Thermax Enviro Solutions empowers the oldest Cement Company of Egypt to meet the challenges of changing Environment Norms.

About Tourah Cement

The Tourah Portland cement Plant, Egypt’s first cement company, was established in 1927. It is owned by Suez Cement company (66.12%). The company consists of two plants located in an area of 10,000,000 m² in Tourah district with 9 production lines.

The Changing Business Scenario

Driver of the Change: Emission Standards

As global awareness and concerns grew about the Air Pollution and its hazards, Egypt also decided to upgrade the emission standards that a cement plant must meet in order to ensure a cleaner and healthier environment.

As per the changes in the law, any cement company in Egypt must meet the new emission standards of SPM < 20 Mg/NM3 from earlier acceptable limits of SPM< 100 Mg/NM3 resulting into a complete change in the business scenario for Tourah Cement.

Affected Applications, Utilities and Challenges

Application Existing APC
Raw Mill x 2 ESP x 2
Clinker Cooler GBF
Alkali By Pass & Gas Cooling Tower ESP

APC: Air Pollution Control Equipment
ESP: Electrostatic Precipitator
GBF: Gravel Bed Filter

Challenges Associated with Rehabilitation

  1. Efficiently meet the expected new emission standards.
  2. Minimize capex and downtime of the plant and without disturbing the other operations much.
  3. Modifications and additions within the little space available posing as a significant constraint.

Solution Offered by Thermax

Thermax studied the requirements of the customer and associated challenges. Based on its years of experience, Thermax Retrofit and Revamp Design team came out with a solution to be executed within 45 days planned shutdown for all the three applications. In order to reduce the Capex, Thermax used its engineering skills so that the existing structures, casing, hoppers etc can be utilized to maximum in the new solution.

Raw Mills (Both) – ESP for replaced with Pulse Jet Bag Filter

Existing Casing was repaired and partition was created to accommodate the new 2 chamber Bag House. Existing building was strengthened and used.

Clinker Cooler – Gravel Bed Filter replaced with Heat Exchanger & Pulse Jet Bag Filter

Heat Exchanger was provided for Clinker Cooler Gases prior to entering the Bag Filter Chamber.
The Bag filter with six compartments was constructed on the structures of the existing Gravel Bed Filter New Ducting connecting to old discharge system was only used.

Alkali By-Pass & GCT – ESP replaced with Pulse Jet Bag Filter

Existing ESP Support structures & Hoppers were used to construct the New Bag Filter
The existing GCT was upgraded to handle dual fuel.

Final Process Parameters

Application Offered Solution Volume (M3/Hr) Temperature (C) Inlet Dust Load (gm/NM3) Outlet Emission Achieved (mg/NM3)
Raw Mill x 2 Pulse Jet Bag Filter 630,000 200 200 < 20
Clinker Cooler Pulse Jet Bag Filter 450,000 120 20 < 20
Alkali By Pass & Gas Cooling Tower Pulse Jet Bag Filter 195,000 200 80 < 20

Achievements

  1. Execution of project covering all the 3 applications completed in the planned shutdown of only 45 days.
  2. Equipment handed over after commissioning in just 15 days.
  3. CAPEX reduced as per customers expectations by utilizing existing structures to maximum possible.

Thermax successfully commissions Asia’s largest energy plant for Greenply industries limited.

INTRODUCTION

Greenply Industries Limited is one of the leading interior infrastructure manufacturing companies in India and is primarily engaged in manufacturing, marketing, distribution of Plywood and Medium Density Fiber (MDF) Boards. The wood industry major has been associated with Thermax Limited for heating solutions for many years.In the year 2009, Thermax commissioned 50 MW Energy Plant in their Uttarakhand plant, which was the first engineered solution by Thermax supplying energy to multiple processes from a single energy efficient system. Reinforcing a decade-long association with Greenply,In March

