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Project overview
A large thermal power generation facility required a flue gas desulphurisation (FGD) system for its 2 × 500 MW coal-based power plant to comply with stringent emission norms.
Following a highly competitive bidding process, Thermax was selected to deliver a comprehensive EPC solution for the FGD systems across both units.
Challenges
- Need to meet strict SO₂ emission norms for large-capacity power units
- Integration of FGD systems with existing boiler and power plant operations
- Requirement for reliable commissioning without impacting boiler availability
- Execution under tight quality, safety, and performance benchmarks
Solution
- Thermax executed the complete EPC scope for the FGD plant, covering:
- Engineering, supply, inland transportation, insurance, installation, testing, and commissioning
- FGD system packages for both 500 MW units
- Erection of a 200 TPH coal handling plant and conveyor system
- Performance guarantee testing to ensure emission compliance
- Structured commissioning trials to ensure seamless plant integration
Result
- SO₂ removal efficiency of 94.25% achieved during commissioning trials
- Gypsum production commenced successfully on the first attempt
- No boiler tripping recorded during FGD unit commissioning
- Reliable and stable operation of the FGD system
- A key milestone in enabling cleaner, more sustainable power generation
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