Cement plants in India are aiming for higher efficiency and profitability in their operations. One of the ways to achieve this is to use waste heat from operations for power generation. A pioneer in waste heat recovery based power plants, Thermax has begun work on a captive power plant at Maihar, Madhya Pradesh for a cement manufacturer, a group company of Birla Corporation Limited. The Rs. 98 crore project will harness waste heat of the cement plant to generate 12.25 MW power. The scope of the project includes boilers, turbine, air cool condenser, ducting, civil, electrical control and instrumentation, and other accessories. For this EPC project, Thermax will install a space-saving vertical preheater boiler. The project is expected to be commissioned by the end of 2018.
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‘City of Lakes’ gets cleaner
The Water & Waste Solutions business of Thermax recently commissioned a Sewage Treatment Plant of 25 MLD (million litres per day) capacity for Hindustan Zinc Limited, the world’s leading zinc-leadsilver producer at Udaipur. Based on the advanced Moving Bed Bio Reactor (MBBR), the treated water from the plant will be reused by HZL at their processing unit in Dariba, around 50 km away.
This project is a part of HZL’s CSR programme, wherein they signed an agreement with Udaipur Smart City Limited in June 2017 to set up the plant to treat the city’s sewage and conserve water (an article was carried in Oct-Dec 2017 issue of Fireside announcing the tie-up). “This utilisation of recycled water from sewage will help in rejuvenation of water bodies in and around the area, in addition to reducing the dependency on fresh water required for the process,” said Hemant Joshi, head of WWS, Thermax.
The STP is also equipped with a solar PV system on the rooftop of the control room, which generates 24 kilowatts of green power.
Thermax wins Rs. 340 crore order from an Indian steel major
Thermax has concluded an order of Rs. 340 crore from a leading Indian steel manufacturer for a specially designed boiler, electric turbo generators and ancillary equipment for their production facility in Maharashtra, India. The specially designed boiler will use waste gases produced in the steel manufacturing process to generate high-pressure steam for power generation using high efficiency reheat cycle.
The scope of work includes design, engineering, procurement, manufacturing, supply, installation and commissioning.
Thermax supplies CCCT to Tata Steel
The Process Cooling division of Thermax bagged a major order by supplying three Closed Circuit Cooling Towers (CCCT) to Tata Steel’s Kalinganagar plant in Odisha. The towers installed for the ladle furnace and steel melting shops will help Tata steel achieve 10% of power saving.
Closed circuit cooling towers offer unmatched flexibility, provide evaporative cooling and optimised solutions for various process requirements and climatic conditions, utilising multiflow configuration.
Implementation of CCCT will eliminate the requirement of various other pumps and cooling towers, and lower the power consumption considerably, while maintaining the water intake.
Thermax’s scope of work includes designing, manufacturing, supplying and supervising the plant and equipment for CCCT, for the ladle furnace and steel melting shop (SMS).
The customer conducted a feasibility study based on the technical analysis provided by Thermax, for the soft water circuits in steel melting shop and found it to be more energy efficient than the conventional system in terms of its operating cost.
Handling fuel shift deftly for a polyester major
One of the largest producers of polyester fibres in India has a plant located at Patalganga in the state of Maharashtra. To deal with the rising prices of hydrocarbon fuels, the customer decided to switch to coal for operating its utilities. Catering to this requirement, the Boiler & Heater (B&H) division of Thermax commissioned two units of 15 MMkcal/hr coal-fired Dowtherm vapourisers for the customer.
Dowtherm vapouriser is a preferred technology in manufacturing heat sensitive products such as fibres as it provides a more uniform heat source and precision temperature control. Thermax being pioneers in this application, customised the design for coal-fired vapourisers successfully.
An atmospheric fluidised bed combustor burns Indonesian coal and is connected to a radiant and convective tube bank which generates the Dowtherm vapour. This solution will not only help bring down fuel costs for the customer but also recover their investment within a short time.
ZLD at a textile major
Thermax recently installed a Zero Liquid Discharge (ZLD) plant with a recycling capacity of 3.6 million litres per day (MLD) at a textile major located at Ambasamudram, Tamil Nadu. This system consists of an effluent treatment plant (ETP), recycling plant & multiple effect evaporators (MEE). The wastewater generated from manufacturing activities such as thread dyeing and bleaching are treated in the ETP followed by the recycling plant. The membrane filtration based processes help recover good quality water from this treated wastewater. While the recovered water is used by manufacturing units, the rejected water is sent to the MEE. MEE reduces the volume of the waste to be handled, thereby disposing off the brine generated; leaving zero discharge at the end of the treatment cycle.
Chiller commissioned at a polyester manufacturer in Taiwan
The Cooling business supplied and commissioned a triple effect chiller at Taiwan’s Far Eastern New Century Corporation, one of the world’s top polyester suppliers.
The 800 TR chiller air conditions the office and the shop floor. Additionally, it is used for jacket cooling in the roller machines. With global firms focusing on the twin objectives of using energy efficient products and protecting the environment, Thermax is building business partnership with reputed business houses across the world. It has also commissioned four double effect steam fired chillers of 1250 TR each to air-condition the R&D building of Samsung Electronics, Korea.
Thermax’s chillers enter Puerto Rico
The Absorption Cooling division of Thermax commissioned a 360 TR multi-energy chiller for ‘De le Concepcion’ hospital at Puerto Rico. Being an island prone to hurricanes, Puerto Rico is adapting to a gas-based distributed power generation model to reduce its dependency on electricity supplied from the grid. Thermax’s chiller forms a part of the Combined Heating Power & Cooling system, which helps recover waste heat from the engines installed and utilises it to provide chilled water up to 5.5ºC for air conditioning the hospital. With this installation, Thermax has become the first company to supply chillers to the region.
Hej IKEA !
IKEA, the Swedish furnishing major for their first store in India, launched at Hyderabad in August 2018, trusted Thermax as their partners for water treatment.
The Water & Waste Solutions division and the Channel Business Group in association with their channel partner, Sanller Systems commissioned a WTP catering to both the potable and non-potable water requirement of the entire store. The scope of supply comprises a dual media filter (DMF), a 2.25 m3 /hr softener and a reverse osmosis plant producing 2,000 litres per hour. The inlet water from the municipal supply passes through the DMF and is further treated by the softener and RO units before being stored in the respective treated water tanks. The water from the softener is blended with the RO water to achieve the global standards of IKEA suitable for drinking and cooking at their food court; amounting to an approximate consumption of 50,000 litres per day. The remaining treated water is used for other applications such as geysers, washing and cleaning.
While several players were vying to be a part of this prestigious project, Thermax’s established references and customer satisfaction with earlier assignments won them this order.
Chillers at Yemen
The Cooling division of Thermax recently commissioned a multienergy driven chiller of 700 TR capacity at Aden Mall, Yemen. The chiller runs on jacket hot water and steam generated from the exhaust of a 2.5 MW diesel engine, with backup diesel firing. Cold water from the chiller is used for air conditioning the mall, one of the most popular destinations in the city of Aden. The mall situated 10 kms from Aden airport was partially destroyed during the war and is undergoing re-construction. This is the second order bagged by Thermax in Yemen, the first a 300 TR chiller for NAD Foods, a supplier of milk, food products and fruit juice. Here, chilled water from the single effect hot water driven chiller is used for process cooling during the production cycle.
