Unicon Engineers Vedapatti, Coimbatore, Tamil Nadu

Working Principle Wet scrubbers relay on the liquid spray to remove dust particles from the gas stream. It is also for the fume absorption; hence very useful in fume extraction systems. It removes air pollutants by inertia of diffusional impaction, reaction with absorbent or reagent slurry or absorption into a liquid solvent. The inlet gas stream usually enters the bottom of the tower and moves upward, while liquid is sprayed downward from one or more levels. UNICON Wet Scrubbers are used for removal of noxious and corrosive contaminants from the flue gases generated by various process in process plants. The gas is washed with suitable liquid medium using spray nozzles or atomizers. Suitable packed bed provides large contact surfaces for the gas and liquid to mix and hence traps the contaminants. Low pressure drop and low liquid flow brings down operating costs. Provisions will be made for suitable dosing methods to neutralize the toxic nature of the saturated water before letting out to the atm. The material of construction would be of Mild Steel (MS)/ FRP/SS depending on the application. The packed beds are usually PP/PVC Pal rings, saddles etc to suit the various toxic gases   Advantages Small space requirement No secondary dust sources Handles high temperature minimal fire and explosion hazards ability to collect both gases and paticles Features High collection efficiency of solid & gaseous pollutants maximum pressure drop fumes can also be absorbed low maintenance cost complete wetting of the product minimum product emission through exhaust ability to handle high temperature spray tower with specially designed high pressure nozzle mist eliminator to remove water droplets

UNICON and its forerunner companies have been designing, manufacturing, supplying and erecting pneumatic conveying system for many years. Our installations have enabled our customers to operate their facilities in compliance with regulatory standards to achieve clean air environmental friendly emissions and effective utilization of Fly Ash.   Principle of operation Stage 1 : Filling Ash inlet is at open position, ash from hopper storage is filled inside the vessel. Stage 2 : Fluidizing When ash is filled up to the level sensor probe, Ash inlet valve will be closed. Once fluidizing valve opens and fluidizes the ash and is ready to transport. Stage 3: Transmitting Discharge valve opens and the fluidized air with ash is transmitted through the pipeline.   Stage 4 : Depressurizing Ash inside the vessel is emptied, the vessel is depressurized and the fluidizing valve closes, again the process is repeated from stage 1. the pressurized vessels feed to the conveying line, the automated control system maintains a constant conveying air mass flow in the pipeline, which prevents plugging and optimizes compressor operating power. Feeder units feed the line however in these system, material flows into the conveying line before the line is pressurized. It is a practical alternative for a vaccum system where headroom is limited. This approach, blending the most efficient flow regimes offers advantages in reliability and reduced maintenance costs that can keep the system operating more efficiently. Challanges of ash handling system Indian Coal presents high ash content generally which tends to be inconsistent. Design of the system has to adequately cover anticipated variations and be capable of handling the worst scenario. System has to be environment friendly. System has to be reliable with least maintenance problems System has to be energy efficient. Advantages UNICON Pneumatic Conveying Systems Commercial utilization of ash in  - Cement additives      - Brick plants.       - Road making etc Saving of water - a precious commodity. Energy Efficient. Most Economical High Capacity Conveying Line High reliability. Long Plant life. Least maintenance. Conveying distance upto 1600 meters Environment concern. Wide range of vessel sizes Operating pressure upto 60psi (415 kpa) Shortest delivery time Programmable Logical Controller (PLC) Better control of pneumatic conveying system whose advantages are given below. 1. Most preferable type of control. 2. Ability to perform relay logic, timing, counting and sequencing functions. 3. performs the tasks required for pneumatic conveying system control. 4. Performs all ash handling controls. 5. Allows flexibility in control schems 6. Ability to troubleshoot, modify and expand with the system.    