2018 Thermax has successfully commissioned the second energy
plant of 97 MW. This plant is installed at Greenply’s state of the manufacturing facility for MDF board located at Chittoor,AP,India. It has an annual capacity of 3, 60,000 CBM and is the largest MDF plant in Asia and the fifth largest plant in the world. MDF is made by breaking down wood into fibers which are again combined with adhesives and the end product is formed into panels by applying heat and pressure.MDF boards are increasingly popular in many parts of the world for furnishing offices, schools and homes. Our esteemed customer is one of the market leader in India and have trusted Thermax for their expansion projects. Greenply being the Major plywood manufacturer in India understood the importance of replacing the traditional inefficient wood panels with wood efficient

MDF panels thereby ensuring sustainable economic development with
minimum burden on the environment and trusted Thermax with their

environment-friendly initiative.

Project details

Medium Density Fiber Boards are manufactured from agro plantation wood such as Eucalyptus, Subabul, Casurina etc. Wood logs are chipped and sent to a size separator (screen) where undersize wood chips are separated and reject is used as the fuel in the Energy plant. Then sized wood chips are sent to the Refiner where it is cooked with steam and converted into fibers. The produced fibers are mixed with appropriate resin and passed through the directly heated dryer. Flue gas from the energy plant is blended with ambient air so as to maintain a consistent temperature of hot gas required in the dryer. The dried fibers with appropriate moisture content then pass through a sifter, forming a line and feed to hot press (continuous press) to manufacture required thickness MDF board.

The heat required for the press is supplied in the form of hot thermal oil from the thermal oil heater at Energy Plant. MDF board from the press is further then sent to trimming and sanding system to get the boards of required size with smooth and even surface. The trim waste and sander dust generated in this process are used as fuel for Energy Plant.

3.6Mn capacity MDF Process as Chittoor plant had following heat requirements from Energy Plant. 50 MW for Hot gas at 350 deg C. 32 MW for Steam at 15 kg/cm2 (g) pressure and 15 MW for Thermal Oil at 290 deg C

Total thermal heat output of 97 MW with a solution on a turnkey with engineering, procurement, construction, and commissioning. Highest efficiency, lower emission, higher availability, automated control and safety systems were the prime criteria for selection of a supplier for Energy Plant system. Energy plant system should have flexibility in terms of fuel and load modulation/control.

The solution provided by Thermax

The challenge was to design largest capacity Energy Plant of 97 MW capacity and it should have fuel flexibility, highest efficiency, lower emission,higher uptime, automated control and safety systems for emergency situations.The critical components of Energy plant system such as combustor, pressure
parts,emission control equipment and control system were designed keeping in mind the above requirements. Some of the features are illustrated below

Combustor

Energy plant was required to be designed for multiple fuels like woodchips, Indonesian coal along with process waste chips and sander dust.Traveling grate as combustor was best- suited system and sander dust fired with the burner at a secondary level.The system had refractory line separate combustor without any heat absorption surface which made the system highly flexible. Flue gas generated in the combustor is controlled at 900 deg C and further distributed to three independent system viz. boiler, heater, and hot gas generator

Pressure Part

Heat recovery was entirely done with flue gas mass hence it required a high amount of heat transfer surface area. Membrane panel assembly in the radiation area reduces flue gas temperature before entering into the convection section thus increase availability of the system. A cross-flow configuration convection section helps to get an optimum area. An online soot cleaning system gives better uptime of the system.

Both boiler and thermal oil heater had independent induced draft fan control for steady control on load, higher turndown for the system.

Emission control device

A typically old Energy plant system had dust cyclone which has a limitation in terms of high power consumption of main induced draft fan, frequent cleaning because of choking and higher emission. Thermax had to offer A Electrostatic Precipitator as emission control to address all issues of the cyclone. Overall it was one of its kind and the innovative solution given by any energy plant supplier and was well appreciated by Greenply.

Safety features

Safety is always a prime criterion while designing any system; one has critically studied the emergency situation that can arise during operation of the system. Experience always plays a major role here:
Thermax’s Energy Plant offers high safety standard, and some of them are:

  • Emergency stack to avoid over-pressurization of the furnace
  • Thermal oil emergency cooler to safeguard the fluid
  • Auto-vent valve for the boiler to a safe start and stop of the system.

