Other Industries in India
Fume extraction system of a ferrochrome plant in India
The existing gas cleaning system of a very old Ferro Alloy plant in eastern India has been commissioned successfully in October 2019 after some modifications, enhancing the capacity of the furnace quite considerably.
The expenses for the modifications towards performance improvement of the existing system have already been recovered through reduction in maintenance expenses as well as quite considerable increase in production.
Health of the Men and the Machines have also been improved resulting into negligible suspended particulate matter in the working zone as well as final emission much below the allowed limits.
Modifications carried out on the existing running plant in 3 stages: First stage - modification of pulse cleaning system of filter bags as well as gas bypass systems from the furnace stacks. Second stage - addition of attachments for proper gas distribution cum pre collection system. Third stage- replacement of trombone cooler by forced draft cooler.
ORIGINAL PLANT
PLANT AFTER MODIFICATIONS
Results of the modified fume extraction system after commissioning:
FLOAT GLASS PIGMENTATION
75% of the Chemical Vapour used for the pigmentation of float glass goes into atmosphere. The Chemical Vapour condenses to dust particulates while travelling in the ducting designed for extraction of the excess vapour. The solid particulates are then successfully collected in Bag Filter of improved design in 2014.
The collected chemical powder is considered as a byproduct and sold to the users.
Chemical Vapour Deposition process using Titanium tetraisopropoxide (Click here for details)
FLOAT GLASS FROSTING
Dust control system with sand recovery from six frosting machines commissioned in 2016. Chemical Vapour Deposition process (Click here for details)
A Chemical Plant in India
Another remarkable success for the air pollution control at the packing machines of a chemical plant (very critical application).
The existing Bag Filter has been modernized and the system design has been modified.
Old Plant
modified plant
Improvised Scrubber at a Chemical plant in India
On July 01, 2009 Shyamal commissioned an improvised two stage scrubbing system successfully at a chemical plant in India. The simple equipment has been designed by Shyamal with two in one concept. In the first stage solid dust particulates are separated from the gas medium and in the second stage inside the same vertical tower the gas is absorbed.
The absorption liquid falls into the settling tank at the bottom of the tower. The clear liquid overflows to the re-circulation tank (all in one) from where it is re-circulated for further absorption.
This is a very interesting successful on-the-Job R&D activity. Control of dust and gas evolving from the same process normally require two separate systems with elaborate arrangements. Investments for such projects are always quite high compared to the simple two in one equipment designed by him.
Similar concepts, if developed further, can be utilized to control fly ash as well as Carbon dioxide from the boiler fume in one simple equipment so as to minimize greenhouse gas emission in addition to control of fly ash resulting into reduction in global warming and climate change.
Improvised Scrubber at a chemical Plant