HEAT RECOVERY SOLUTION FOR

CARBON BLACK INDUSTRYFROM

Thermal Systems ( Hyderabad) Pvt. LtdHyderabad , India

Contact : Mr. B. S. ViswanathMobile : +91 9849598986

Email : viswanath@thermalindia.cominfo@thermalindia.com

CARBON BLACK INDUSTRY : BRIEF OUTLINECARBON BLACK is produced by subjecting hydrocarbon feedstock to extremely high temperatures in acarefully controlled combustion process. Carbon black is used as a high performance reinforcingcomponent in technical rubber products and as a color pigment. It is a quality determining component anddefines the characteristics of the final product.

The heat contained in the mixture of process gas and carbon black can be returned to the process bymeans of heat exchangers or can be used externally by a waste heat boiler to generate steam. Afterseparation of the carbon black a combustible waste gas remains. Incineration of this tail gas in acombustion chamber enables the recovery of energy for the use in carbon black dryers or for steamgeneration.

Air Pre heater and the Oil Pre heater convey heat from the process gas directly back to the reactor; thusfuel 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 firedBoilers also produce steam for turbine drive and power generation. Rotary Dryers dry the carbon blackpellets by using the heat from combustion chambers using carbon black process’ tail gas as a fuel.

CARBON BLACK INDUSTRY : PFD

INTRODUCTION : THERMAL SYSTEMSØ Started in 1984Ø Located in Hyderabad, India.Ø “ISO 9001 – 2008 “ Engineering company Ø Accredited with ASME S, U, R, PP stamps, Ø Creditable reference of more than 400 + installation for Boiler & Other Heat

Transfer Equipment.Ø Largest Installation of 176 TPH in India.Ø Largest Installation of 252 TPH outside of India.Ø Supplied Boiler in more than 40 countries.Ø Delivered 18 Boilers on Lean Gases like Tail Gas & BF Gas

Started with Pressure Vessels/ Package Boilers

Entered in Fired Boiler & Waste Heat Boiler for Sulphuric Acid Plant

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.Commissioned 2 X 500 TPD WHB for SIP for Visa Steel2. Delivered 25 Nr WH Boiler for SIP

1. 2 X 65 TPH-WH Boiler for COB commissionedAt USHA Martin

2. Largest SRU in India completed 1 Yr of Successful operation.

1. 252 TPH Boiler commissioned at JIFCO

2. Received order for complete INC PKG for CPCL from Punj Lloyd on EPC Basis

Delivered WH BoilersIn more than 40 Countries

With more than 150 + WT WH Boiler in Operation

1. Got ISO 9001 –2008 Certificate

Started Product Line for Refinery

THERMAL SYSTEMS : SNAP SHOT

Milestone ProjectsØ 2 X 176 TPH Boiler at IFFCO, ParadeepØ 1 X 252 TPH Boiler at JIFCO, JordonØ 1 X 214 TPH Boiler at TIFERT, TunisiaØ 1 X 168 TPh Boiler at EUROCHEM, Russia Ø 1 X 142 TPH Boiler at Fertiberia, SpainØ 1 X 135 TPH Boiler at PCIC Kuwait.Ø 1 X 75 TPH Boiler at Alexandria Carbon, EgyptØ 1 X 60 TPH Boiler at Continental Carbon Limited, Ghaziabad Ø 1 X 50 TPH Boiler at Thai Carbon , ThailandØ 1 X 30 TPH Boiler at Phillips Carbon Limited at Mundra

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7 Reference in USA2 Reference in CUBA1 Reference in in Canada1 Reference in MexicoMajor Installation100 TPH for CII Rain

1 Reference in Peru of capacity 54.5 TPH.

Office in Germany24 References in EuropeMajor Reference168 TPH for Kingisepp – Russia142 TPH for Fertiberia, Spain

22 References in AsiaMajor Reference252 TPH for JIFCO –Jordon135 TPH for PCIC-Kuwait 75 TPH for Alexandria , Egypt

2 References in Australia1 Reference in Newzeland

15 References in Africa Major Reference75 TPH for NAMZINC 57 TPH for Roan Congo

GLOBAL FOOT PRINT / REFERENCE OUTSIDE INDIA

World Map PowerPoint TemplateClientele Reference / Indian Reference

World Map PowerPoint TemplateClientele Reference / International Reference

World Map PowerPoint TemplateQuality Philosophy

FOR RELIABLITY,AVAILABILITY & MAINTAINABILITY OF THE EQUIPMENTS / SYSTEMS

DESIGN

EXECUTION

TIMELY EXECUTION OF CONTRACT

QUALITY

QUALITY

MAINTENANCE OF CONSISTENT QUALITY IN COMPLIANCE WITH CUSTOMER / CODE REQUIREMENTS

Ø Carbon Black : Reactor W.H. Boilers and COG Boilers

Ø Coke Dry Cooling : Waste Heat Boilers

Ø Coke Oven Batteries : Waste Heat Boilers

Ø Coke Petro Calcination : Waste Heat Boilers

Ø Hydrozen Plants : Process Gas Boilers

Ø Incinerators : Waste Heat Boilers

Product Range

Ø Pig Iron : BF gas Boilers

Ø Sulphuric Acid Plant : Complete WHRS plant.

Ø Sponge Iron Plant : Waste Heat Recovery Steam Generators

Ø Spent Acid Regeneration : Waste Heat Recovery System

Ø SRU : WH Boilers + Condensers

contd…Product Range

World Map PowerPoint TemplateIn 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

Stringent Quality • ISO 9001 – 2008 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 3834 – 2, AD 2000, EAC, RTN

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

•

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.

Challenges in Tail Gas BoilerChallenges

Lean Gas

Reliability

Maintainability

• Low Calorific Value• Fluctuation in calorific value

• 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

• shall be accessible for Inspection and repair

World Map PowerPoint TemplateOur 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

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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.

COMBUSTOR WITH LINING

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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.

World Map PowerPoint TemplateOur 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.

World Map PowerPoint TemplateCombustor for TGB at Phillips Carbon, Mundra

Tail Gas Boiler at Philips Carbon, Mundra

Tail Gas Boiler at Continental Carbon, Ghaziabad

Tail Gas Boiler at Continental Carbon, Ghaziabad

Performance Certificates

Performance Certificates

Performance Certificates

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