Post on 11-Jan-2023
In view of our constant endeavour to improve the quality of our products, we reserve the right to alter or change specifications without prior notice.
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The Thermax Enviro Portfolio
Air pollution controll Baghouses - Reverse Air, Pulse Jet & Insertables
l Electrostatic Precipitators - Dry and Wet
l Particulate Scrubbers - Venturi, Cyclonic
l Gaseous Scrubbers - Packed Bed, Spray/Tray Towers
l Flue Gas Desulphurization (FGD) Systems
l Dedusting & Fume Extraction Systems
l Coal Preparation Plants & Coal Injection Systems
l Pushing Emission Control Systems for Coke Ovens
l Combofilter
l Retrofit and Rebuild
l Spares & Services
The Electrostatic Precipitators on the front cover
ENVIRO DIVISION
With special features to achieve low emissions
Cleaning the air for better returns
Electrostatic Precipitators
The division also undertakes turnkey projects to offer complete
technology on air pollution control and its management
ESP on Biomass fired boiler in a 9.9 MW unit
Other ESP installations for reference
On two 80 TPH petcoke fired boilers in a 36MW captive power
generation plant
On a 14 TPH multi-fuel AFBC boiler used by a packaged food manufacturing MNC
On a coal & sludge fired AFBC boiler at a viscose fibre plant in Indonesia
On a clinker cooler in a cement plant
On waste heat recovery boilers for sponge iron kilns
www.thermaxglobal.com
Sustainable Solutions in Energy & Environment
Registered Office
D-13, MIDC Industrial Area, R D Aga Road, Chinchwad, Pune 411019, India
Tel : +91 20 66122999 / 66155000 Fax : +91 20 27472049
enquiry@thermaxglobal.com
Thermax Business Portfolio
Heating
Cooling
Power Generation
Air Pollution Control
Chemicals
Water and Wastewater Solutions
Solar
Specialised Services
Thermax offers products,
systems and solutions in
energy and environment
engineering to Industrial and
commercial establishments
around the world. Its
business expertise covers,
heating, cooling, waste heat
recovery, captive power,
water treatment and
recycling, air pollution control
and waste management and
performance chemicals.
Thermax brings to customers
extensive experience in
industrial applications, and
expertise through technology
partnerships and strategic
alliances.
Operating from its
headquarters in Pune
(Western India), Thermax has
built an international sales &
services network spread over
South East Asia, Middle East,
Africa, Brazil, UK and US. It
has a full fledged
manufacturing set up that is
certified for ISO 9001:2000,
ISO 14001 and safety
management according to
OHASAS (ISO 18000).
ENVIRO DIVISION: Cleaning the air for better returns
Enviro division was conceived with a belief that ‘Pollutants are
inevitable but pollution is not’. An acknowledged leader in Air
Pollution Control business, it offers a wide range of Flange-to-
flange products, customised systems and value added services.
Enviro is present in most industries and application segments
therein, Viz. Cement, Iron and Steel, Power, Nonferrous
metallurgical, Fertilisers, Tyres, Paper, Chemicals, Petrochemicals
and Textiles.
Thermax Limited:
Improving your Business
is our Business
Thermax LimitedEnergy & Environment Research
Centre, Pune, India
Thermax LimitedEnviro DivisionOffice, Pune, India
Thermax LimitedEnviro Division,
Manufacturing Facility, Solapur, India
Thermax LimitedCorporate Office Pune, India
TIGI RAPPERS
COLLECTINGELECTRODE
GAS DISTRIBUTIONSCREENS
TR SETS
DISCHARGE ELECTRODE
Cross Sectional View of a
Typical Thermax ESP
Collecting Electrode
l Accurate plate alignment
tolerance.
l Structural integrity and
superior ability to transmit
rapping energy and its
clean ability under all types
of service conditions and
plate heights.
l Preformed modules with
interlocking edges that fit/
snap securely together and
require no field assembly.
l The top and bottom edges
are reinforced and stiffened
by tubular structural
members.
l Mechanical interlock
prevents deformation and
oil canning.
The Thermax discharge electrode possesses excellent performance characteristics over a wide range
of applications.
l Rigid structural matrix.
l Precisely manufactured to
fit within the collecting
plate arrangement.
l Fabricated from structural
tubing with uniformly
spaced corona studs to
optimise voltage/current
relationship.
l Corona studs are annealed
to prevent fatigue cracking.
l Design configuration
minimizes arcing and
allows considerably
elevated voltage before sparkover occurs.
l TIGI - Thermax impulse gravity impact type rappers. Gravity assisted rapping effectively reduce the
Re-entrainment.
l Complete rapping mechanism is
placed outside the gas stream
on roof facilitating on-line
maintenance.
l Can provide maximum plate
acceleration in excess of 200
g’s.
l The electric single impulse (ESI)
rapper accommodates on-line
adjustment of rapping intensity
and frequency.
l 100% microprocessor backup.
l Longer life resulting from less
wear and tear.
l Uniform distribution of force.
l Ideally suitable for installations
with variable process conditions.