UNICON     Cyclones and Multi Cyclones are used for collection of coarse dust particles in cement industries and steel industries. Our cyclones are effectively designed to remove dust with an emission level upto 200 mg/m3. The pressure drop across the cyclones are as low as 50-100 mm WG resulting in energy savings. For high dust loading condition they act as primary filtering system before the bag filter or Electrostatic Precipitator. They do not require any maintenance. Multicyclones are offered to handle larger volumes of hot gas and to achieve better operating efficiencies. Rotary air lock valves or Double flap valves are used as discharge devices to these cyclones. Cyclones can use for dusts of moderate to coarse particle size, as your primary collector with or without the optional after-filter. The UNICON Cyclone will remove up to 90% (Above 40 microns) of dust generated, if we use Cyclone or Multi Cyclone as a precollector for any of UNICON’s more efficient final collectors such Bag Filter or Electrostatic Precipitator. By reducing the dust load on the higher efficiency final collector, a more economical final collection may be selected and a longer collector life can be obtained.                    We offer these cyclones as particulate pre-separation as settling chambers, high flow and high efficiency cyclones, Twins, Triplex and Quads in single profile or series cascade as well as multi clones. Accessories like air locks, RAV, Double Cone Valves or Double Flap valves are also available. A multycyclone comprises a number of small cyclones built into a steel plate housing. Because of the aero-dynamic shape of the inlet vanes, the small diameter and the high volume per cyclone, strong centrifugal forces swirl the dust from the air stream to a greater extent than in a conventional larger cyclone. Generally dust particles larger than 10 micron are separated.          Application: Woodworking, Metalworking, Sponge Iron Plants, Foundries, Plastics, Rubber, Chemicals, Grains, Food, Coal, Ceramics, Rock products, Cement Industries and more... Advantages: Unlike Dust collectors the UNICON Cyclone contains no moving or replaceable parts and is so essentially maintenance free. The air is drawn into the Cyclone tangentially and rotates at high velocity around the inner circumference. The heavier dust is separated from the air by centrifugal action and is deposited in the barrel or hopper. High dust loading. Can be used for Elevated temperature Higher collection efficiency on account of the higher centrifugal force applied to the dust particles with decreasing diameters of the cyclone Proper gas distribution Higher Particulate size (specific gravity)

Electrostatic Precipitator UNICON has a credential record of success in designing, engineering, fabricating, Supplying, erection and commissioning of electrostatic precipitator (ESP). To achieve this effectively, and to find out the solution for pollution problems by providing Electrostatic precipitators (ESP) for Power Plants upto 1000MW, UNICON entered into MoU for Transfer of latest technology, expertise, experience and favorable logistic support with M/s. Tianjie Group Co. Limited. Please Click Here to download our ESP Questionniare and to send Enquiry. Basic Working Principle of ESP In high- voltage electrostatic field, affected by the electric field force, gas ionization takes place. There are tremendous amount of electrons and ions existing in the ionized gas. After the dust particles are combined with these electrons and ions, they will be polarized, most of them are negatively polarized. Under the action of the field force, negatively charged particles migrates towards the positive electrode and in turn release electrons and attach to the positive electrode. When the particles agglomerate and the layers reaches a certain thickness on the plate, rapping system will start to work and the particles will be dislodged from the collecting plate by vibration and falling into the hopper. That ends the collection process.                Special features of UNICON ESP: 1.Collecting electrodes are Cold roll formed with shape provided to ensure stiffness and to enhance rapping characteristics2.Individual Collecting electrodes are suspend from top to form a curtain. This also ensures that the Collecting system is not bulky and thus ensures good rapping characteristics. 3.Discharge electrodes are stretched spring coils of small lengths. This ensures that the straightness of electrodes are maintained easily and alignment of electrodes with respect to the collecting system is easily ensured.4.The spring tension also enhances the rapping characteristics of the electrode.5.This design of electrode ensures that no bending takes place. 6.The discharge electrode system is a rigid box frame structure. Ensuring rigidity and proper alignment of complete system. 7.The electrode system is so designed that approach to any level is possible for inspection and maintenance.8.Rapping system is the tumbling hammer type. Each electrode row is rapped individually. This has the advantage of low re-entrainment and effective rapping. Each rapping system can be tuned to rapping cycle suitable to the dust load handled by that field.9.Separate rapping is provided for each field. One for collecting electrodes rows and another for discharge electrode rows10.Electrode system is the PART of the electrostatic precipitator which decides its performance and reliability. 11.Support insulators of the discharge system are housed in individual insularor housings. These are provided with inspection covers, heaters and are fully sealed when closed making it air leak proof and also water leak proof. Ensuring that the Insulator surface is always clean.12.The individual insulators housings enables easy acess to each insulators for inspection and maintenance.13.Access doors are provided at inlet and outlet of each field, on hoppers and at the roof for easy access and maintenance.14. Safety interlock system is also provided for safety of maintenance and operation staff.15.Walkways and stairways are provided for easy approach to various equipments of the ESP.

