Complete Solutions

Thermax Advantage

! Single point solution for all ! Thrust on process & detail An ISO 9001 Enterprise

Sustainable Solutions in
your Water, Waste Water engineering Energy & Environment
Treatment and Waste ! High performance culture WATER & WASTE SOLUTIONS
Sai Chambers, 15, Mumbai Pune Road
Management ! After-sales operations & Wakdewadi, Pune - 411 003
Tel.: 020 - 25541010
! Vast experience in project maintenance support Fax.: 020 - 25541236
E-mail: jaisitty@thermaxindia.com

engineering
! National and international
AHMEDABAD
Tel. : (079) 2657 5408 / 2657 7073
Fax : (079) 2657 7270
E-mail : aadmin@thermaxindia.com
Water & Waste Solutions
installation base BANGALORE
Tel. : (080) 2346 7760/ 2341 8939
Fax : (080) 2346 7760
E-mail : adminblr@thermaxindia.com
CHENNAI
Major sectors served Tel. : (044) 2435 3831/2 /3/ 4
Fax : (044) 2435 3841
E-mail : chennaidivsupp@thermaxindia.com
Pharmaceuticals Pesticides Petrochemicals
HYDERABAD
Tel. : (040) 2331 0254, 2331 2013
Fax : (040) 2331 2335
E-mail : hyd_secr@thermaxindia.com
KOLKATA
Tel. : (033) 2229 2423/ 2229 2428
Fax : (033) 2245 2491
Chemicals Automobiles E-mail : thermcal@giascl01.vsnl.net.in
MUMBAI
Tel. : (022) 2204 5391/ 2, 2202 5324
Fax : (022) 2204 0859
E-mail : psecreta@thermaxindia.com
NEW DELHI
Tel. : (011) 2614 5319, 2614 5326
Fax : (011) 2614 5311
A partial reference list of satisfied users E-mail : cdelhi@thermaxindia.com
VADODARA
! CibaGeigy (Syngenta) ! Du Pont Tel. : (0265) 2345442/ 2332636
Fax : (0265) 231 0051
! ONGC ! Whiley Foils E-mail : badmin@thermaxindia.com
! NOCIL ! Cheminor Drugs
! Cheminova (Lupin) ! Bharuch Enviro INTERNATIONAL OFFICES
n UK n USA n UAE n Thailand n Indonesia
! Pesticides India ! Reddy Labs n Russia n Kazakstan n Kenya n Saudi Arabia
n Nigeria n Malaysia n Bangladesh
! Bajaj Auto ! SmithklineBeecham n Sri Lanka

! Bayer India ! Morepen

! Johnson Mathey ! Purolator www.thermaxindia.com
! Jubilant Organosys ! Johnson & Johnson Thermax Business Portfolio
! Maruti Suzuki ! Toyo Thai
! Mico ! Tamil Petroproducts Ltd. Water & Waste Solutions

INCINERATION
! Lubrizol ! Reliance
! DRDO ! Asian Paints Air Pollution Control
! Honda Siel ! Libra (SFCCL)
! Polyolefins Industry ! Ranbaxy Chemicals
Limited (RCD)
Boilers & Heaters Today's answer to a burning problem
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. All photographs shown in this publication are representative in purpose, and to be used for reference only. For actual details and
specifications, please refer to Thermax offer document.
Absorption Cooling