Rapping SystemElectrodes
TR Sets & TIGI Rappers on a precipitator roof- a typical arrangement
Discharge electrode
DISCHARGE ELETRODE BOTTOM GUIDE FRAME
DISCHARGE ELECTORDE
SUPPORT
Typical Discharge Electrode System
DISCHARGE ELETRODE
COLLECTINGSURFACE
RAPPER ROD
COLLECTINGSURFACE
A Typical Collecting Surface Arrangement
GIRDER
COLLECTINGSURFACE
SPACE BAR
ROOFGIRDER &COLLECTINGSURFACESUPPORT
FLOATINGCHANNEL
PRECIPITATORROOF PLATE
ANVIL
Transformer Rectifier
l Extra heavy duty design suitable
for 120 or 90 KV peak voltage,
based on application
requirements.
l Built-in current limiting reactor to
protect the electrical system
from frequent short circuit in the
field.
l Top as well as side output HT
bushing.
l Pressure release valve to take
care of excess pressure in tank.
Control Cabinet
l Complete automatic transformer
rectifier control.
l Glow tubes are provided in the
field for feedback circuit for protection.
l Necessary surge suppressors are provided for noise elimination.
l Audio-visual alarm annunciator and time totaliser are provided.
l Back-up over current protection is provided.
Electrical Components
Optiklin - The Thermax Intelligent Microtapper Controller
l A variety of peripheral systems form part of our overall system design and supply capability.
l These include conditioning towers, duct work, stacks, fan, screw conveyors, duct valves, bucket elevators, storage silos and supporting steel, all of which can be supplied on a turnkey basis.
Ancillariesl Computerised Flow Modeling facilities,
available in-house, can be taken up for ensuring proper gas distribution in critcal cases, typically for high flow rates.
l
highly respected suppliers, the land maintenance costs of these precipitators are a result of extensive experience in the industry.
l Experience in the industry covered electrostatic precipitators for gas cleaning or product recovery from wet and dry process
One of the rock products industry's most ow operating
Cement & Rock Productsrotary kilns, clinker coolers, dryers and ball mills for raw and finish grinding.
l Electrostatic precipitator for other rock product applications include material from kilns processing alumina, dolomitic lime, sludge lime for the paper industry, metallurgical lime and others.
Utilities
l
types has provided extensive data base to
accurately determine most economical design
for optimum performance under varying load
conditions.
Experience in dealing with a multitude of fuel l
and verification of design assumptions ensure
a high degree of reliability in precipitator
sizing and performance guarantees.
Continuing accumulation of operating data
Four stage suspension preheater kiln precipitator
(right) and alkali bypass precipitator (left)
ESP on clinker cooler,
handling 4,38,000 m3/hr.
l A Programmable Logic Control based system for efficient and optimum operation of the rappers.
l Highly reliable with improved immunity to noise and adverse industrial supply conditions.
l Easily programmable for individual applications.
l Excellent LCD Touch Panel Graphic Human Machine Interface which incorporates live mimic, alarms, diagnostics, reports and help menus with password protection.
l Ensures precise setting of lift, round trip time etc.
l High current solid state switches used for Row and Column selection which allows for long, trouble free life.
l Rugged power source with built-in safety for the maximum current and voltage levels.
l Detection of rapper open and short - circuit conditions and their annunciation.
l High efficiency, less power loss and less heating of the panel.
l Compact panel - lesser number of components allows for easy maintenance.
l Easily expandable for larger systems.
Captive Power Plants
ESP after 107 TPH, ‘F’ Grade & Petcoke fired CFBC Boiler Captive Power Plant for Cement Industry, India
in ESP after 85 TPH, Indonesian coal fired CFBC Boiler Captive Power Plant for Cement Industry, Yemen
in
ESPs after 4X250 TPH CFBC boiler 4X61.5MW Power Plant
in ESPs for 43 MW, Captive Power Plant
ESP after Coal & Sludge fired AFBC Boiler
ESPs on PC fired boilers in a 2X150 MW unit ESPs on coal fired CFBC boilers in a 2X135 MW unit
Recovery Boiler Precipitatorsl Leading suppliers of particulate emission control systems for the pulp and paper industry.
l Modern steel casing design features no internal struts, vanes or rapping devices that could lead to dust buildups.
l Development of the top or bottom inlet and outlet plenum configurations which minimise the potential for salt cake buildup.
l The TIGI system including the heavy gauge T-Line collecting electrode, electric impulse rapper, heavy duty transformer rectifiers,state of the art PLC based controls, and a heavy duty dry bottom drag system conveyor, adds upto one of the most reliable and preferred recovery boiler precipitator systems in the industry today.
Pulp & Paper
Steel
Application
Sinter Plant Waste Gas and Plant De Dusting ESP Sintering process is a pre-treatment step in the
production of iron, where fine
particles of iron ores, Coke, Flues
viz., Lime stone & Dolomite and in
some plants, also secondary iron
oxide wastes (collected dusts, mill
scale), are agglomerated by
combustion process.
