Steel manufacturer improved ESP performance by 40% with Thermax Opticor®

Project overview

A major steel manufacturer operating a direct reduced iron (DRI) kiln needed to improve the performance of its existing electrostatic precipitator (ESP) system in response to revised emission norms.

The customer explored options to enhance performance while avoiding costly and time-consuming mechanical modifications.

Challenges

The existing ESP performance was insufficient to meet updated emission standards.
Conventional solutions such as adding ESP fields or retrofitting were capital-intensive.
Need to achieve emission compliance without disrupting operations or modifying existing infrastructure.

Solution

Thermax conducted a detailed inspection of the existing ESP system.
Replaced existing controllers with Thermax Opticor® advanced controllers.
Improved power and current supply to ESP fields without any mechanical changes.
Enabled a quick, low-footprint upgrade with minimal operational disruption.

Result

Achieved approximately 40% reduction in particulate emissions.
Enhanced dust collection due to improved electrical performance.
Delivered overall improvement in ESP efficiency without internal or external modifications.
Enabled compliance with emission norms and led to repeat orders across other plants.

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