INNOVATION
BY
INDIAN
Abhitech Energycon Ltd., INDIA
THERMACT – PROUD TO BE…
TECHNOLOGY
Abhitech Energycon Ltd., INDIA
INNOVATIONS
CATALYSTS
THERMOL (DEC. ’98)
--FOR PETROLEUM FUELS
THERMACT (MAR ’03)
-- FOR SOLID FUELS
Abhitech Energycon Ltd., INDIA
Manufacturing Unit at Baddi, Himachal Pradesh
Abhitech Energycon Ltd., INDIA
COMPANY INFORMATION
Group of Companies

Abhitech Energycon Ltd.

Technocraft Switchgear Ltd.
(System house of ABB for MV switchgears)

Adi Atharv Corporation
Group Turnover : 152 Crore
Technology Collaboration
with
IIT, Bombay
Abhitech Energycon Ltd., INDIA
ABHITECH PRESENCE IN DIFFERENT SECTORS
Sugar Sector
Steel
Industry
Hotel Industry
Power Plant
Sector
Paper Industry
Agro Industry
Mining Sector
Pharma Sector
Refinery Sector
Cell Tower
Abhitech Energycon Ltd., INDIA
ABHITECH COMPANY PROFILE
EXISTING COMPANIES
ABHITECH s.r.o.
ABHITECH GHANA LTD
PROPOSED COMPANIES
BRAZIL
SAUDI ARABIA
BANGLADESH
Abhitech Energycon Ltd., INDIA
POWER SECTOR
THERMACT
A MULTIFUNCTIONAL COMBUSTION CATALYST
USED IN
AFBC, CFBC & PF FIRED BOILERS
(15 MW to 830 MW)
Abhitech Energycon Ltd., INDIA
STEEL SECTOR
THERMACT-Mt
CATALYST IN COKE MANUFACTURING PROCESS
THERMACT-BF
CATALYST USED WITH FUELS IN BLAST FURNACE.
THERMACT-SI
CATALYST FOR SPONGE IRON PROCESS.
NO CAPEX / MODIFICATION
REQUIRED
Abhitech Energycon Ltd., INDIA
THERMACT PRODUCTS FOR STEEL INDUSTRY
 THERMACT-Mt :
Catalyst for Coke Manufacturing Process
Tested at RDCIS & used by CSN, Brazil
Dosage : 1 kg for 7 Tons of Composite Coal Blend
 THERMACT-BF :
Catalyst for Blast Furnace Process
Tested at CIMFR & used by CSN, Brazil
Dosage : 1 kg for 6 Tons of Fuel (Coke + Nut coke + Coal)
Abhitech Energycon Ltd., INDIA
THERMACT-Mt
Catalyst for Coking Coal
Benefits :
 Reduction in Carbonization or Coking Time.
 Improved quality of Coke produced.
 Reduced energy input to Oven.
 Reduced Blend cost by modifying Blend composition
without affecting Coke quality.
Abhitech Energycon Ltd., INDIA
THERMACT-BF
Catalyst for fuels used in Blast Furnace
Benefits :
 Improved temperature profile in Blast Furnace.
 2% to 4% reduction in Coke Consumption / Ton of Hot
Metal.
 Increased rate of reduction of Iron Ore.
Abhitech Energycon Ltd., INDIA
BENEFITS OF THERMACT-SI
 Increases yield of CO & H2, therby aiding reduction process.
 Reduces cycle time & hence increase in through-put.
 Increases ash fusion temperature, reducing accretion in Klin.
 Reduces coal consumption by 2 to 5%.
Abhitech Energycon Ltd., INDIA
DOSING OF THERMACT-Mt
THERMACT-Mt
Hopper
(750 Kg capacity)
The Feeder will
be provided by
Abhitech
Vibro Feeder
Feeder Regulator
A/c Supply 230 v, 50 Hz
1 Kg of THERMACT-Mt for 6 Tons of Coal
COAL TOWER
CHARGING CAR
OVENS
Abhitech Energycon Ltd., INDIA
SCHEMATIC DIAGRAM OF BLAST FURNACE –
DOSING SYSTEM
Coal
Pulverized coal
THERMACT-BF is added with a
Adjustable Hopper arrangement
into the Coal Silo.
Abhitech Energycon Ltd., INDIA
DOSING OF THERMACT-BF
Dosage:
1 kg : 6,000 kg of Fuel
Fuel = (coke + Nut coke + PC)
HOPPER with
THERMACT-BF
mounted on the
roof of Coal silo
Abhitech Energycon Ltd., INDIA
SCHEMATIC DIAGRAM OF DOSING SYSTEM
THERMACT-SI
Dosing System
Coal
Hopper
Coal
Hopper
Screw feeder with
Gear
- Motor
Weigh feeder
Weigh feeder
Klin
Rotary Feeder
Injection Side
Abhitech Energycon Ltd., INDIA
DOSING
THERMACT-SI was dosed @
1:7000 kg/kg basis (1 kg
THERMACT-SI for 7000 kg of
Coal) along with the coal, with
the help of screw feeder as
shown.
Abhitech Energycon Ltd., INDIA
THERMACT AT THERMAL POWER STATIONS
OUR PRESTIGIOUS CLIENTS
CLIENT NAME
LOCATION
CAPACITY
Coastal Gujarat Power Ltd. (A Tata Group Co.)
Gujarat
5 x 800 MW
Adani Power Limited
Gujarat
1 x 660 MW
MPPGCL – Sarni TPS
Madhya Pradesh
1 x 62.5 MW
Chachai
1 x 120 MW
Birsinghpur
1 x 500 MW, 4 x 210 MW
Tenughat
2 x 210 MW
Odisha
6 x 120 MW
Karnataka
7 x 210 MW
Chennai
2 x 210 MW
Amarkantak TPS
Sanjay Gandhi TPS
Tenughat Thermal Power Station
NALCO
KPCL – Raichur Thermal Power Station
TNEB – North Chennai Thermal Power Station
Abhitech Energycon Ltd., INDIA
CLIENTS / USERS