Captive Power
 Improving your business
is our business
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 & recycling, air
pollution control & 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 &
service network spread over
South East Asia, Middle East,
Africa, Russia, UK and the US. It
has a full fledged ISO 9001:2000
and ISO 14000 accredited
manufacturing setup.
In Water & Waste Solutions,
Thermax offers expertise in water
management and recycling. Its
water and waste water treatment
systems support power plants,
oil & gas installations, fertilisers,
petrochemicals and other
industries. Its waste management
systems serve the health and
hospitality sectors, townships
and colonies, chemical and allied
industries.
Hazardous Waste Management Rotary Kiln Incinerator
- for a cleaner world
Most production processes generate residues and
undesirable by-products that can contaminate both,
the product and environment.
These residues then have to be reduced and
rendered harmless from the points of view of the F
environment and human health. Thermal treatment/
incineration of industrial waste is an economically
feasible and environmentally acceptable solution, C
for reduction of hazardous organic industrial waste
in a foolproof way, with the added possibility of
energy/ material recovery.
A WASTE FEEDING
Incineration System B
B ROTARY KILN
D
- a typical arrangement C SECONDARY COMBUSTION CHAMBER
D BURNERS
WASTE A E ASH REMOVAL
F EMERGENCY FLAP
WASTE WASTE
INCINERATOR
PREPARATION FEEDING
D
PRODUCT RECOVERY/
ASH DISPOSAL
DEMISTER ACID GAS PARTICULATE HEAT RECOVERY/
AND STACK REMOVAL REMOVAL GAS COOLING E
RESIDUE
TREATMENT This is a versatile incineration system, in which all kinds of wastes (solids, semi-solids, liquids, aqueous waste, tars, slurries
etc.) can be burnt. Suitable feeding devices are provided for different types of waste. The rotary kiln is lined with refractory,
The detailed design of any waste treatment system is determined by the mounted horizontally with slight incline and rotated at a controlled speed.
characteristics of the waste to be treated. This requires detailed analysis to be The rotary kiln acts as the Primary Chamber, and ensures burning of the waste under controlled conditions of temperature,
undertaken in order to develop a profile of the chemical, physical and thermal excess air and residence time for solids. While all the volatiles are liberated, other carbonaceous matter is totally burned in the
properties of the waste. The end products are also determined and energy recovery rotary kiln. The temperature is maintained at a minimum of 800OC.
options evaluated. Rotary kiln connects to the Secondary Combustion Chamber (SCC) which operates at a minimum temperature of 1100OC to
While the physical characteristics determine the type of waste preparation, feeding ensure complete combustion of all volatile and unburnt material in the flue gas. A continuous ash removal system and an
mechanism and type of incinerator, the chemical characteristics mainly influence emergency flap for safe venting of the gas is also attached to this chamber.
operating parameters, selection of downline equipment and their MOCs. The SCC is followed by the heat recovery unit (optional) and a suitable choice of air pollution control equipment.
Incineration technologies available
Based on technologies developed through in-house R&D and absorbed through tie-
MERITS
ups with reputed technology partners, Thermax offers a full range of incinerators: ! Suitable for all kinds of wastes
! Rotary kilns ! Feed capability for drums and bulk containers
! Fluidized bed incinerators ! Can be operated at high temperatures
! Liquid/ gaseous waste incinerators ! Residence time adjusted by varying kiln speed
! Fixed hearth (Pyrolytic/ Controlled air) ! Waste feeding: without much preparation
! VOC incinerators
The Thermax edge in incineration
! More than 3 decades of experience
! 650+ installations of non-hazardous and bio-medical waste incinerators
! 80+ installations of hazardous waste incinerators
! 15 installations of volatile organic compound incinerators
Fluidised Bed Incinerator Liquid/ Gaseous Waste Incinerator
A

