Enersys Talawade, Pune, Maharashtra

Any exhaust gas stream with temperatures above 150°C has the potential for significant waste heat recovery. Typical examples include plant process heating, combustion air pre-heating, boiler feed water pre-heating and furnace exhaust heat. In addition to savings in everyday fuel consumption, many facilities can market and sell carbon credits back to industry. State funding is often available for waste heat recovery projects helping to reduce capital costs and expedite system payback. Enersys heat recovery systems are designed for ease of installation at industrial facilities. We can generate clean, reliable, and low-cost energy from a wide range of processes. Enersys offers solution to improve the efficiency of these industrial processes while increasing financial returns. VARIOUS SOURCES FOR WASTE HEAT RECOVERY: All boilers, thermal fluid heater systems and related processes Exhaust heat in flue gases from all type of D.G. Sets (HSD fired, LPG fired, and heavy fuel oil fired). Jacket heat recovery from engine. Exhaust heat recovery from gas turbine exhaust. Paper mills Steel plants Oil & gas refineries Textile process Food and pharmaceutical Gas compressor stations Hot waste gases from :–      o Scrap steel furnace        o Cement kilns        o Industrial Furnace        o Glass plants        o Waste gases from chemical process        o Incinerators 1.2 MW saving in Captive Power Plant at m/s Shah Alloys Ltd, Santej, near Ahmedabad.. The heat recovery system generates pressurised high temperature water which is used for process heating, replacing electrical heating of furnace oil and lube oil purification etc. It is integrated seamlessly with the Captive Power Plant (CPP) facility with automatic Control System. The CPP has 7 DG sets (FO fired) to generate more than 6,00,000 units/day. 200 kW Heat recovery facility is supplied to Jindal Steel Ltd, Hissar for saving power from 2500 kW furnace oil fired DG sets. 350 kW Heat recovery facility is supplied to Maral Overseas Ltd, M.P. for saving power from 2 nos 2500 kW furnace oil fired DG sets. A large size “Heat Recovery Air Heater” designed and manufactured for Birla White (Cement), Jodhpur, for kiln exhaust gas. This was in association with Enviro division of Thermax Ltd.

Description Available in API 650 designs Designed for earthquake zones, wind and snow loading   Options Heating coils for viscous products. Exterior insulation, metal cladding and heat tracing. Level indicators. Flat top, sloped or cone bottom.   Materials UsedCarbon steel or stainless steel. b. Horizontal Storage Tank Description Carbon Steel tanks are blast cleaned, primed and finished with two coats of rust inhibiting enamel or epoxy. Supplied with flat ends or dished ends and support saddles. Butt-welded joints with submerged arc welding ensures quality and attractiveness.   Options Heating coils for viscous products Exterior insulation, metal cladding and heat tracing Level indicators. Special linings for corrosive liquids, chemicals, potable water or food grade applications Pump mounting platform Compartmentalized configurations Static head design   Materials UsedCarbon or stainless steel.

Enersys design experts have experience of more than 36 years in designs of self-supported steel chimney / stack required for minimizing atmospheric pollution due to flue gas from boiler, thermal fluid heater, hot water generator, hot air generator, IC engine, furnace, etc. Designs are done as per the requirements of specific industry and country. Design considerations of the stacka) Mechanical design and construction comply with standard procedures outlined in IS 6533-1971b) Height selection is as per norms of Pollution Control Board taking into consideration the location of site, surrounding topography and building structures, quantum of emission (SOx, NOx and Particulate content)c) Various guidelines outlined in the code for design of stack are followed for design of holding down bolts, base plate, foundation etc.d) The design is checked for stresses and stability against earthquake, wind and found that the design is safe against these factors.e) The dynamic analysis is carried out to ensure the safety of the design. Finally it involves a CAD drawing of the designed stack.

The process vessel use heat, pressure and/or vacuum to change a product condition and are mainly used for hydrolysis, neutralization, crystallization, distillation evaporation and storage in food, medicine, and chemical industries. Reactors are used for a variety of process operations such as solids dissolution, product mixing, chemical reactions, batch distillation, crystallization, liquid/liquid extraction and polymerization. In some cases, they are not referred to as reactors but have a name which reflects the role they perform (such as crystallizer, or bioreactor). They are usually fabricated in steel, stainless steel, glass-lined steel, glass or exotic alloy. Liquids and solids are usually charged via connections in the top cover of the reactor. Vapors and gases also discharge through connections in the top. Liquids are usually discharged out of the bottom. Within the chemical and pharmaceutical industries, external cooling jackets are generally preferred as they make the vessel easier to clean.

