Project overview
A global pharmaceutical leader with a strong presence across Europe, the US, and emerging markets partnered with Thermax to upgrade its steam generation system at its Western India facility in Gujarat. Having previously worked with Thermax, the client sought to transition from costly fossil fuel-based boilers to a sustainable, biomass-fired solution.
Steam plays a critical role in the client’s operations, supporting HVAC systems, multi-effect evaporators, and other essential processes. The objective was to reduce operating costs while meeting stringent pharmaceutical and environmental standards within a brownfield setup.
Challenges
- The project involved navigating the complexities of a brownfield installation with significant space constraints, requiring seamless integration within an existing boiler house. Stringent cleanliness and compliance requirements specific to the pharmaceutical industry had to be met. High steam generation costs due to reliance on oil and gas-fired boilers posed a financial challenge. Additionally, the client aimed to achieve ambitious sustainability targets by transitioning to biomass fuel.
Solution
- Thermax delivered an end-to-end turnkey solution centered on a 10 TPH UltraPac biomass boiler equipped with advanced Reciprocating Grate Technology. The compact and modular boiler design, with a design pressure of 10.54 kg/cm² and operating pressure of 8 kg/cm², was ideal for space-constrained installations. The solution incorporated emission control systems such as an electrostatic precipitator (ESP) and scrubber to manage particulate emissions. Clean operation was ensured through a dedusting system and an automatic ash handling system. An online SOx, NOx, and SPM analyser was also installed to enable continuous emission monitoring and compliance with environmental norms.
Result
- The transition from oil and gas to biomass significantly reduced steam generation costs. The boiler’s unique configuration delivered high efficiency, multi-fuel flexibility, and exceptional operational uptime. The project helped the client achieve major sustainability milestones, including an estimated annual reduction of 9,750 tonnes of CO₂ emissions, with particulate matter emissions maintained below 50 mg/Nm³. The compact, modular design ensured successful installation within a limited footprint, making it an ideal solution for the brownfield site.
Case study
Thermax sets a record by installing and commissioning a bi-drum boiler in just 40 days for a pharmaceutical major in Indonesia
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