A BURNER
A BURNER
B INJECTORS
B WIND BOX
C INCINERATOR
C FLUID BED
D D FREE BOARD
C

B A

The fluidised bed furnace is a cylindrical, refractory lined vessel with the following components: The incinerator furnace is a unit of cylindrical construction that can be vertical/ horizontal and down-fired/ side-fired.
n Windbox: to admit air for fluidisation Waste water is introduced through injectors into the flame. This meets the prime requirement for burning organic liquids or tar -
that of ensuring adequate viscosity at burner inlet for proper atomisation. The waste gases are admitted through the burner or
n Air distribution plate: to distribute air in fluidised bed uniformly
nozzles directly. Turbulence is achieved by swirling or providing baffles which promote back mixing.
n Fluid bed: into which feed/ fuel is injected
n Freeboard for secondary combustion BURNER
The bed of inert material is fluidised by the upcoming air. The vigorous boiling action and the extremely large heat transfer area The burner is the most critical component of this incinerator. It breaks the fuel/ waste into small particles and mixes them with the
not only results in thorough mixing of the waste with the oxygen and hot bed medium, but it also ensures high combustion air for combustion, to produce a short and intense flame. This ensures availability of the combustion chamber for complete
efficiency. The flue gas then makes its way from the bed to freeboard area, where combustion of unburnts/ volatiles is completed. combustion.
Manufactured under strict quality controls, these burners offer manifold advantages:
APPLICATIONS MERITS n Multi-fuel capability
+ Distillation bottom tars + Ability to handle heterogenous waste n Modular construction
+ Organic liquid and semi-solid waste + High efficiency due to n High turndown
n Robust construction to suit high temperature requirements
+ Sludge with high moisture content † vigorous mixing in the bed n Ease of operation and maintenance
+ Organic sludge † high retention time
+ Pharmaceutical sludge † proper combustion temperature APPLICATIONS MERITS
+ Aqueous waste containing Sodium + Low NOx formation due to † Low melting distillation † Chlorinated waste from PVC/ † No requirement of secondary combustion
Sulphate, Sodium Carbonate and recovery † lower operating temperature, and bottoms ECH manufacturing † Simple construction
+ Granular, powdery waste Organic liquid waste High Fluorine containing waste † No moving parts
† low excess air † †
+ Can also be applied for general garbage + lnbed neutralisation possible for removal of † Waste waters † Waste containing other † Low maintenance
(after shredding) and gaseous waste, in acid gases † Gaseous waste halogens
combination with the above types
+ Quick restart due to heat stored in the bed
+ Absence of moving parts, hence low
maintenance
Fixed Hearth Incinerator
+ Flexibility to handle diverse fuels It consists of a Primary Chamber with a fixed hearth on which waste is loaded. Air is admitted, in a controlled way for effective
incineration and minimal ash carryover in the flue gas. This is followed by a secondary combustion chamber that ensures
complete oxidation of volatiles and unburnts.

APPLICATIONS: Primarily used for eliminating biomedical waste and non-hazardous waste from industries, municipalities,
offices and hotels. It is also used for burning of hazardous waste like paint sludge and pharmaceutical waste in small quantities.
VOC Incinerator
Volatile organic compounds (VOCs)
Many industrial operations involving printing, dyeing, paint baking and coating, as well as manufacturing of pharmaceuticals and
chemicals, emit organic compounds into the air from their exhausts. Not only do these gases and vapours, known as Volatile Organic
Compounds (VOCs), contribute a great deal to the destruction of the ozone layer, global warming and smog formation, but they also
pose considerable health risks. Incineration or thermal oxidation is the method that is commonly used for their effective control.
Recuperative Incinerator
When the exhaust stream contains high VOC concentration, fuel consumption can be reduced considerably by preheating the
contaminated air in a stainless steel heat exchanger before incineration. Depending on the concentration of VOC and its calorific
value, the incinerator can capture 40 to 60% of exhaust heat, thereby preheating the incoming VOC laden air to just below auto
ignition temperature. In most applications, a minimum temperature of 760OC and adequate residence time will ensure oxidation of
contaminants in excess of 99%.
In order to maintain the incinerator temperature, refractory lining of the retention chamber is required. In some cases, high VOC
concentration will even make the system self sustaining without external fuel. Mixing of the VOC laden preheated air with the flame
results in high destruction efficiency.

Types of VOC Incinerators offered

1) Direct Oxidation 2) Recuperative 3) Regenerative

Sources of Volatile Organic Compounds (VOCs)

! Paint baking ! Textiles
! Ink manufacturing ! Packaging
! Metal decorating ! Resin manufacturing
! Coil and strip coating ! Food Processing VOCs Handled
! White spirit
! Core baking ! Wire enameling ! Mercaptans ! Ethyl Acetate
! Hardboard coating and curing ! Oil sulphurisation and hydrogenation ! Toluene
Asphalt blowing Nitric acid plants ! MIBK
! ! ! Alcohols ! Xylene
! Paper mill digesters ! Synthetic rubber manufacture ! MEK
! Sewage treatment ! Odorous chemical manufacturing

