Archives: Case Study

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.

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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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GREEN STEAM SUPPLY AVT NATURAL PRODUCTS LTD.TIPTUR

Thermax process heating solutions reduced carbon footprint- the plant is equivalent to carbon capture by 3 LAKH TREES!

PROJECT BACKGROUND


AVT is a public limited company promoted by AV Thomas Group. AVT Natural Products Ltd (AVT NPL) is a venture promoted, as a strategic diversification from the traditional plantation business. Operating in line with its corporate signature, the company specializes in the extraction of colors and flavors from a natural source. The Group consists of diversified Business in Tea, Rubber, and Consumer Products viz. spices, food ingredients, and healthcare products.

AVT identified with Thermax on the shared belief towards dedication to the customer satisfaction and adherence to highest quality standards and gave us the contract for a Greenfield Boiler Project.

SOLUTION PROVIDED

ComBlocUltra Biomass Boiler Model: CBRG100-Ultra with Reciprocating Grate using Lambion, GmbH Technology

CA 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.

BUSINESS PROPOSITION

Thermax proposed a briquette-fired boiler of 10 TPH@14 kg/cm2(g) ensuring energy (steam) delivered at an optimum price leveraging high-end automated biomass boiler installation. Combloc – a compact, plug & play modular construction boiler with fully automatic operation ensuring high efficiency. Thermax has offered OPEX proposition with BOO (Build-own-operate) model ensuring highest uptime at all time.

BOILER AT A GLANCE

  • Model: CB Ultra- 100/14
  • Capacity: 10 TPH (F&A 100°C)
  • Type: Hybrid Water & Smoke Tube design Boiler with automated,air-cooled reciprocating combustor system of Lambion (German Technology)
  • Design Pressure: 14 kg/cm2
  • Operating Pressure: 9.5 kg/cm2

POSITIVE IMPACT

  • Optimum Cost-Effective Steam Price
  • Guaranteed Boiler Uptime & Efficiency throughout the Product Lifecycle
  • A significant decrease in SPM emissions
  • Dedicated biomass fuel supply chain
  • Ensuring consistent quality at the right price
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Thermax supports ITC’s green initiative by offering 100% biomass-fired boiler ensuring cost saving up to 45%

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.
Our legacy is enriched with the green effect projects for which we are the first choice for some of the global brands in the word. ITC Group which holds a market capitalization of 50 billion USD with a turnover of 8 billion USD crediting to their robust portfolio of traditional and Greenfield businesses is one such esteemed business alliance for Thermax process heating solutions.
The multi-business conglomerate encompasses various manufacturing plants across India and one of them is at Ranjangaon, Pune MH. This food production unit manufactures instant noodles and potato chips. A heating system is the heart of any food processing unit and ITC group partnered with Thermax for a robust heating system. ITC group’s association with Thermax was cemented with the commitment to supply a
heating system to fulfill their steam requirement for which three FO (Furnace oil) fired boilers were commissioned for the same.

Project Insights

In 2012 ITC was looking for expansion and was keen to have a greener, cost-effective fuel, they decided to go for 100% biomass briquettes fired boiler from Thermax. There were three main criteria’s for this project – 1) Uninterrupted steam supply, 2) fast response to fluctuating load and 3) high efficiency. As ITC was keen to have 100% biomass-fired unit the biggest challenge was maintaining steam-fuel ratio as the calorific value of fuel i.e. biomass briquettes changes drastically due to the variation in moisture content, bulk density, ingredients of briquettes etc. Thermax understood customer’s requirement and proposed a fully automatic CPRG (Combipac Reciprocating Grate) boiler with automatic fuel feeding system, air pre-heater, and economizer to ensure best in class efficiency with suitable equipment.

Innovative solution by Thermax

The solution provided by Thermax-CPRG (Combipac reciprocating grate) boiler which can provide 14000 kg per hour steam for high-pressure steam requirements in chips and noodles frying process. The boiler is designed to respond to sudden load changes which are typical for food processing industry. Thermax has proposed boiler with a unique offering of “moving floor” which saves space and has automatic fuel level controller. From the moving floor, the fuel is then sent to fully automatic fuel feeding system comprising of dosing bin and multi-screw fuel feeder. To ensure steam to fuel ratio of 5.0 Thermax has offered Lambion Reciprocating grate technology. Thermax has technology tie-up with Lambion who has over 100 years of experience in biomass firing solutions.

