Steel major in Bangladesh gains significant savings with Thermax chillers

Abul Khair Steel (AKS) is one of Bangladesh’s major steel producers meeting more than half of the country’s steel demand. For its environmental considerations and waste reduction, AKS collaborated with Thermax in its major step towards sustainability. AKS has opted for two double effect steam driven vapour absorption chillers of 250TR each. Steam recovered from Thermax’s waste heat recovery boilers, which is otherwise emitted into the environment, is used to drive the vapour absorption chillers. Chilled water at 7°C is used for cooling applications in the company’s captive power plant spread over an area of 50,000 square feet. Harish Uppoor, Sr. General Manager at AKS attributes their approximate monthly savings of $7000-8000 to the installation of Thermax’s chillers when compared to electrical chillers. Our chillers have helped the company cut down their carbon emissions by 1286.4 tonnes and save about 1.34 million units of electricity annually.

 

Iron Ore Pellatisation Application in Steel Industry – Grate Kiln Process

THE CUSTOMER PROFILE

Vale S.A. is a Brazilian multinational diversified metals and mining corporation. In addition to being the second-largest mining company in the world, Vale is also the largest producer of iron ore pellets. Vale S.A opened a 9 MTPA (2 x 4.5) Iron ore pellatisation plant in Sohar, Sultanate of Oman., on March 3rd, 2011. High
grade iron ore for the plant is imported from Brazil & finished product is sold to Steel plants globally as a raw
material feed for Blast furnace or Electric arc furnace.

THE PELLETIZATION PROCESS

Pellatisation process turns fine –grained iron ore into hardened balls of approx. 8 to 16 mm diameter, which are used as feed in Blast Furnace, Electric arc furnace or DRI plant. Fine grained high quality Iron ore is mixed uniformly with Lime stone, Coke Breeze along with Bentonite & moistened with water & taken to a balling drum were in centrifugal force reduce the moistened raw material to ‘Green Pellets’ of required size as specified by customer. The Green pellet thus obtained is taken to an indurating furnace having heat resistant perforated cast iron traveling grate bars arranged on two rotating drum to make an end less belt.
Green Pellet is evenly placed at the feed end & burners are arranged opposite each other on longitudinal sides of the preheating & firing zone. As the belt progress a series of heavy duty fan draw air through the pellet bed & coke breeze in the Green pellet catches fire. The speed of the belt is arranged in such way that the pellets harden uniformly & emerge as red hot pellet at discharge end.
The dust laden gases are treated in Pollution control equipment before letting out through stack. Unlike in ‘Straight Grate’ process a ‘Grate Kiln’ process employ only one burner situated at the discharge end of the Rotary Kiln. Forced ‘Annular coolers’ are located at discharge end to uniformly cool pellet by an updraft of ambient air before transporting to storage silo.

THE CHALLENGE

Grate Kiln process is unique process designed to evenly indurate pellets to increase its mechanical properties. This process employ a conventional ‘Straight Grate’ followed by a ‘Rotary Kiln’ designed to churn the pellets & thus increase even heating as well to avoid fragmentation in transportation. As against a conventional burner the hot gases from the Rotary kiln are reused to preheat the green pellets so that the moisture in the Green pellet is gradually released & avoid steam formation inside pellet which would otherwise rupture the pellets.
Technology for the Project was offered by KOBELCO, Japan. who has recommended Grate Kiln Technology of Metso Minerals. ‘Grate Kiln’ process was then a ‘first- of- a-kind’ application for Thermax, despite having supplied numerous Air pollution control equipment on ‘Straight Grate’ Pellet plant. The challenge in this case was the high dust load generated due to churning of pellet inside the Kiln as well space constrain in Location of
ESP’s.

THE THERMAX ENVIRO SOLUTION

Process engineers at Thermax carried out extensive study & based on performance data of ‘straight grate’
Pellatisation Process derived optimum design of ESP for ‘Grate Kiln’ Process & accommodated in the given
floor space without compromising on technical parameters .

The performance Guarantee test was done after commissioning of ESP & all ten units of ESP shown an emission of less than 50mg/Nm3

‘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.

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