Braj Projects Pvt.Ltd.

Sanathal, Ahmedabad, Gujarat

In such grim situation one has to really start thinking a fresh on various profit making avenues which were being ignored in better times. The ideal way of looking at it is basically looking at points to save wastages of various resources and recover it profitably wherever possible.

Details :Braj Projects Pvt.Ltd. has a team who have an experience of More then 10 Years in recovery from waste offering various projects such as heat recovery systems , salt recovery and caustic recovery system / caustic recovery plant

Explanation :Mercerisers for Textile Mills generate dilute caustic liquor, which if drained to effluent treatment plant, will create considerable problems in meeting the environmental standards. Caustic recovery system / caustic soda recovery plant by concentrating wash liquor and using the same back in Merceriser is the only feasible solution.

Principle :Under caustic recovery system / caustic soda recovery , Caustic at low concentration is heated to its boiling point with the help of a heat source and the vapors generated due to boiling are used to heat the weak liquor. This hot liquid is then flashed at lower pressure  and the vapors so generated used again. The weak liquor is concentrated to 250-300 GPL as in case of dry Merceriser or 450-500 GPL in case of wet Merceriser which can be reused with a minor topping up of caustic.

Operation :

• Weak Caustic lye, around 5-6 Be ( 40 - 50 gpl ), is collected from the impregnation and washing chamber  into a storage tank. It is then taken to a filtration unit to filter the suspended solids, fluff etc. The feed to CRP then passes through a series of preheaters which preheat the wash liquor with the help of flash vapors from the condensate flashes ensuring minimum steam loss in heating the Wash liquor to its boiling point.The liquor in the tubes comes in contact with the steam in the shell side of heater 1 and the liquor starts boiling. The vapor liquor mixture enters the flash vessel through a tangential entry and the vapors get separated and enter the shell of the 2nd stage.
• The boiling in the successive effect takes place due to lower pressure created with help of a water ring vacuum pump. Due to lower pressure the boiling point of the liquor is reduced and it starts boiling.
• The concentrated liquor enters the 2nd heater due to the pressure difference and comes in indirect contact with the generated vapors and the same procedure is repeated. The concentrated product is removed from the last stage by a product pump.This later is taken either to a storage tank or to a Concentrated Lye purification system .
• Under caustic recovery system / caustic soda recovery plant vapors generated at the last stage need to be condensed. This is done by either HotWateror an Adiabitc Evaporatorsystem. In case of a hot water system, water at room temperature is passed through tubes of an exchanger and it gets hot due to the vapors. This hot water is uncontaminated and hence can safely be used in the process or the boiler as per the requirement.
• In some cases where the hot water generated cannot be effectively consumed the effluent is passed through the exchanger and sprayed in an Adiabatic Evaporator Here the waste heat is lost in form of vapors and hence effective steam consumption of steam is reduced. Also nuisance of excess hot water is eliminated.

Power Saving System saves energy for gas discharge lamps like tube light, sodium vapor lamp, mercury vapor lamp, metal halide lamps, etc without altering existing fittings. This is achieved by our Magnetic Amplifier coils and is fitted before MLDB. We are enlisted among the reputed Manufacturers, Exporters and Suppliers of Power Saving System. The manufacturing and testing of our Power Saving System are done under the strict vigilance of experts. Benefits :

• Steady Lumen Upto 20-30% Saving
• ROI within one to two years
• Continuous energy saving for 12-15 years
• 80% IT depreciation Luminary recurring cost down by half
• Cost effective compared to localized accessories

Advantages :

• SCENE Mag-Amp technology closed loop current controlled
• Coil based
• No thyrister firing
• Harmonics free contactor -less
• 12-15 years performance
• Easy to install and commission
• Reduces heat loss of Lamp/chokes/cable
• No lamp flickering

Braj Projects Pvt.Ltd., every plant is tailor – designed to suit various process conditions like; Feed Temp, Feed Concentration, Product Concentration and Characteristics of Material like Heat Sensitivity, Flow Characteristics, Corrosion & Scaling tendencies.