CSN Brazil
:
CSN :
5 Million Tons of Steel.
THERMACT-Mt
THERMACT-BF

Bengal Energy
:
THERMACT-Mt

TATA Sponge
:
THERMACT-SI
Abhitech Energycon Ltd., INDIA
Abhitech Energycon Ltd., INDIA
Abhitech Energycon Ltd., INDIA
INSTITUTIONAL APPROVALS
RDCIS : For THERMACT-Mt
CIMFR : For THERMACT-BF
Abhitech Energycon Ltd., INDIA
THANK YOU
Abhitech Energycon Ltd., INDIA
Validation of working principles
Test at
RDCIS
Without THERMACT-Mt
With THERMACT-Mt
Addition of THERMACT-Mt,
showed faster rise in coke
mass temperature & the
end
coke
mass
temperature was about 10
0C
to
15
higher
as
compared to base blend.
Abhitech Energycon Ltd., INDIA
RDCIS REPORT – TEST DETAILS
The results of key parameters are given below:
Without
THERMACT-Mt
With
THERMACT-Mt
Difference
Coke Mass Temperature
of 1000 0C
16:48 min
15:40 min
1 hr.
Coke Mass Temperature
at end of Carbonization
Period
1080
1095
15 0C higher
63
52
66
56
Improved
0.12 psi
0.10 psi
No Change
Parameters
GIESELER PROPERTY
Plastic Range
Max. Fluidity
Wall Pressure
Ash Fusion Temp.
Porosity
Ash Chemistry
No Change
54.6
53.8
No Change
No Change
Abhitech Energycon Ltd., INDIA
WORKING PRINCIPLE OF THERMACT-Mt
 THERMACT-Mt reduces the
activation energy required
to
release
the
Volatile
Matter in Coal.
 This Catalyst, when added
with
Coal
before
Carbonization,
helps
in
faster evolution of the
Volatiles.
 Inherent Moisture present
in
Coal
is
utilized
to
generate
heat
in
the
presence of Carbon.
Abhitech Energycon Ltd., INDIA
WORKING PRINCIPLE
THERMACT-BF
Carbon
Catalyst 1
C + H2O
CO + H2
H2O
Catalyst 2
Inherent Moisture
C + 2H 2
CH 4
THERMACT-BF
Catalysts
 Both CO & H2 are good reducing agents and help
in accelerating the reduction of Fe3O4 to Fe.
Abhitech Energycon Ltd., INDIA
RDCIS REPORT – TEST DETAILS
The following parameters were studied for effect of THERMACT-Mt:

Proximate & Ultimate Analysis of Coal and Coke

Crucible Swelling Number (CSN)

Gieseler Plastometric Properties

Petrographic Analysis

Temperature Profile

Wall Pressure

Porosity

Micum Indices and other relevant parameters.
Abhitech Energycon Ltd., INDIA
Validation of working principles
Test at
RDCIS
Without THERMACT-Mt
With THERMACT-Mt
Addition of THERMACT-Mt,
showed faster rise in coke
mass temperature & the
end
coke
mass
temperature was about 10
0C
to
15
higher
as
compared to base blend.
Abhitech Energycon Ltd., INDIA
RDCIS REPORT – TEST DETAILS
The results of key parameters are given below:
Without
THERMACT-Mt
With
THERMACT-Mt
Difference
Coke Mass Temperature
of 1000 0C
16:48 min
15:40 min
1 hr.
Coke Mass Temperature
at end of Carbonization
Period
1080
1095
15 0C higher
63
52
66
56
Improved
0.12 psi
0.10 psi
No Change
Parameters
GIESELER PROPERTY
Plastic Range
Max. Fluidity
Wall Pressure
Ash Fusion Temp.
Porosity
Ash Chemistry
No Change
54.6
53.8
No Change
No Change
Abhitech Energycon Ltd., INDIA
THERMACT-BF : CIFMR Studies
 THERMACT-BF was studied under Lab conditions at CIFMR,
Dhanbad (Central Institute of Fuel & Mining Research)
 The following tests were carried out on samples of Iron
Ore, Iron Ore+Coke and Iron ore + Coke + THERMACT-BF
in the dosage of 1 : 6000.
 Thermo Gravimetric Analysis (TGA)
A TGA is done to study the rate of change in weight of a
material as a function of temperature in a controlled
atmosphere.
Abhitech Energycon Ltd., INDIA
THERMACT-BF : CIFMR Studies
Differential Scanning Calorimeter(DSC)
 A DSC measurement provides vital information, qualitative
& quantitative on physical & chemical changes that occur
in materials as a result of exothermic or endothermic
processes.
 Reduction Behavior :
The Degree of Reduction of Iron ore + coke with /
without THERMACT-BF.
DR can be measured using the formula ;
DR = ( W / TO ) x 100 where
W = Loss in weight of pellet
TO = Total Oxygen
Abhitech Energycon Ltd., INDIA
Degree of Reduction with THERMACT-BF
Reduction behavior of Iron ore with coke
Sr. No.
Time (Min.)
Initial
weight (g)
Final
weight (g)
Loss in
weight (%)
Reduction
(%)
1.
60
3.0
2.12
29.33
87.73
2.
90
3.0
2.12
29.33
87.73
3.
120
3.0
2.11
29.66
88.14
Reduction behavior of Iron ore & Coke with THERMACT-BF
Sr. No.
Time (Min.)
Initial
weight (g)
Final
weight (g)
Loss in
weight (%)
Reduction
(%)
1.
60
3.0
2.08
30.66
89.40
2.
90
3.0
2.07
31.00
89.85
3.
120
3.0
2.07
31.00
89.85
 Gas Chromatography of top Gases:
Characteristics of Gases evolved during the reduction
of Iron ore & Coke with THERMACT-BF were studied.
Abhitech Energycon Ltd., INDIA
THERMACT-BF : CIFMR Studies - RESULTS
The results & consequential inferences from above tests are;

The combustion of Coke starts at a lower temperature
on addition of THERMACT-BF as compared to Base sample.

The Activation temperature of reaction of Iron Ore
with Coke has reduced on addition of THERMACT-BF.

As per DR, it was observed that the Efficiency of
reduction of Iron Ore and Coke increased on addition of
THERMACT-BF.
Gas Chromotography tests confirm that no harmful
gases are evolved on addition of “THERMACT-BF” to Iron Ore
and Coke.

Abhitech Energycon Ltd., INDIA
INSTITUTIONAL
CERTIFICATION
Abhitech Energycon Ltd., INDIA
Indian Institute of Technology, Bombay
Abhitech Energycon Ltd., INDIA