Impact Created

Thermax’s 97 MW Energy plant has created history in MDF industry with the revolutionary one of its kind energy efficient and environment- friendly system.
Thermax Energy plant utilizes almost all wood waste generated from the process as the fuel thus reduces consumption of fresh wood making it environment-friendly. It assures the highest thermal efficiency of 94% which is a benchmark in the solid fuel-fired systems thus ensures the lowest operating cost.
While catering to varying load fluctuations it has to turn down ratio almost to the tune of 1:5. Independent control of each stream makes the system more flexible.
Our pollution control devise Electrostatic precipitator (ESP) gives lowest emission as compared to conventional systems.
The plant has the highest availability which makes it most economical compared to other competitors.
Thermax’s EP offers a completely automated system with highest safety standards with various emergency controls in thermal oil, steam and hot gas.
Thermax is committed to give the best solutions to our customers, time and again have proven the metal with cutting-edge technology solutions which are energy efficient and cost effective.

THERMAX’S HEAT PUMP SAVES 40% ENERGY AT ASIA SILICON IN CHINA

 

Introduction

Our customer, Asia Silicon (Qinghai) Co. Ltd based in Xining, China placed an order with Thermax for a heat pump with capacity of 4450 kW. The Thermax heat pump was utilized to raise the temperature of waste hot water from 108°C to 152°C leading to optimum utilization of energy.

Asia Silicon (Qinghai) Co. Ltd engages in the manufacturing, marketing, and distribution of silicon and poly-silicon products to solar energy equipment makers

Project description

At the customer’s site, the waste hot water at 108°C from the hydrogenation furnace and the reduction furnace is fed to the heat pump and the temperature was raised to 152°C. The saturated vapour at 152°C when cooled to 145°C can be used to heat the hydrogenation furnace and the reduction furnace to help them attain their working temperature (110°C -130°C ) when it is cooled to 145°C. This is an unique application given by Thermax in poly-silicon industry.

Highlights

  • The installation of our heat pump resulted in saving 30%-40% energy at the customer’s site.
  • The customer was able to make savings of 10-20 % on manufacturing of poly-silicon products.

THERMAX CHILLERS USED BY LARGEST TOY MAKERS IN THE WORLD-LEGO

Introduction

Our customer, Asia Silicon (Qinghai) Co. Ltd based in Xining, China placed an order with Thermax for a heat pump with capacity of 4450 kW. The Thermax heat pump was utilized to raise the temperature of waste hot water from 108°C to 152°C leading to optimum utilization of energy.

Asia Silicon (Qinghai) Co. Ltd engages in the manufacturing, marketing, and distribution of silicon and poly-silicon products to solar energy equipment makers

Project description

At the customer’s site, the waste hot water at 108°C from the hydrogenation furnace and the reduction furnace is fed to the heat pump and the temperature was raised to 152°C. The saturated vapour at 152°C when cooled to 145°C can be used to heat the hydrogenation furnace and the reduction furnace to help them attain their working temperature (110°C -130°C ) when it is cooled to 145°C. This is an unique application given by Thermax in poly-silicon industry.

Highlights

  • The installation of our heat pump resulted in saving 30%-40% energy at the customer’s site.
  • The customer was able to make savings of 10-20 % on manufacturing of poly-silicon products.

THERMAX CHILLERS USED BY LARGEST TOY MAKERS IN THE WORLD-LEGO

Thermax supplied three 610 TR (1830 TR or 6425 kW) Exhaust + Jacket water driven chillers last year to the LEGO plant in Hungary. These chillers were used for the application of cooling during the injection molding process using waste heat recovered from a 2.6 MW GE Jenbacher gas engine.

Project Introduction

At the Lego facility at Nyíregyháza, Hungary there were 768 moulding machines.