Incineration with a heat recovery boiler/ heater Regenerative Incinerator

In most plants where VOCs are generated, the process itself needs This incinerator is ideally suited for processes that have high
heat in the form of hot water, steam or hot thermal oil. A fume exhaust volumes and low VOC concentration. High heat
incinerator, attached to a waste heat boiler/ thermal oil heater, is recovery efficiency, typically in the range of 90 to 95%, is
commonly used in such cases. achieved by regenerators using ceramic elements. These
regenerators, on a cyclic basis, alternately recover heat from
When small quantities of gases are to be incinerated, and the
high temperature incinerated gases and then preheat the
burner throughput is governed by the thermal output of heaters/
incoming process air.
boilers, the burner control is simple and directly proportional to the
In the retention chamber, burners help to maintain the right
heater output. On the other hand, when larger volumes of VOCs are
temperature. A high degree of preheating ensures fuel
to be incinerated, with a small requirement for waste heat recovery,
requirement to the order of 0 to10% of the fume incinerated
part of the heat can be used to preheat all the incoming
without heat recovery, depending on concentration of VOCs.
contaminated gases. Thus, a combination of waste heat boiler and
A purge system is provided to prevent emission of unburnt
an air preheater ensures optimum fuel consumption.
hydrocarbon at every cyclic change, and to flush the
It is possible to design a system in which the incinerated hot gases regenerator with atmospheric air before exhausting
can be passed into the heater/ boiler or air preheater in any incinerated gases. Low leakage valves for the incoming air as
proportion that is determined by the heater load. In some cases, well as the exhaust line are actuated pneumatically.
this job is made simpler by providing a dump cooler where the If the concentration of VOCs is more than 2gm/ m3, an auto
excess recovered heat is dumped, when it cannot be used in the thermal system operation is possible. In this case, no
process. When using a thermal oil heater as heat recovery system, additional fuel is required. With higher concentrations, excess
this dump cooler could be in the form of a stem generator or air heat can also be utilised.
blast cooler.
HOT OIL TO
IN BURNER BURNER STACK