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. This gives toppling action to the fuel particle and hence ensures complete combustion. This grate offers progressive combustion with distinct combustion zones. Relative motion between fuel bed and grate helps to deal with poor fuels up to 60% moisture content.

Energy efficient and low emission operation

High efficiency is an important aspect of achieving an energy efficient operation process of the chips and noodles frying process. Thermax offers both air pre-heater to preheat the combustion air up to 150°C and economizer ensuring the water is preheated up to 120° C. CPRG offers advantages like 100% combustion, highest uptime and efficiency and low emission. Thus the fuel consumption during steam generation is reduced drastically, and hence compared to FO fired boilers the fuel cost saving is 45%*

Positive impact

The flue gas exit temperature is at 100-120° C. The boiler achieves SFR of 5 and ash percentage is as low as 14-15%. The SPM level is as low as 28 ppm. In order to achieve optimum fuel consumption, an O2 controller is integrated into the plant. An oxygen probe measures oxygen continuously and compensates changes in air temperature and air pressure automatically. This optimizes the efficiency of the boiler and reduces the negative environmental impact at the same time.

Continues automation and reliability

The high degree of automation in the steam boiler plant provides comfort and safety to the boiler operator who can see complete process of the boiler from a system linked computer screen. The controller can also manage the equipment and other parameters like fuel feeding, feed water section, combustion manager, and flue gas section, making the boiler unit an automated, timely and reliable solution. This makes the entire plant operation automated and the process can be managed by limited no of people.

The result

The Adaptation of an efficient boiler system from Thermax and the change in fuel from FO (furnace oil) to biomass briquettes helped ITC to save fuel cost by 45%*. The PLC (programmable logic controller) system
continuously monitors the performance of boiler thus
ensuring safety and optimum performance. The proven
construction of combipac together with appropriate plant
equipment and reciprocating grate technology ensures
continuous and high steam quality for chips and noodles
frying process. Thermax’s service team ensures optimum
plant settings, a constantly high efficiency, very low
emission and longer life of the entire plant with their
regular maintenance services.

Thermax successfully commissioned a steam boiler at Govind dairy Phaltan

Thermax’s CPFD a multifuel Boiler is utilized by the dairy company throughout the year for consistent steam supply

PROJECT BACKGROUND

Govind Milk and Milk Products Pvt. Ltd was set up at Phaltan, near Pune, The growth of the company also led to the socio-economic development in the geographical area in and around the company, At Govind, the best procurement and processing systems are employed to process milk and produce milk products. A fully integrated, processing unit with International standards, with the capacity to process in excess of 10 lac liters of milk every day, is currently in use in Phaltan.

Thermax’s association with Govind Dairy is since June 2014 when we received an inquiry for boiler and there were several levels of technical discussion with Govind Dairy team and there Consultant at Phaltan. Finally, we were able to convince them that technically an AFBC boiler is more appropriate for Govind airy against RG influenced by FV. The order was commissioned in August 2016 since then the steam boiler is running successfully without any complaints.

SOLUTION PROVIDED

Our Heating system is required for Milk Powder plant which is a very critical application, the constant pressure of 16kg/cm2 is required at the inlet of the dryer to maintain good quality Milk powder. CPFD 160 / 21 kg-Cm2, F&A 100 DegC steam boiler was proposed after understanding customer’s steam consumption pattern in the process. This plant uses steam to manufacture various products like ghee, Pedha, Icecream, Paneer consuming steam as a standard requirement in the process. The most important heating process required in the whole dairy process is the pasteurization of the milk for which consistent steam is supplied by the Thermax boiler.