Details :

• Steam always enter the first heater. Vapors from the first evaporator are fed to the second heater and so on. The heaters transfer heat indirectly.
• The vapor liquor mixture enters the flash vessel & gets separated in 3 – stage separation program and more or less pure water vapors enter the 2nd stage, guaranteeing quality of condensate to be recycled. The concentrated liquor enters the 2nd heater, gets heated by indirect contact with the generated vapors and the same procedure is repeated.
• The overall result of such meticulous design is very encouraging in these days of high energy costs and the Processing Costs on our Evaporation Plants are un-matched in the Industry.
• When the liquor contains soluble organic or inorganic contents, they tend to separate out when solubility is reduced because of either increase in concentration or decrease in temperature or both.
• The total characteristics of the effluent are seldom known or even if known keep changing as per the product mix. Due to this inconsistent feed quality, there are very high chances of tube fouling and maintenance operations.
• If the separated solids / crystals are not taken care of properly, they will choke Evaporator, piping or Exchanger tubes. Consequent excessive scaling also would call for stoppages for cleaning.
• Since Evaporation systems are susceptible to fouling as described above, there is a limitation to the achievable concentration of the product in an evaporator.
• Usually most of the salts start crystallizing / scaling after about 27% concentration. So to reduce downtime and cleaning costs, it is best suggested to concentrate the effluent in the forced circulation evaporator up to a concentration depending upon the nature of effluents and then take it for further processing : Crystallization / solidification, depending upon the nature of salt.

 
Post Evaporation Drying :Based on the available infrastructure and the pollution norms various Post evaporation methods are employed by industries are as follows :

• Solar Pond
• Crystalliser & Centrifuge
• Thickener
• Agitated Thin Film Dryer
• Spin Flash Dryer
• Spray Dryer

Rcc-Chimney Benefits:

• RCC-CHlMNEY's have a longer life, compare to MS chimney the life of RCC-CHIMNEY's are 90% more.
• RCC-CHIMNEY’ s are Self Supporting Chimneysthey do not require supporting cable.
• RCC-CHlMNEY's takes very little space compared to MS chimneys.
• RCC-CHIMNEY's are shock-proof, as the body is concrete based Lighting will not ow through it.
• RCC-CHIMNEY's does not require regular maintenance like rust-proof coating, painting, supportive cables strength checking, etc.
• Lightning arresters, Aviation lamps, Painting can be installed at any time with ease.
• Easy to erect LADDER with safety hoop guards and more space from bottom to the top of the chimney
• Does not need higher capacity cranes for erection and installation.
• Cost-wise not much difference between RCC Chimney and MS chimney, etc.

We construct RCC Chimneys for Process Industries like Paper, textiles, Sugar, Ethanol, Rice mills, Chemicals, Pharmaceuticals , Steel etc.

Steam Turbine works on revolutionary concept with a view to keep the cost to minimum. It has three different modules integrated to generate electrical power namely Turbine, Gearbox and Generator. Apart from this, oil pumps, oil cooler and oil filters are also the part of Steam Turbine. We are named among the renowned Manufacturers, Exporters and Suppliers of Steam Turbine. We manufacture Steam Turbine using quality approved components and advanced technology at our well-equipped production unit. Features :

• NO - Gearbox / Lubricating system / Couplings / Alternator
• Retrofitted with existing low pressure stem boilers
• Power generation at almost ZERO cost
• Low RPM
• Very Compact, Indigenous manufacturing
• Low maintenance
• Pay back period about 12-15 months
• Modern PID based control system
• Light weight of special alloy
• Estimated life 10-12 years
• Design, Installation and Commissioning of a new turbine set within 9-10 weeks
• No special infrastructure required

Price Range : Ranging from Rs. 5 Lakhs to 2 Crore

We are offering steam turbine for generating electricity from boilers, low pressure saturated steam boilers high pressure superheated steam boilers.

We have developed a revolutionary concept in Steam Turbines with a view to keep the cost to the barest minimum and enable small steam users to install a steam turbine.

How Low Cost Saturated Turbine is different from conventional Steam Turbines ?

A conventional Steam turbine will have three different modules integrated to generate electrical power namely :

• Turbine
• Gearbox
• Generator

• Apart from the above the following sub-systems form part and parcel of any Steam Turbine Generation system.