“We are going to build a brand new factory, that will be designed and constructed with a high focus on integrating sustainability – and it will be the future workplace for approximately 1500 dedicated LEGO employees,” says Bali Padda, the Chief Operating Officer, Executive Vice President and Member of Management Board at LEGO.

Since the facility is situated near the Ukranian border the availability of power is a major concern for them. Hence in order to resolve this problem LEGO had installed 3nos. x 2.6 MW GE Jenbacher JMS 620 gas engine to cater to the captive power requirement.

The production capacity at this facility has gone up and the plastic moulding machines are having a throughput of around 16,000 toys /day/machine . Because of this, the cooling requirement for these moulds had also gone up. Initially to cater to this cooling requirement of the moulds LEGO had been using electrical chillers, but for additional cooling Thermax suggested to LEGO that they opt for an exhaust driven chiller.

The client had an existing gas engine and the exhaust from this engine was liberated in the atmosphere without any recovery, hence a solution was provided to the client to recover this waste heat from the exhaust of the gas engine which however was going unused to the atmosphere. This heat from the exhaust of the engine and the jacket hot water is used to trigger the absorption chiller which provides output in the form of chilled water.

Highlights

By using our chillers, LEGO was able to

  • Optimize their utilization of the waste heat from the engine exhaust.
  • They saved on energy consumption
  • They were also able to save on the operational cost of the chillers
  • They helped reduce 8500 tons of Carbon Dioxide which is equivalent to planting of 457,000 trees

MAKING DATA CENTRES GREENER

Have you ever wondered where all the data in a company gets stored? All companies have Data Centres that back up and store all the data. In more technical terms, Data centres are physical or virtual infrastructure for housing computer, server and networking systems and components for a company’s IT needs.

The environment of a Data centre is controlled in terms of temperature and humidity, both to ensure the performance and operational integrity of the systems within. These facilities will generally include power supplies, backup power, chillers, cables, fire and water detection systems and security controls.

According to a report by Mckinsey, Data centres are responsible for over two per cent of global electricity consumption which is increasing year on year. By 2020, rising carbon emissions from data centres are predicted to exceed those of the airline industry. Hence, there is growing pressure on data centres to look for greener operating solutions.

To work effectively a data centre needs to have a cold aisle/hot aisle configuration with cooled air passing through the front of the enclosure and hot air being removed effectively at the back.

Thermax provides one of the most complete ranges of data centre cooling solutions that work smarter and are energy efficient. From the smallest server room to the largest data centre, we deliver the kind of tailored data centre cooling solutions you need with a service that is second to none.

CASE STUDY:

That has never been a truer statement than today, when the world depends on the data flowing through our electronic lines of communication. But power comes at an increasingly high cost, both in dollars and environmental impact on our planet. That is why Syracuse University, IBM, and New York State joined together to create the Green Data Center. Through a combination of new innovations and smarter technologies, this partnership has created one of the most energy-efficient data centers in the world.

As part of its “Smarter Planet” initiative, IBM has worked with SU to look beyond computer hardware and software to the actual infrastructure of the data center. The Green Data Center—with its own electrical Tri-Generation system and IBM’s latest computers and computer-cooling technology—is expected to use 50 percent less energy than a typical computer center, making it one of the “greenest” in operation today. The good news is that Thermax was a part of this green project.

Persuing the dream of having a green Data Centre-IBM and SU placed an order with Thermax for tri-generation systems wherein two exhaust fired absorption chillers of 180 TR would cater to their comfort cooling requirement utilizing exhaust gas from a 4.5 MW gas turbine installed at their premises.

Data center air-conditioning is a mission critical application as maintaining temperature in a data center is essential for proper functioning of the servers. In order to safeguard the data centre in the event of a component failure, micro-turbines were procured to take care of the backup in the event of a power failure. The 6,000-square-foot data centre at the educational institute features its own electrical tri-generation system and incorporates IBM’s latest energy-efficient computers and computer-cooling technology. Six micro-turbines of 65 kW capacity each are used for generating power at this data centre. The exhaust of these micro-turbines is used as an input to trigger Thermax’s exhaust driven absorption chillers. These absorption chillers provide chilled water at 14.4 °C during summers in order to maintain the ambient condition inside the data centre.