BUSINESS PROPOSITION

 

CPFD 16 TPH boiler ensuring energy (steam) delivered at an optimum price leveraging high-end automated boiler installation.Thermax has offered AFBC technology with air preheater recovery unit with 92 % efficiency.The fuel bed is fluidized by the injection of air from the bottom of the bed through a set of air nozzles. This results in very turbulent air and fuel mixing leading to very efficient combustion and heat transfer.This also results in the tumbling action of the fuel like a boiling fluid causing higher residence time or combustion. O2 emissions are approximately 6% and a Zironia based O2 analyzer is installed at the site for online Monitoring.

POSITIVE IMPACT

  • Govind Dairy team opened boiler first time after 6months to check for cleaning, however, found compete boiler system was clean. They have now started cleaning boiler only during annual IBR shut down/Inspection.
  • 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.

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Green Steam Supply for Dairy Industry

Thermax Onsite Energy Solutions Limited

Biomass Boiler Installation at ITC, Munger – Dairy Plant

ITC Group is one of India’s foremost multi – business enterprise with a robust portfolio encompassing Fast
Moving Consumer Goods (FMCG), Hotels, Paperboards & Specialty Papers, Packaging, Agri-Business, and Information Technology.

In the modern dairy, steam is used in a variety of processes and to help maintain clean, sterile conditions. Steam is used because it is an efficient carrier of heat providing constant temperatures essential for achieving good quality of products.

Thermax Onsite Energy Solutions Limited (TOESL), a subsidiary of Thermax Limited, provides outsourced
utility delivery services based on the Build-Own-Operate (BOO) business model, enabling customers to optimize costs, reduce CO2 footprint and remain focused on their core business.

PROJECT OVERVIEW

ITC uses steam in its Dairy plant for indirect heating for the following manufacturing processes:

  • Skimmed Milk Powder
  • Dairy Whitener
  • Ghee, and
  • In the process of Pasteurization

Of the above applications, major steam consumption is to produce powdered milk in the Spray Dryer.

Previously, TOESL had set up 2 biomass utility plants for steam supply under BOO model for Tobacco and
Snacks & Noodle plants of ITC. Having reaped the benefits from said projects, TOESL was re-approached by ITC Group for a Steam Supply proposition based on biomass as fuel for their first milk processing facility in Munger, Bihar. This facility is a part of customer’s CSR initiative to create sustainable livelihoods in villages through a livestock development program.

In a move to generate cost savings and to be carbon-positive, ITC chose TOESL offering of Biomass-fired
boiler and entered into a long term BOO/T based Steam Supply Contract, inked in September 2013.

TOESL now supplies green steam to ITC’s Tobacco, Food and Dairy businesses.

1.BIOMASS FUEL MAPPING

  • Fuel survey undertaken for the particular site location to identify biomass fuels available within a 300 km radius of the site, in the province of Bihar
  • Fuels identified: Paddy Husk Paddy husk is available throughout the year in and around the site location
  • Vendor development to establish fuel supply chain network from source to site
  • Evaluation of biomass price and available quantity over the course of a year

2. PROJECT ASSESSMENT AND OUTLINE

  • Study of load patterns of the process plant
  • Study of steam consumption by the processes – minimum, average and peak
  • Establish the minimum steam off-take
  • Evaluate space available on-site

3. TECHNOLOGY SELECTION AND ENGINEERING

  • Leverage state-of-the-art, multi-fuel technology by Thermax and provide optimized, highly efficient and sustainable offerings to the customer
  • Undertake detailed engineering to deliver customized high-end solutions

4. INSTALLATION AND COMMISSIONING

Install and commission the biomass-fired boiler along with boiler accessories, fuel and ash handling systems and air pollution control equipment

5. OPERATION AND MAINTENANCE

  • Undertake comprehensive O&M along with fuel, ash, chemicals, consumables and spares management
  • Deploy experienced and trained manpower
  • Routine regulatory compliance
  • Maximize uptime and operating efficiency
  • Online & remote performance monitoring