  1. Lubrication system comprising of oil pumps, oil cooler, m oil filters etc.
  3. Couplings between turbine gearbox and alternator gearbox.
  5. Speed governing system
  7. Base frame

  8. Thus making the whole system quite expensive.

     This Low cost Saturated Steam Turbine eliminates the gearbox, lubrication system, couplings and speed governing which drastically reduces the first cost to customer. The novel concept envisages the turbine to be mounted directly onto the shaft of an induction generator eliminating the items described in point 1, 2 and 3 above. This not only reduce the acquisition cost but also the recurring expenditure on maintenance spares and services, such as :

     • Lube oil replenishment refill Low Cost Saturated Steam Turbine does away lube oil.
     • Maintenance spares such as oil filters, bearings, couplings, governor spares, etc. Low Cost Saturated Steam Turbine not need only of these.
     • Man power cost on O & M almost nil for Low Cost Saturated Steam Turbine.
     • Cost of providing cooling water supply to the turbine Low Cost Saturated Steam Turbine require no cooling water.

     • Low Cost Saturated Steam Turbine operates at moderate efficiency due to its lower operating speed (3000 RPM as compared to 5000 plus of a conventional turbine). It will generate anywhere between 70 to 100% power of a conventional turbine depending on customers steam parameters. Low Cost Saturated Steam Turbine is targeted at small steam users and for power generation in 40 to 500 kW range. It costs less than 50% of a conventional turbine thus making it an attractive proposition.

We are amidst the dependable Manufacturers, Exporters and Suppliers of the Zero Discharge System. The Zero Discharge System evaporates water from Pretreated Effluent in almost the same way as thermal evaporators, employing the principle of diffusion at normal temperature. To recapitulate the basic aspects of the novel design :

• Braj Projects Pvt.Ltd. design basically differs from conventional evaporators in the underlying principle; the former uses heat to evaporate water, whereas the later (Braj Projects Pvt.Ltd.'s design) employs the natural phenomenon of diffusion of water which does not require heat.
• The natural process of diffusion is as such slow, but can be greatly enhanced by, large inter facial area between air and water, turbulence, finer particle size of water and large air to water ratio.
• It has been proven scientifically in the highly reputed universities and renowned institutions in the West that at sub-micron size of the water particles in the normal atmosphere, the natural process of evaporation, called diffusional evaporation, ensures that it is completely vaporizes before it hits the ground, if released at sufficient height.
• In order to utilize this well-proven principle for practical and effective evaporation of effluent into water in the atmosphere, the effluent has to be adequately stripped off all its dissolved organic and inorganic contents beforehand, besides removal of turbidity, suspended solids etc.
• This process of natural evaporation would be dependent on the atmospheric conditions like humidity, wind speed, temperature etc and therefore should be harnessed and designed for the adverse combinations of governing parameters so that at all other time higher evaporation would occur.
• Braj Projects Pvt.Ltd. does not claim that it has Invented Natural Evaporation By Diffusion, but it does claim that it has harnessed this principle for practical, effective evaporation of effluent into water by perhaps more user-friendly method suitable for the Indian conditions

With above background, it becomes clear that the effluent has to be properly pretreated before it is pumped into Braj Projects Pvt.Ltd.'s ZDS involving; equalization, pH control, removal of volatile organics, removal of suspended solids and turbidity, and lastly adequate removal of dissolved impurities. There are basically two types of dissolved impurities in the effluent, organic and inorganic, manifesting themselves as COD, BOD, TOC, etc. and TDS. Firstly, the effluent has to be passed through a packed bed of activated carbon, granular form, with app surface area about 80-100sq meter per gram. It is well known that activated carbon of good quality possesses extremely good adsorptive for most of the organic impurities present in the textile effluents. Therefore, after passage thru carbon bed , most of the dissolved organics of the effluent would be removed, with optimum contact time and sufficient depth of the bed, say, .5m to 1.0meter and dia of about 0.5 to 0.75m.The carbon bed as usual would have distributors, supporting plate, mild steel shell, inlet and outlet and so on. After removal of organics in the carbon bed of adequate quantity, the effluent is passed through a mixed bed of anionic and cationic resins which are well known to remove inorganic salts from the effluent by the ion exchange process. This would be also made from mild steel shell lined with epoxy to withstand corrosion by the effluent. It would be a packed bed with usual connections like inlet, outlet, distributor etc. The anionic and cationic resins would be in the form of spherical particles packed to sufficient depth and adequate residence time. Both the carbon granules and resins are available in India and have been used in the industry for effluent/water treatment with a high degree of success over the last several decades. Their designs have been standardized in our country. The Overall Picture of Our ZDS Is As Follows