THERMAX VAPOUR ABSORPTION MACHINE GIVES -2°C COOLING IN THE COCA-COLA PLANT AND SAVES ELECTRICITY BY 90%

Introduction

This was indeed an exciting collaboration with Coca-Cola, the world leading beverage company.Thermax designed a steam fired 200 TR vapour absorption machine (VAM) for them. The absorption chiller was to give -2°C chilled brine while using CFC free refrigerant in order to meet the bottle cooling requirement in the Coca-Cola plant at Pirangut near Pune located in Western India. This VAM uses steam energy input of 8 bar pressure. It replaced an old compression chiller where it saved 1240 MW-hr of electricity per annum.

The process of bottle cooling is an important step in beverage manufacturing. Solubility of CO2 in water decreases as temperature increases. So before filling the bottles it is necessary to cool the bottles to contain the CO2 inside the solution.

Getting -2°C from the existing electrical chiller was having larger running cost. A specially designed 200 TR double effect steam fired VAM was supplied by Thermax to meet this requirement.

Our VAM runs on the readily available steam from boiler, thus saving the electrical output 235 kW per hour. This in turn saves the operational cost by significant amount as power cost in that area was high and steam cost was low.

Thermax successfully commissioned a biomass boiler for an FMCG major in India

Thermax’s CPRG boiler at Dabur’s katni plant is used 24 hrs a day to make their renowned product Chyawanprash.

PROJECT BACKGROUND

Dabur India Ltd. is one of India’s leading FMCG Companies, building on a legacy of quality and experience of over 133 years,Dabur is today India’s most trusted name and the world’s largest Ayurvedic and Natural Health Care Company. Dabur India is also a world leader in Ayurveda with a portfolio of over 250 Herbal/Ayurvedic products. Dabur’s FMCG portfolio today includes five flagship brands with distinct brand identities Thermax’s association with Dabur is for their two plants Sahibabad and Katni. At Sahibabad Plant,in 2013 Thermax has successfully commissioned a 5 TPH boiler that effectively uses wet herbal waste with 70% moisture which is a residue of their process making of various Herbal products. and continuing the trusted partnership Dabur gave the order for 8TPH for their Katni plant.

Dabur India Katni Plant was a manufacturing unit of Chyawanprash previously now it only produces initial raw material for Chyawanprash then this raw material is transferred to their Sahibabad unit for the final product.

SOLUTION PROVIDED

CPRG 8TPH biomass boiler was proposed understanding the customer’s steam consumption pattern in the process. This plant uses Mustard briquette as fuel that is used for preparing raw material for Chyawanprash. Steam gets utilized for boiling Amla and then it is mixed with ghee to produce initial raw material for Chyawanprash.

BUSINESS PROPOSITION

A CPRG briquette-fired boiler of 8 TPH ensuring energy (steam) delivered at an optimum price leveraging high-end automated biomass boiler installation. Thermax has offered Lambion Reciprocating grate technology.Reciprocating Grate utilizes successive oscillation of grate linkage for the continuous movement of fuel; alternate movement of grate blocks pushes the fuel in the distinct combustion zones of a grate to ensure high steam to fuel ratio.

 

 

POSITIVE IMPACT

  • Optimum Cost-Effective Steam Price
  • Ensuring consistent quality at the right price
  • Guaranteed Boiler Uptime
  • Efficiency throughout the Product Lifecycle

Thermax Process Heating Solutions

A strategic business unit offers packaged boilers, thermal oil heaters, waste heat recovery boilers, hot water, and air generators. These are available in modular construction as a standard package configuration or a custom design for specific requirements. Innovated by a strong R&D that focuses on customer applications, we
offer a range of heating systems designed to combust a wide range of solid, oil & gas fuels including biomass and heavy liquid fuels.