Enersys has acquired thorough knowledge and experience in design and manufacturing of pressure vessels as per ASME Sec-VIII, Div-1 and all the related standards for materials and inspection. Our design engineers have prolonged experience to design various parts as per the rules of relevant standard. Enersys has own quality management system with standard procedures, sample forms and records formats in QC system and QC manuals besides the ones provided by ASME, which are only for WPS (Welding procedure specification) and PQR (Procedure qualification record), but not for other manufacturing activities. Pressure vessels are used in a variety of applications for Oil & Gas, Petrochemicals, Refineries, Water Treatment Plants, Refrigeration Plants and other Chemical Industries. They appear in these sectors as industrial compressed air receivers, domestic hot water storage tanks, distillation towers, pressure reactors, autoclaves, pneumatic reservoirs, hydraulic reservoirs under pressure, storage vessels for liquefied gases, shells of heat exchangers, etc. Enersys vessels are engineered with adequate safety factor, corrosion allowance, conservative design temperature and pressure. Necessary nondestructive testing, such as ultrasonic testing, radiography, and pressure tests (hydro or pneumatic) is carried out by experienced engineers.A Deareators is used for the removal of air and other dissolved gases from the feed water to steam generating boilers. The dissolved oxygen in boiler feed water causes serious corrosion damage in steam systems by attaching to the walls of equipment and forming oxides (rust). It also combines with any dissolved carbon dioxide to form carbonic acid that causes further corrosion. Most Deareators are designed to remove oxygen down to levels of 7 ppb by weight (0.0005 cm³/L) or less. Spray & Tray Type Deaerating Heaters Spring-loaded nozzles located in the top of the unit spray the water into a steam atmosphere where the steam heats water and at the elevated temperature the solubility of oxygen is extremely low and most of the dissolved gases are removed from the system by venting. The spray will reduce the dissolved oxygen content to 20-50 ppb, while the scrubber or trays further reduce the oxygen content to approximately 7 ppb or less. For optimum oxygen removal, the water in the storage section must be heated to within 3 º C of the temperature of the steam at saturation conditions. From inlet to outlet, the water is deaerated in less than 10 seconds

Enersys offers high quality efficient and cost effective heat exchangers for an extensive range of processing applications across a diverse spectrum of industries like chemical, petrochemical, food & beverage, paper & pulp, pharmaceutical, edible oil & fats, bio diesel, oil & gas, textile, steel, cement, rubber, power, effluent treatment, automotive, space heating, refrigeration, air conditioning, and various other process Industries. We use clinical approach to evaluate your plant / process for energy efficiency and offer most optimum heat exchange solutions, thereby delivering quality solutions that ensure sustainability with a competitive edge. Our product range includes :Enersys supplies heat exchangers with finned tubes of various designs and material combinations. Rectangular fin twin-tubes Spiral (helical) wound fin tubes Fins materials: Aluminum, SS 304 / SS 316, MS (G.I.), Copper Tube Material: SS 304 / SS 316, MS (G.I.), Copper, Brass, Cupro-nickel. Casing Material: Stainless steel or Carbon steel Some of our standard designs are- a) Process Air heaters with Steam / Hot Water / Thermal Fluid Enersys supplies fin tube type hot air generators required in various industrial process heating and drying operations. Heat sources may be steam, thermal fluid, pressurized hot water, electricity and combinations of these. Some of the major applications are- Spray Drying Plant for production of dried milk products, such as ordinary skim milk, whole milk, whey powder and baby foods. Note: Special design “L- Footed” fins give optimum contact pressure of the foot of the fin on to the base tube thus maximizing the heat transfer properties. The foot of the fin considerably enhances the corrosion protection of the base tube. Maximum operating temperature for this fin type is 250°C for Steel (SS / CS) and 200°C for Aluminum fins.Enersys Dehumidifiers are efficient and suitable for sanitary applications e.g. to prevent organic deposits and to prevent wet outer surfaces. The units are easy to access and to clean efficiently - both mechanical and by CIP. Therefore they are widely used within food industry and pharmaceutical industry. Enersys supplies a large range of capacities of Dehumidifiers. They are adapted to many available coolant e.g. brine, low temperature thermal fluid, ice water or refrigerants. For the re-heater section, any heating fluid can be used i.e. steam, thermal fluid, hot water or electrical heating. Standard design includes gas tight execution, all parts in stainless steel except fins, pull-out drip-catcher, condensate reservoir, drain with trap, supporting adjustable legs, air flanges and counter flanges. Re-heater section is optional (reheating should always be established).