Agglomeration of the fines is
necessary to enable the passage
of hot gases during the
subsequent blast furnace
operation.
Thermax by leveraging its vast
experience in steel vertical has
also gained entry in Sinter Plant
Application. With required
application know how and trust
worthy engineering and execution
capability we have successful
running installations in the industry.
Pelletisation Plantl Leading supplier to the sponge iron segment.
l The precipitators are used in sinter plants to capture fine particulate generated in the mixing and
agglomerating of iron ore and
other additives for blast furnace
feed stock.
l Tars and other particulates in
coke oven gases are removed
by tubular or concentric ring
precipitators before the gas is
recovered and collected for
storage as an energy source for
coke oven operation. The stored
gas is cleaned by a secondary
fuel gas precipitator prior to
combustion in the ovens. This
process removes a majority of
the remaining tars and
particulates to ensure proper
gas flow through the oven
combustion nozzles.
l Precipitators are operating in
open hearth and basic oxygen
shops to remove particulates
before exhaust gases are
discharged into the atmosphere.
ESP on recovery boiler in a paper plant
Cocentric collecting electrode tar precipitator for 1.8 MTPA Coke Oven.
Sinter Plant
Waste gas ESP on 90 m2 Sinter Grate Area
ESPs for 2 X 4.5 MTPA Pellet Plant in Oman
Iron ore Pelletisation & hardening process takes place in the Ore mine far from the Location of Iron & Steel making process. The Pelletisation plant transform the Iron ore fine Powder into hard lumps or balls for transportation & as a direct feed into Blast Furnace for Iron making. The process involve mixing of Iron Ore , Bentonite as binder & fluxes in certain proportion by adding
water & rotating in a drum designed to give a spherical shape of approximately 8 to 16 mm size , the pellet thus produced are referred to as "Green Pellet" . These pellets are Baked in an Indurating Furnace at approximately 800 to 1000 Deg C high enough to transform to a semi molten state & subsequently cooled & discharged as hardened Iron Pellets.
l
experience and specialised equipment have
helped to solve a variety of air pollution,
material recovery and gas cleaning problems
in the chemical processing and non-ferrous
metal refining industries.
l Continuous development has resulted in
improved designs for various demanding
applications, e.g. our enclosed tube balanced
pressure acid mist precipitator with a design
that effectively protects against tube collapse
common with exposed tube section types.
l TIGI System Precipitators have been used
successfully in petroleum refineries to remove
catalyst and coke lines from exhaust gases.
Our extensive process knowledge, vast
Chemicals, Food Industry & Non-Ferrous Metals
l ESPs have been designed and manufactured
to handle gases generated from processing
operation for copper, zinc, chromium, sodium
carbonate, phosphorus pentoxide and
calcium fluoride.
l Dry precipitators are being used to remove
solid particulate from gases which contain
sulfur oxides. In some applications, these
gases are then passed through our tubular
lead acid mist units to remove corrosive acids
harmful to the equipment and catalysts used
in the manufacture of sulfuric acid.
Boiler ESP for Food Industry, Russia ESPs after 170 TPH and 60 TPH TG Boiler for Sugar Industries, Thailand
One 36 tube FRP tubular fibre glass
acid mist precipitator (Wet Electrostatic Precipitator)
Electrostatic Precipitator for Alumina
Calcination Kiln Gas Flow - 20,616 m3/hr
Application:
Pelletisation ESP for Process Gas (Draft Drying & Pre-Heating ESP) & Plant de-dusting (Pellet Cooler & Screening area ESP).
Process:
Two or more FD fan pumps in ambient air underneath the cooler beds & heated air is used to drying green pellets. A series of ID fan at the out let draws the dust laden air & is processed in an ESP before letting through the chimney & these are typically referred to as Draft Drying ESP, Pre-Heating ESP, Pellet Cooler ESP. In plant dedusting is done using a Screening ESP. This process of reducing Pellet is referred to as Grate -Kiln Process.
In Addition to Sponge Iron plant, Sinter Plant,
Pelletisation Plant, Coke Oven Plant our Electro
Static Precipitators preferred equipment for Blat
ESPs for 4.1 MTPA Pellet Plant in INDIA ESPs for 4.1 MTPA Pellet Plant in INDIA
Application: Pelletisation ESP for Process Gas (Wind Box & Hood Exhaust) & Plant de-dusting ESP.
Process:This process requires high Gas flow Volume out of Wind Box underneath the belt & hood installed on top of Pellet Plant. Two FD fan create the necessary draft required for Indurating machine & Gases are suctioned out using wind box ID Fan & Hood exhaust ID fan as shown in the schematic Diagram below) .These dust laden gasses are made to pass through an ESP before letting through stack to atmosphere. The collected fine dust in ESP is again send back to ore preparation plant to be reduced to pellet. This process of reducing pellet is referred to as Straight - Grate Process.
Steel : Other applications
Furnace - Stock House, Cast House, BOF
Secondary Dedusting and Scarfing Machine.