THERMAX MADE IT POSSIBLE! UP TO 45% FUEL COST SAVING USING 100% BIOMASS FIRING

Introduction

Thermax is committed to ‘Conserving energy and preserving the environment’, two areas vital for the world. We support business establishments to be more energy efficient and environment-friendly.ITC Group a multi-business conglomerate is one such customer for Thermax. They have various manufacturing plants across India and one of them is at Ranjangaon Pune MH. This food production unit manufactures instant noodles and potato chips.

PROJECT INSIGHTS

In 2012 ITC was looking for expansion with a cost-effective fuel solution and was keen to have 100% biomass-fired unit, yet the biggest challenge here was maintaining steam-fuel ratio as the calorific value of fuel i.e. biomass briquettes changes drastically.

There were three main criteria’s for this project :

  1. UNINTERRUPTED STEAM SUPPLY
  2. FAST RESPONSE TO FLUCTUATINGLOAD”
  3. HIGH EFFICIENCY

INNOVATIVE SOLUTION BY THERMAX

A heating system is the heart of any food processing unit. ITC group partnered with Thermax for a reliable solution which consisted of a 14 TPH boiler (CPRG 140) with economizer and air pre-heater ensuring higher efficiency and uptime for high-pressure steam requirements in the chips and noodles frying process.

RECIPROCATING GRATE

Reciprocating Grate utilizes successive oscillation of grate linkage for the continuous movement of fuel;
alternate movement of grate blocks pushes the fuel in the distinct combustion zones of a grate.

Advantages

  • 100% combustion
  • Highest uptime and efficiency
  • Low emission

To ensure steam to fuel ratio of 5.0 Thermax has offered Lambion Reciprocating grate technology. Thermax has Licensed Lambion technology that has over 100 years of experience in biomass firing solutions. The grate offers progressive combustion with distinct combustion zones making it ideal solution for biomass firing up to 60%
moisture content.

The Adaptation of an efficient boiler system from Thermax and the change in fuel from FO (furnace oil) to biomass briquettes helped ITC to achieve these challenging results with just 3-4 people managing the complete plant operations.

  1. STEAM TO FUEL RATIO 5.0
  2. FUEL COST SAVING UP TO 45%
  3. SPM LEVEL AS LOW AS 28 PPM

Thermax welcomes another happy customer in its fold

THERMAX HELPS BUDHANI BROS WAFERWALA TO SAVE FUEL COST BY 20%

Introduction

Budhani bros waferwala trusts thermax for their potato chips frying process for the last two decades sharing a
journey of quality, reliability , and sustainability.

The famous food major is associated with Thermax since 2003 from the time they introduced a fully automatic system for chips frying and purchased 1st Thermic fluid heater of 10 lac Kcal/hr. The association since then has resulted in a trusted bond that made Thermax an obvious choice when they were expanding in 2016 and purchased second Thermopac of 25 lac Kcal/hr.

THERMAX’S THERMIC FLUID HEATER–THERMOPAC-OFFERS

  • Fuel flexibility
  • Minimal maintenance
  • Best in class efficiency

IN CONVERSATION WITH MR. ARVIND BUDHANI
OWNER BUDHANI BROS

He refers to their mission of “ensuring optimum utilization of resources by integrating latest technology to provide the best quality and appropriately priced snacks to everyone, everywhere ” explaining Thermax’s thermopac have been an integral part of the growth of small household business venturing into a business empire.

THERMAX’S THERMIC FLUID HEATER OFFERS ENERGY SAVING UP TO 20%

The well-known quality of these chips comes from the sustained crispiness, size,and color. Thermax’s Thermopac helps maintain these crucial parameters with an uninterrupted hot oil supply and consistent temperature of the oil with precision up to +/-1 degree C at the fryer. The process is continuous and any small deviation in the temperature can ruin a complete batch of final product.

Customer proudly mentions that they have no standby unit thanks to the efficient and reliable thermopac and real-time services maintained over a period of time by Thermax Ltd.

Thermax Limited continues to be a trusted business partner for Budhani bros.

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