TECHNICAL SPECIFICATIONS

  • Biomass Fired Boiler having Fluidized Bed Combustion
  • Boiler Type: Horizontal Multi-tubular Shell Type Smoke Tube with Water Wall Furnace Boiler
  • Boiler Model: CPFD80
  • Boiler Capacity: 8 TPH F&A 100 °C
  • Boiler Design Pressure: 21 kg/cm 2 (g)
  • Primary Fuel: Paddy Husk

TOESL STEAM SUPPLY AGREEMENT

  • Customer invests in the civil foundations and structure for the utility plant
  • Complete capital expenditure of the equipment undertaken by TOESL
  • Agreement period of 10 years
  • Customer shall pay interest free security deposit at the time of signing of agreement which shall be
    refunded at the end of agreement period
  • Fuel is charged on a pass-through basis
  • Utility is charged as per off take
  • Utility costing is done on the basis of the minimum off take decided between customer and TOESL
  • Utility price reduction on consumption exceeding minimum off take
  • Guaranteed delivery of uptime

BENEFITS TO CUSTOMER

  • Cost reduction due to effective utility price
  • Sizeable carbon savings as against fossil fuel boiler
  • Guaranteed boiler uptime & efficiency throughout product lifecycle
  • Operational Excellence – uptime and efficiency delivered higher than committed
  • Downtime planned in conjunction with process plant shutdown
  • No investment in utility plant and machinery by customer
  • Minimal SPM through advanced APC equipment
  • Dedicated biomass fuel supply chain ensuring consistent quality at right price

On operation of biomass-fired boiler over the years, ITC-Munger Dairy Division has contributed to reduction in CO2 emissions of over 7740 tons as of January 2019.
(Biomass Boiler Plant commissioned in August 2015)

Thermax sets a record by commissioning a 40 TPH boiler in just 40 days for Pharmaceutical major in Indonesia.

Introduction

Thermax’s esteemed customer PT Cheil Jedang alias CJ Bio awarded an order for a 40 TPH Bi drum boiler. Thermax successfully completed erection and commissioning of the entire plant within eight months against a typical duration of twelve months. The entire commissioning activity was completed within 40 days instead of a four-months usual period.

Project Insights

  • 40 DAYS FOR COMMISSIONING 40 TPH BOILER
  • 0 REPORTED INCIDENTS HIGHEST SAFETY STANDARDS
  • 100% SERVICE EXCELLENCE THROUGH ENGINEERING & PROJECT MANAGEMENT

Appreciation

In appreciating Thermax’s work Mr. Mukh Mustain (Engg Construction Manager) from CJ Bio said that “Erection of the boiler was completed on account of Thermax’s proper planning, safety, and technical expertise.”. He specially mentioned the work that was done by Sateesh D, Vaibhav Mohite and Rakesh Kumar and their respective teams for ensuring timely installation and commissioning.

Thermax Experts

This feat was possible owing to the high-quality execution by Thermax experts that eliminated any extra time spent in rework. The entire project was completed in adherence to the highest standards of safety resulting in zero reported incidents.

A critical success factor was the collaboration between CJ Bio and Thermax. The client provided all necessary support with logistics, planning, and execution.

The early commissioning not only helped customers resume operations before stipulated time but also helped Thermax achieve higher efficiency and cost savings.

Thermax is proud to welcome another satisfied customer to its fold and looks forward
to a strong association with CJ Bio in the future.

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THERMAX PROVIDES CHILLER FOR SOLAR COOLING OF A MEDICAL CENTRE IN USA

Industry:Medical Centre
Status: Installed in 2010

Project Snapshot

Client : Chromasun
End Customer : Crow Canyon Medical Center (CCMC)
Location :  Danville, CA, USA
Total capacity : 50 TR (175 kW)
Application : Air-conditioning at Medical Centre
Energy Source : 338°F hot water heated by solar ray
Chilled In/Out : 66°F/54°F (19°C /12°C)

Project Overview

Thermax’s installation at a medical centre located in California is the first solar thermal system to provide air cooling and heating, and domestic water heating for a U.S medical facility. Here,50 TR high temperature hot water is driven in the two stage chiller with back-up firing option has been installed at facility to cool the office area of 64,000 sq. ft. It is a complete energy efficient heating and cooling system which uses solar energy to generate the hot water.

