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Project overview
A leading multinational tyre manufacturer in western India operates a process-critical, batch-sensitive production environment with stringent quality controls and high uptime expectations.
Steam pressure stability is vital to ensuring batch integrity and uninterrupted operations. While the site had historically relied on oil and gas-fired boilers, the organisation sought to transition to a lower-carbon energy solution aligned with its carbon-neutrality goals without compromising steam consistency or process reliability.
Challenges
- Continuous tyre manufacturing with minimal tolerance for steam pressure variability
- Fluctuating steam load demand increasing downtime and batch quality risks
- Concerns over biomass fuel handling fluctuating loads without pressure swings
- Potential compliance and hygiene risks from ash and dust compared to furnace oil operations
- Need to ensure uninterrupted, assured utility supply during energy transition
Solution
- Thermax conducted a comprehensive, end-to-end process study through TOESL and designed a biomass-based steam system capable of handling load fluctuations while maintaining steam stability.
- Variability controlled at source through strict fuel discipline and tight operating routines
- Ash handling treated as a governed and compliant operational process
- Delivery of assured utility through steam-aaS with an 18 TPH biomass boiler
- Structured FuelSure supply of biomass briquettes (approximately 60 tonnes per day) This integrated approach ensured consistent steam pressure while enabling a reliable transition away from fossil fuels.
Result
- Stabilised uptime of over 99% under fluctuating load conditions
- Elimination of steam pressure swings impacting batch quality
- CO₂ abatement of 11,731 MT (YTD FY26–27)
- Approximate annual cost savings of Rs. 10 crore compared to furnace oil
- Enabled circular economy practices through controlled biomass usage and ash capture with compliant repurposing pathways
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