• Equalization
• VOC removal by vigorous aeration (optional in the textile effluents)
• pH control
• Removal of suspended and turbid particles in a multimedia filter
• Removal of dissolved organics by the activated granular carbon bed
• Removal of highly concentrated portion of waste water as recycled stream in effluent storage tank or sludge drying beds
• Removal of dissolved inorganic(TDS) in a packed bed of ion exchange resins, anionic and cationic both, and then pumping the so pretreated effluent into our ZDS along with compressed air through diffuser modules mounted at 50-60 feet elevation.

Typical Characteristics Of The Equalized Textile Effluent

• pH : 6.5 -8.5
• S S : 150-400ppm
• C O D : 800-3000ppm
• B O D : 200-450ppm
• Color : Moderate
• Oil and Grease : 5-30 ppm
• Ammoniacal Nitrogen : 50-150 ppm
• TDS : 5000-15000 ppm
• Toxicity : Not detected

Typical Characteristics of the Pretreated Effluent before Zero Discharge System

• pH : 6.5 -7.5
• S S : 10-500 ppm
• COD : 70-50, 000 ppm
• BOD : 20-3000 ppm
• Color : Almost colorless
• Oil &Grease : 2-100 ppm
• TDS : 100-2, 00, 000 ppm

The packed beds of activated carbon and ion exchange resins are cylindrical, vertical columns with valves, pressure gauges, drains, level indicators, opening lids and man holes for cleaning and are self -supporting structures of about 2-3 feet diameter and 4-6 feet cylindrical heights, made from mild steel of about 4-6 mm plate and coated with epoxy paint. The present study on a pilot plant at Braj Projects Pvt.Ltd. over two years and exhaustive study of the commercial plant at a local chemical industry over the last 1.5 years have shown that there are no adverse effects of any kind either on the local climate or human beings or plantations in the vicinity of the ZDS plant as well as in the long ranges by the emissions from the ZDS. This is on the expected line technically also, because what is being discharged from the ZDS is water vapor well mixed with large amount of air and that too at highly elevated level of 50-60 feet from the ground. If we compare this with the discharges of the greenhouse gases from the boilers, driers, thermic fluid heaters and even multiple effect evaporators already approved by the regulatory authorities emitting vapors without mixing with air or the much -touted incinerators' gaseous emissions comprising carbon dioxide, carbon monoxide, heat and toxic substances as byproducts of combustion of the fossil fuels used for generation of heat/steam. This method of zero discharge is superior and much more eco-friendly on equivalent basis. Needless to mention, that like all other novel technologies emerging in the horizon in the global environmental scenario, the ZDS is also not cent per cent perfect, it does have a few limitations, however, if the industry has to opt for a zero discharge system that is very near to the sustainable, practical, cost effective and eco-friendly method of ensuring no liquid discharge. Braj Projects Pvt.Ltd.'s ZDS provides and tries to fill in the vacuum amongst the plethora of pseudo- zero discharge systems available in the Indian market. During the developmental process of the Zero Discharge System Braj Projects Pvt.Ltd. learnt that in one of the highly developed countries, such systems of very large capacities at industrial scale have been operating successfully for over 10-15 years. Now Braj Projects Pvt.Ltd. also has gone up to a full-fledged commercial plant employing this novel concept and it is of the opinion, based on exhaustive trials so far, that the system is techno-economically viable and sustainable remedy to the Zero Discharge compliance problem of the industry has ultimately arrived on the Indian horizon. Outcome of the Zero Discharge system

• Treated trade effluent disposal problem of a land locked industry will be solved on a sustainable way.
• Compliance of Zero Discharge norm will be achieved by the industry.
• Occasional underground pollution of the water strata will be solved.

Price Range : Ranging from Rs. 5 Lakhs to 2 Crore