VOC REGENERATOR REGENERATOR REGENERATOR

BED 1 BED 2 BED 3

CERAMIC CERAMIC CERAMIC

EXHAUST
MEDIA MEDIA MEDIA
FAN

VOC

HOT OIL PURGE

OUT AIR
P r o j e c t P r o f i l e s
Bayer (India) Ltd.
Thane, Maharashtra
WASTES HANDLED
Approximately 7.2 TPD of mixed chemical wastes,
comprising solid tars, semi-solid tars, pesticides,
solvents, waste water and other industrial garbage.
PLANT DESCRIPTION
This is India's first hi-tech rotary kiln incinerator system,
which has been provided with sophisticated waste
handling mechanisms to introduce different wastes into
the rotating furnace. The hot flue gases are then
completely oxidised at high temperatures in a separate
post combustion furnace. The hot gases are passed
through a special membrane panel boiler to generate
about 2 tons of steam as by-product. A spray tower
quench, employed to cool the gases, is designed to
handle larger loads in case the boiler needs to be
bypassed. The flue gases are scrubbed out in a venturi
scrubber before being released into the atmosphere.
Polyolefins Industries Limited (Rubber Chemical Division)
New Mumbai, Maharashtra
WASTES HANDLED
2.4 TPD of tars, generated from distillation column
bottoms, and 0.4 TPD of solvent waste..
PLANT DESCRIPTION
The viscosity of the waste tars is brought down to
atomisable range by heating in a tank. The entire waste
handling system is maintained at a high temperature by
using high pressure steam. The tars are then pumped
into a vertical, down fired furnace, where they are
thermally oxidized at high temperature. The solvent
waste is separately injected into the furnace.
The gases are quenched and cooled in the quencher,
which connects to a low energy venturi scrubber where
particulate matter is removed. Further cleaning of the
gas is effected in a packed bed scrubber, where the
sulphur dioxide generated from the combustion of high
sulphur containing tars is removed. The entire system
is maintained under negative pressure by an induced
draft fan.
Tamil Nadu Petroproducts Limited (Epichlorohydrin plant)
Chennai, Tamil Nadu
WASTES HANDLED
12 TPD of organic liquid waste, containing high levels
of chlorine, generated from the Epichlorohydrin
manufacturing process
PLANT DESCRIPTION
The waste is burnt in a down fired incinerator and
oxidized at an elevated temperature without any
support fuel.
The hot flue gases are cooled down in a waste heat
recovery boiler (WHRB) and heat is recovered in the
form of steam.
The WHRB leads to flue gas cooling and HCl recovery
system. The HCl recovery system produces 26% HCl,
which is further purified and concentrated in a
distillation column to generate commercial grade
32% Hcl.
Jubilant Organosys Limited (Pyridine plant) - 2 systems
Gajraula, Uttar Pradesh
WASTES HANDLED
140 TPD of waste water, generated from the pyridine
manufacturing process.
PLANT DESCRIPTION
Waste water is injected around the burner of a down
fired incinerator furnace and oxidised at high
temperature. Biogas, which is the fuel used to
maintain the incinerator temperature, is generated as
a by-product from the waste water plant.
The hot flue gases are cooled down in a Waste Heat
Recovery Boiler, and heat is recovered in the form of
steam for use in the process.
Pesticides Industries Limited (Speciality Chemicals)
Ankleshwar, Gujarat
WASTES HANDLED
15TPD of waste water, with high salt content, generated
from the pesticide manufacturing process.
PLANT DESCRIPTION
Waste water is injected into a deep fluidised bed, which
is maintained at high temperature by injecting fuel oil.
The extra depth of the bed maximises the combustion
of the waste in the bed itself. Inbed neutralisation of
sulphur and halogens present in the waste is carried
out by lime injection. Additives are added to the bed, to
prevent clinker formation due to salts.
The fluidised bed incinerator leads to a high energy
venturi scrubber and tray column, for removal of
particulate matter and acidic gases. The entire system
is operated under forced draft and sophisticated
controls are provided to ensure correct operating
conditions.
Ranbaxy Limited (Pharma and Bulk Drugs)
Devas, Madhya Pradesh
WASTES HANDLED
Solid wastes (powders, activated carbon and
packaging material) from pharmaceutical
manufacturing, ETP sludge, distillation residues,
solvents and aqueous waste.
PLANT DESCRIPTION
The incineration plant consists of a drum burning
chamber (drum detoxification), a pyrolytic chamber
(solid, sludge waste) and a secondary combustion
chamber (solvents, aqueous waste).
The incinerator is connected to a spray dryer, cyclone
separator and venturi scrubber for flue gas cleaning.
Most of the salts, in dry form, are removed from the
spray dryer and cyclone separator, which results in a
very low quantity of wet discharge from the system.
The system is also provided with instrumentation for
controlled and safe operations.
Syngenta India Ltd.
Goa
WASTES HANDLED
120 tons per day of aqueous waste and 24 tons per
day of hazardous organic waste.
PLANT DESCRIPTION
Aqueous and organic waste, stored in day tanks, are
pumped at a controlled rate into injectors/ burners
located on the top dome of a down fired liquid waste
incinerator. Here, under controlled conditions of
time, temperature and turbulence, all hazardous
organic compounds in the waste are completely
destroyed.
The system is integrated with a heat recovery boiler,
to produce steam, as well as air pollution control
equipment, to meet discharge norms laid down by
the Central Pollution Control Board of India.
Bharuch Enviro Infrastructure Limited
Ankleshwar, Gujarat
WASTES HANDLED
This is a common facility that handles hazardous
waste generated from the industrial belt in and
around Bharuch, Gujarat. Thermal capacity of the
incinerator, which is 6.5 million Kcal/hr, is equivalent
to 1 to 2 tons/hr of hazardous waste in different
forms.
PLANT DESCRIPTION
A waste handling system, that incorporates
conveyors, waste feeding hopper, double flap dump
valve, ram feeder, progressive cavity pumps,
metering pumps etc., handles solids, liquids and
sludge. The incinerator consists of a rotary kiln,
which is the primary chamber, followed by a
secondary combustion chamber.
The rotary kiln ensures proper mixing of the waste,
liberation of the volatiles and complete burning of
the carbonaceous matter. The unburnts, in the flue
gas, are completely oxidized in the secondary
combustion chamber. Appropriate air pollution
control equipment, comprising bag filter and
scrubber, ensure eco-friendly emission of gases.