Thermax Opticor® improves clinker cooler ESP performance by 25%

Project overview

A leading cement manufacturer in India was facing emission compliance and performance challenges with the electrostatic precipitator (ESP) installed at its clinker cooler.

Thermax partnered with the customer to enhance ESP performance and ensure continuous, compliant plant operations without major mechanical modifications.

Challenges

Frequent spark occurrences observed in the clinker cooler ESP TRCC panel
Voltage and current readings were below standard operating requirements
Stack emissions from the clinker cooler were nearly 70% higher than the permissible limits
Need to improve ESP performance without extending ESP fields or undertaking costly mechanical upgrades

Solution

Replaced existing TR controllers with Thermax Opticor® advanced controllers
Implemented a compact, plug-and-play solution with a low footprint and pre-wired cables
Enabled better power delivery to ESP fields, improving dust charging and collection
Allowed remote monitoring and control through Opticor®’s modular design

Result

Particulate emissions reduced by 25%, bringing stack emissions within regulatory limits
Significant reduction in spark occurrence
Improved voltage and current supply across ESP fields, leading to higher dust collection efficiency
Enhanced overall ESP performance without costly mechanical modifications
Enabled stable, reliable, and compliant operation of the clinker cooler ESP

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