HEAT RECOVERY SOLUTION FOR CARBON BLACK INDUSTRY FROM Thermal Systems ( Hyderabad) Pvt. Ltd Hyderabad, India Contact : Mr. B. S. Viswanath Mobile :

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1 HEAT RECOVERY SOLUTION FOR CARBON BLACK INDUSTRY FROM Thermal Systems ( Hyderabad) Pvt. Ltd Hyderabad, India Contact : Mr. B. S. Viswanath Mobile : viswanath@thermalindia.com info@thermalindia.com

2 CARBON BLACK INDUSTRY : BRIEF OUTLINE CARBON BLACK is produced by subjecting hydrocarbon feedstock to extremely high temperatures in a carefully controlled combustion process. Carbon black is used as a high performance reinforcing component in technical rubber products and as a color pigment. It is a quality determining component and defines the characteristics of the final product. The heat contained in the mixture of process gas and carbon black can be returned to the process by means of heat exchangers or can be used externally by a waste heat boiler to generate steam. After separation of the carbon black a combustible waste gas remains. Incineration of this tail gas in a combustion chamber enables the recovery of energy for the use in carbon black dryers or for steam generation. Air Pre heater and the Oil Pre heater convey heat from the process gas directly back to the reactor; thus fuel is saved and the yield of the carbon black process is increased. Quench Boilers and Reactor Boilers generate steam for turbine drives and external use. Tail gas fired Boilers also produce steam for turbine drive and power generation. Rotary Dryers dry the carbon black pellets by using the heat from combustion chambers using carbon black process tail gas as a fuel.

3 CARBON BLACK INDUSTRY : PFD

4 INTRODUCTION : THERMAL SYSTEMS Started in 1984 Located in Hyderabad, India. ISO Engineering company Accredited with ASME S, U, R, PP stamps, Creditable reference of more than installation for Boiler & Other Heat Transfer Equipment. Largest Installation of 176 TPH in India. Largest Installation of 252 TPH outside of India. Supplied Boiler in more than 40 countries. Delivered 18 Boilers on Lean Gases like Tail Gas & BF Gas

5 THERMALSYSTEMS : SNAP SHOT Started with Pressure Vessels/ Package Boilers Entered in Fired Boiler & Waste Heat Boiler for Sulphuric Acid Plant 1. Got ISO Certificate Started Product Line for Refinery 1. Received Order 2 X 176 TPH- WH Boiler for SAP from IFFCO 1.Received Order 8 X 57 TPH- WH Boiler for COB from JSW 2. 1st RDF Fired Boiler in India, Commissioned at Shriram Energy 1. 2 X 65 TPH- WH Boiler for COB commissioned At USHA Martin 2. Largest SRU in India completed 1 Yr of Successful operation. 1.Commissioned 2 X 500 TPD WHB for SIP for Visa Steel 2. Delivered 25 Nr WH Boiler for SIP TPH Boiler commissioned at JIFCO 2. Received order for complete INC PKG for CPCL from Punj Lloyd on EPC Basis Delivered WH Boilers In more than 40 Countries With more than WT WH Boiler in Operation

6 Milestone Projects 2 X 176 TPH Boiler at IFFCO, Paradeep 1 X 252 TPH Boiler at JIFCO, Jordon 1 X 214 TPH Boiler at TIFERT, Tunisia 1 X 168 TPh Boiler at EUROCHEM, Russia 1 X 142 TPH Boiler at Fertiberia, Spain 1 X 135 TPH Boiler at PCIC Kuwait. 1 X 75 TPH Boiler at Alexandria Carbon, Egypt 1 X 60 TPH Boiler at Continental Carbon Limited, Ghaziabad 1 X 50 TPH Boiler at Thai Carbon, Thailand 1 X 30 TPH Boiler at Phillips Carbon Limited at Mundra

7 World Map PowerPoint Template GLOBAL FOOT PRINT / REFERENCE OUTSIDE INDIA 7 Reference in USA 2 Reference in CUBA 1 Reference in in Canada 1 Reference in Mexico Major Installation 100 TPH for CII Rain Office in Germany 24 References in Europe Major Reference 168 TPH for Kingisepp Russia 142 TPH for Fertiberia, Spain 22 References in Asia Major Reference 252 TPH for JIFCO Jordon 135 TPH for PCIC- Kuwait 75 TPH for Alexandria, Egypt 1 Reference in Peru of capacity 54.5 TPH. 15 References in Africa Major Reference 75 TPH for NAMZINC 57 TPH for Roan Congo 2 References in Australia 1 Reference in Newzeland