Project Description

A primary business goal for our client was to operate one of the most energy-efficient and environmentally sustainable buildings showcasing the potential of solar thermal technology to offset both cooling (electricity) and water heating (natural gas) in the U.S. hospital industry. The medical centre has 75 Chomasun MCT of 3352 sq. ft. collector area total which gives hot water of 338°F which gives energy to run the 50 TR chiller delivering 54°F water. This water is circulated to cool the air for comfort cooling in the office area of 64,000 sq. ft. thus saving 145 MW-hr of electricity per year. It reduces carbon emission by 102 tons per year which is equivalent to the emission from 26 cars.

Highlights

-By installing Thermax’s chiller, our client was able to make savings in power of about 145 MW-hr/year.

-We also helped them in the reduction of carbon emissions of about 102 Tons/year which is equivalent to the emission from 26 cars.

Thermax’s Biomass boiler commissioned at Serum Institute is a boon for saving the environment and reducing fuel cost by 30%.

PROJECT BACKGROUND

Thermax is committed to conserving energy and preserving the environment, two areas critically monitored globally. We support businesses with 100% biomass-fired boilers ensuring fuel savings with lower emissions. Serum Institute of India is one such esteemed customer benefiting from green energy since 2013.

Saving the world with one vaccine at a time- Serum Institute of India Pvt. Ltd. is now the world’s largest vaccine manufacturer by number of doses produced and sold globally (more than 1.3 billion doses) which includes Polio vaccine as well as Diphtheria, Tetanus, Pertussis, Hib, BCG, r-Hepatitis B, Measles, Mumps and Rubella vaccines. It is estimated that about 65% of the children in the world receive at least one vaccine manufactured by Serum Institute.

Thermax has successfully commissioned 22 TPH biomass briquette fired boiler for their Hadapsar (Pune) vaccine plant. The main issues faced were the space constraint and the impact of the biomass fuel dust near the vaccine plant. This plant layout and boiler installation are customized to remove the space constraint which is the unique pentagon-shaped area. There was a tough competition for this project and Thermax process heating solutions bagged this opportunity with technology advancement and expertise in the field of biomass combustion.

SOLUTION PROVIDED

Thermax has offered Combipac Reciprocating grate boiler ensuring 100% firing of biomass briquettes. Thermax has technology tie-up with Lambion GMBH who has over 100 years of experience in biomass firing solutions. Reciprocating grate offers progressive combustion with distinct combustion zones making it the ideal solution for biomass combustion with moisture up to 60%.

This grate offers huge fuel flexibility and can burn complex fuels like forest wastes, empty fruit bunches, spice waste, soya stock, and many other biomasses. Reciprocating utilizes successive oscillation of grate castings mounted on different trolleys for the continuous movement of fuel. These trolleys are driven by independent hydraulic cylinders and alternate movement of grate blocks pushes the fuel in the distinct combustion zones of the grate. This gives toppling action to the fuel a particle hence ensures complete combustion.

The advantages of reciprocating grate are:

  • 100% combustion
  • Highest uptime and efficiency
  • Very low emission

BUSINESS PROPOSITION

The steam generated from the boiler is used throughout the plant for an important process of sterilization and
clean steam generation for advanced procedures in the plant. On an average 2 lakh, the vaccine is manufactured
in a single lot and 12 lakh vaccine on an everyday basis through this process

This entire boiler plant is automatically operated with only 2-3 operators are needed for managing the entire operation. In the current world of dynamic pricing of the furnace, oil customer is benefited with an assured 30% cost savings by shifting to biomass briquettes. High-quality steam and assured uptime is the key for any successful operation of the pharma industry.

Thermax has once again demonstrated its capability as a reliable partner for customer’s success.
Cementing the long-term association of the two companies Thermax is proud to be a part of the biotechnology company’s work of saving the children with the vaccines that are manufactured at this plant while also saving the environment.

POSITIVE IMPACT

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

  • Fule cost saving up to 30 %
  • Space constraints resolved
  • Higher efficiency steam generation

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.

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