germany. Earlier, Danstoker also supplied a 43 TPH boiler to Solar Technologies in Qatar, which is expected to be commissioned in April 2018.

21 Exhaust Gas Boilers Commissioned in Bangladesh

Thermax’s Boiler & Heater division commissioned 21 exhaust gas boilers (EGB) at United Power Generation & Distribution Co. Ltd. in Bangladesh as a part of their project involving the setting up a 200 MW Integrated Power Plant (IPP).

 These boilers, installed at the outlet of the Diesel Generator (DG) sets, help recover flue gases emanating from the fuel-fired engines of 9.8 MW capacity each. Put together, the 21 units produce 75 TPH steam at 18 bar(g) which is then fed into the steam turbine, to generate 13 MW of electricity. 

This is the highest number of boilers supplied by Thermax for a single project so far and was completed in a short span of nine months.

Flue gas cooler at Sweden’s energy plant

In November 2017, Thermax’s Danish subsidiary Boiler works installed a flue gas cooler at an energy plant of Sweden’s largest producer of renewable energy, Vattenfall, in Uppsala, Sweden. 

The combined heat and power plant utilises excess heat from waste incineration plants and other sources to generate electricity and produce district heating. 

Flue gas coolers are special heat recovery units where heat contained in waste gases is used to produce steam, or for energy conservation purposes. The system supplied by Boilerworks cools down flue gases in the waste incineration plants. The cooler, located before the chimney, lowers the temperature of flue gases from about 160°C to 70-80°C. 

The contract bagged in April this year, included the supply, manufacture, delivery and installation of the unit. The installation successfully tackled the challenge of removing the existing old cooler and installing the new one within 48 hours, minimising losses in the production of power and heat.

Thermax energy project for Reliance: Meticulous planning and execution

Thermax completed its biggest ever project by successfully commissioning nine 500 TPH circulating fluidized bed combustion (CFBC) boilers and allied emission control systems at Reliance Utilities & Power Pvt. Ltd. in December 2016. Five boilers were installed at Hazira and four at Dahej. These nine cogeneration boilers support the customer’s power and steam requirements by generating 630 MW power and 1520 TPH process steam, simultaneously eliminating the use of costly gas as a fuel. 

Thermax’s scope included design, manufacture, transportation, construction and commissioning of boilers and electrostatic precipitators. The units are designed to meet stringent NOx, SOx and particulate emission requirements, mandated for such power plants. Almost 1000 drawings and engineering documents were generated for this unique project. Manufacturing of the equipment was carried out at the company’s facilities at Savli (Gujarat), Chinchwad (Maharashtra) and at the Shirwal (Maharashtra) plant of the joint venture, TBWES. 

Though the units are designed to fire coal from Indonesia and India, and petcoke, they are versatile Thermax energy project for Reliance: Meticulous planning and execution 17 enough to fire other coals. South African and Russian coals, for example, have been successfully fired. 

During project execution, more than 8000 vehicles – mostly trailers – carried goods to the sites. Total erected weight was approximately 85,000 MT(metric tonnes), and insulation area close to 2,50,000 Sq. m. 

At its peak, the project had nearly 8000 workmen at the sites. Safety was accorded the highest priority, with Thermax cumulatively logging in 27 million safe man-hours. 

A significant feature was ensuring the sealing integrity of the CFBC boilers, which helps to maintain a dust-free coal fired power plant. The boilers are operated via remote control, using artificial intelligence for smooth start-up and operation. 

Says Rajan Nair, Project Director, “Successfully completing a project of this magnitude for Reliance, known for their project management excellence, enhances Thermax’s own capabilities, and qualifies us for similar and larger assignments in the future.” 

Bechtel USA was the technical consultant designated by Reliance. 

On this project, Boiler & Heater and Air pollution control (Enviro) divisions of Thermax collaborated seamlessly for boilers and electrostatic precipitators. They were ably supported by the subsidiary, Thermax Engineering Construction Company Limited.

Unlocking the green potential in pharma

“Thermax Onsite Energy Solutions Limited (TOESL), a Thermax subsidiary, providing outsourced utility services under the build-own-operate business model, established its presence in the pharma sector by concluding steam supply agreements with two customers. TOESL partnered with a pharma major to supply ‘green’ steam to two of its plants in Tamil Nadu and Andhra Pradesh; deploying a 10 ton Combipac boiler and a 6 ton Combloc reciprocating grate boiler respectively. Subsequently, TOESL collaborated with a pharma MNC and commissioned a 4.5 ton biomass boiler plant in its Haryana unit. Under the agreement, TOESL guarantees delivery of quality steam for 10 years, leveraging agro-waste biomass fuels, sourced through the vast biomass supply chain developed by the company.”

A significant leap in the Middle East

The Power division of Thermax recently commissioned a 40 MW coal-based captive power plant for Sharjah Cement Factory, a leading cement and clinker manufacturer in the UAE. 

This is the first full-fledged EPC project to be executed by the division in the region. It comprises two CFBC boilers of 90 TPH capacity each that are capable of firing multiple varieties of coal along with a first-of-a-kind 30% wood chip firing. 

The project scope involved the supply and commissioning of Thermax DM plant, bag filters and dust extraction system along with other Balance of Plant equipment. The plant was conceptualised and synchronised within a record time of 18 months. Commencing 25th March, the plant is operating on stable load and generating power till date.

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