8 World Map PowerPoint Template Clientele Reference / Indian Reference

9 World Map PowerPoint Template Clientele Reference / International Reference

10 World Map PowerPoint Quality PhilosophyTemplate QUALITY DESIGN FOR RELIABLITY, AVAILABILITY & MAINTAINABILITY OF THE EQUIPMENTS / SYSTEMS QUALITY MAINTENANCE OF CONSISTENT QUALITY IN COMPLIANCE WITH CUSTOMER / CODE REQUIREMENTS EXECUTION TIMELY EXECUTION OF CONTRACT

11 Product Range Carbon Black Coke Dry Cooling Coke Oven Batteries : Reactor W.H. Boilers and COG Boilers : Waste Heat Boilers : Waste Heat Boilers Coke Petro Calcination : Waste Heat Boilers Hydrozen Plants Incinerators : Process Gas Boilers : Waste Heat Boilers

12 Product Range contd Pig Iron Sulphuric Acid Plant Sponge Iron Plant : BF gas Boilers : Complete WHRS plant. : Waste Heat Recovery Steam Generators Spent Acid Regeneration : Waste Heat Recovery System SRU : WH Boilers + Condensers

13 World Map PowerPoint Template In house Capabilities In house Design & Engineering In house & Innovative Design In house resources Latest Software such as HTRI, KED, PV Elite,Pro-bad, Staad Pro, Tekla, AutoCAD, Ceaser, Plant 4D Well versed with International Certification like GOST R / EAC & RTN, PED, CE, DIN State of Art Manufacturing Facility State of Art Manufacturing Facility In house manufacturing facility for Pr & Non Pr Parts with International Inspection Agency such as Lloyds BVQI TUV SUD TUV NORD TUV Rhineland SGS Stringent Quality ISO Certified Company In house quality & testing facility comprising of Radiography, Ultrasonic, M.P. Test, D.P. Test, Universal Testing Machine, Hardness Testing Machines, PMI (Positive Material Identification), Boro-scope Accredited With ASME S, U, PP, R Stamp, NB, EN , AD 2000, EAC, RTN Competent Field Service In house field service department to undertake Erection & Commissioning in any part of India Team of supervisors available in Germany and in India to extend supervision support for erection & commissioning in India and outside of India. Competent after sales service team to handle operational related issues post commissioning.

14 Challenges in Tail Gas Boiler Challenges Lean Gas Low Calorific Value Fluctuation in calorific value Reliability Part of the Process plant hence shall be reliable. Premature failures and shutdowns to be avoided. Shall be designed to follow process parameters i.e higher Turndown Maintainability shall be accessible for Inspection and repair

15 World Map PowerPoint Template Our Solutions for Carbon Black Industries Design Philosophy Radiant Type Boilers are suitable for high calorific value fuels like coal, oil, natural gas..etc since combustion is self sustainable, where as Tailgas is a lean gas, if fired in a Radiant Boiler due to heat pickup by Water Wall of Furnace the Combustion collapses. Hence Combustion shall be completed without heat recovery in a Furnace and then Convective Boiler is required. Our solution is of Convective Boiler constructed in Horizontal, Refractory lined External Combustor which ensures 100 % combustion of gases within. Designed the Combustor with 3Ts philosophy TIME, TEMPERATURE, TURBULANCE Our solution requires no supporting fuel during normal operation Natural Circulation Fuel such as LDO / CBFS are only start up

16 World Map PowerPoint Template Our Solutions for Carbon Black Industries Operational Philosophy Start up fuel is used to raise temperature of the Refractory up to 550 Deg C. and subsequently to with Tail Gas. CO gas enters tangentially at high velocity, in cyclonic path hugging the hot refractory, gets warmedup and further complete flameless combustion. Combustion air is injected in various steps for staged combustion - 10% of air injected through wind box, 40 % of air through Primary air ring and 50 % air through Secondary air ring. Total retention time of 1 sec for complete combustion.

17 COMBUSTOR WITH LINING

18 World Map PowerPoint Template Our Solutions for Carbon Black Industries Manufacturing Philosophy Modular construction is to minimize the Site work and maximize the Shop work for better quality. This will result in less time for site work. Parts are Trail assembled in shop eliminates mismatches during erection. Minimum field weld joints on Pressure Parts.

19 World Map PowerPoint Template Our Solutions for Carbon Black Industries Operational Benefits Lower steam cost as compared with Radiant boiler as supporting fuel is not used. Fully drainable and requires less shutdown. Gases are completely combusted thus resulting in higher steam generation.

20 World Map PowerPoint Template Combustor for TGB at Phillips Carbon, Mundra

21 Tail Gas Boiler at Philips Carbon, Mundra

22 Tail Gas Boiler at Continental Carbon, Ghaziabad

23 Tail Gas Boiler at Continental Carbon, Ghaziabad

24 Performance Certificates

25 Performance Certificates

26 Performance Certificates

27 World Map PowerPoint Vote of Thanks Template