  UNICON has been Manufacturing clamshell gates for bulk material handling systems for more than decade. Our clamp shell gates can be used for any type of bulk material handling whether it is high temperature, adhesive or abrasive. We are giving Hrdox 400 or Hardox 450 lining for all material contact surfaces according to the application. Our state-of-the-art clampshell and testing facilities is the key to achieving optimal performance.         The outboard end of the hinge pins of double clamshell gates are supported to keep them in line even as the parts wear. The box and blades are heavy enough to do the work they were designed to do. The blades are shaped to reduce friction as they slice through the material in closing. The tooth gear quadrants that we use on our double clamshell units are designed for long trouble free use. One big advantage of using a double clamshell gate is that the material drops out of the center of the opening as the gate blades separate.   UNICON Clamshell Gate Features Include:     Construction is of minimum 1/4" mild steel plate, heavily reinforced where necessary. Bolting flange is constructed of heavy structural steel angle. All welding is per AWS standards. Gate pivot shafts are C-1045 steel shafting, and are attached to heavy backing plates welded to the gate body.       Regreasable bushings are located at the four pivot points attached to the gate radius plates. Bushings are easily regreasable via pressure lubrication fittings located on the pivot shaft ends. Duplex clamshell design incorporates timing gear sectors at each of the four pivot points. This configuration assures smooth, even actuation of both clamshell halves. Gate valve flange includes our standard bolt hole pattern. Actuation is by two heavy-duty, pivot-mounted, double acting pneumatic cylinders, constructed to ANSI specified dimensions for interchangeability. Cylinders include hard chrome plated rods, and long-wearing, double seal configurations. Cylinder rods are clevis-mounted to the gate blades. Cylinders are sized for actuation at a minimum of 80 psig clean plant air. OR Actuation is by two or three heavy-duty, pivot-mounted hydraulic cylinders, constructed to ANSI specified dimensions for interchangeability. Cylinders include hard chrome plated rods, long-wearing, double seal configurations, and heavy steel cylinder tubes. Cylinders are clevis-mounted to the gate blades. Cylinders are sized for actuation at 1500 psi hydraulic pressure.    OPTIONAL EQUIPMENT:    Add for material contact surfaces to be lined with abrasion resistant steel - 360 BHN. Add for a directional control valve mounted to the gate housing and piped to the cylinders. Add for each pair of limit switches mounted to the gate housing for remote open/close position indication.

ADVANTAGES UNICON filter Bags are lapped, stitched, integral collar and optimum bag length gives strong bags and do not give away Modular design Over 999% efficiency Top Bag removal Verity of bag to suite different applications Bags were Polyester, Non-woven Polyester with needle punched, PTFE coated, Nomex, Ryton and Fiber Glass Bags Corrosion resistant cages Long Bag Life Guarantee Explosion vents Designs Durable casing & Quick Access doors PLC Controlled Cleaning Turn key installations Automatic air pulse jet system with adjustable sequential timer to clean filter bags on-line Bottom cone angle of housing is 45 degree hence powder slides freely down Heavy duty cages provide firm bag support and stability for long life     Solenoid valves with steel plunger, programmed sequential controller for complete automatic cleaning Smooth tube sheets avoid tearing of the bags while expansion We carefully select filter bag fabric considering temperature, particulate size, air-to- cloth ratio The Felt media bag minimizes pressure fluctuations giving uniform and high collection efficiency Specially selected Anti-stick coating on bags minimizes bag choking Bags are sealed by snap rings to ensure easy removal of the bags and cages To achieve the above UNICON is having the expertise in providing an efficient systemUNICON has handled a variety of dust in various industries UNICON bag filter is compact, results in low civil and erection cost