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.