Heavy duty, continuous type ball mill is with three compartment and screen. Replaceable Liners are fixed inside entire mill. Liners material and shape is selected based on material to be grind. Input material is fed in two primary grinding compartments. Large diameter balls for reduce particle size are laying inside first compartment. Material comes into second compartment for further grinding. Small size Balls are laying inside second compartment. Material comes into third for fine grinding. Smaller size media are laying inside third compartment for fine grinding. Diaphragms may place to regulate material level and control retention time. Material is feed and discharged through hollow trunnion at opposite end. Accessories like air classifier, cyclone, blower, return air circuit or dust collector can also be placed for close loop system. Girth gear is fixed on shell, which driven mating gear, gearbox and motor, which are fixed on heavy drive base.

NSI Equipments Pvt. Ltd. Continuous Ball Mill is useful for grinding coarse feed to get fine powder in single continuous operation. It is for grinding Ceramics, Cement, Pencil, Paint, Chemical, Ink, Marble, Coal, minerals, Ferro Alloys etc.

In a Bag Lifting type Centrifuge a chain pulley block and hoist is required to lift the bag out of the centrifuge and there are chances of product contamination in these devices, instead for a clean room application a specially designed hydraulic lifting device is used for lifting the basket top with filter bag along with solids after filtration.

This arrangement consists of a central pillar with hydraulic ram movement inside the pillar attached to the lifting arm. These ram aides the movement of arm up and down with hydraulic power pack controlled through a control panel. After filtration the basket top cover with filter bag and solids are hooked to the arm of the bag lift arrangement to lift the bag vertically upwards and to turn around through its pillar centre pivot point, mounted on bearings and the solids are unloaded. This system eliminates the usage of any chain pulley block.

The system is also available confirming to cGMP standards.

Hydro-Extractors are also called Centrifuges. Centrifuges are for water extraction (dewatering, pre-drying) of textile materials. Values of approx. 15% for residual moisture content can be achieved depending on the type of textile fiber. Centrifuges with perforated drums or baskets ( up to approx. 2000 mm) which oscillate vertically in ball-and-socket joints suspended on three points are produced in various designs as pendulating, suspension, cage and vertical centrifuges, also with so called gliding support bearings as gliding support centrifuges or in horizontal resp.

vertical arrangements as open-width, horizontal and warp-beam centrifuges, etc. Most centrifuges have electric drives for speeds of approx. 750-1200 rpm and are generally provided with automatic control over various ranges.

For safety reasons, an interlocking lid is essential on a centrifuge so that the motor cannot be started until the lid is locked, nor the lid rose until the basket is stationary again after the machine has been stopped.

We are a profound manufacturer ofMS Rubber Lined Centrifugesthat utilized for corrosive services. Manufacture using MS or rubber-lined MS or SS (AISI 304 or 316) at the contact surfaces, these ergonomically engineered centrifuges find applications in diverse industries such as Pharmaceutical, Chemical Plants and Fertilizer Plants owing to their superior quality.

Apart from this, ourMS Rubber Lined Centrifugesare based upon advanced technology, and can be customized as per specific requirements of the customers.

• The hollow rotating agitator shaft imparts heat to the product, scrapes the shell wall, and tumbles the product for maximum heat transfer and discharge product when required.
• The large heat transfer area available on the wide paddles and hollow shaft give maximum heat transfer efficiency to the product.
• The scrapers have minimum calculates clearance from the shell to keep the shell clean and increase heat transfer co-efficient.
• Unique condensate removal mechanism employed in the shaft.
• Mechanical seal are offered for high vacuum.
• Shaft is hardened and ground when gland packing is used.

• User friendly discharge valve design provides vacuum tight closing when the material is processed and quick opening lever facilitates filling of bags when material is discharge and packed.
• Pneumatically closing, opening, locking and cleaning mechanism is offered for automation.

These are most efficient axial flow impeller. It is recommended for blending, solid suspension, heat transfer etc. It provides maximum flow at minimum power. Mostly available in three blade version. But different number & width of bade are also common in special applications. This is also called as fabricated propeller.

These are axial mixing impeller with considerable amount of radial flow. It produces suction when placed near the liquid surface. Hence used for blending of immiscible liquids, solid incorporation etc. It is also a preferred choice for applications where the viscosity change during the process is large. These are mostly available in four blades @ 45 degree. But different numbers of blade with various angles are also used depending on application.

Mostly used for gas dispersion application. Curve blade (Concave, parabolic etc.) disc can handle 2 to 6 times more gas than flat blade disk turbine. Power drop between gassed and un-gassed condition is very less than conventional flat blade disk impellers. Hence it is preferred choice for gas dispersion application viz. Fermentation, Hydrogenation, Oxidation, Carbonisation, Ethylation etc.

Anchor/Gate type impellers are close-clearance impeller. This impeller provides adequate mixing under the laminar flow conditions encountered viscosity applications for heat transfer. These are many applications that other type of impellers is integrated with the anchor.

This impeller sweeps the whole wall surface of the vessel and agitates most of the fluid batch through physical contact. Anchor impellers are used for liquid viscosities between 5, 000 and 50, 000 cP. When reaction /mixing homogeneity is required, other type of impellers are recommended.

Disperser disk provides large amount of shear and mostly used for liquid-liquid dispersion and powder dissolution or de-agglomeration etc.

A single mechanical seal consists of two very flat surfaces that are pressed together by a spring and slide against each other. Between these two surfaces is a fluid film generated by the product. This fluid film prevents the mechanical seal from touching the stationary ring. An absence of this fluid film (dry running of the pump) results in frictional heat and ultimate destruction of the mechanical seal.

Mechanical seals tend to leak a vapor from the high pressure side to the low pressure side. This fluid lubricates the seal faces and absorbs the heat generated from the associated friction, which crosses the seal faces as a liquid and vaporizes into the atmosphere. So, it's common practice to use a single mechanical seal if the product poses little to no risk to the environment.

We are a prominent organization that manufactures supplies a vast spectrum of Chemical Reactors. Available in various specifications, these products are extensively used in chemical and pharmaceutical industries.

The offered range is manufactured using premium quality material following standards and norms of the industry.

To mix dry powder & granules, this Industrial Powder Blender is considered very suitable and effective.

These ribbon blenders are extensively used for cosmetic powder, food, chemicals. It is an efficient and versatile machine used for mixing powder and granules homogeneously. All the contact parts of the blender are made from materials with grades as required by customers. Our blender offers uniform mixing and easy discharge of material.

Features :

• U-shaped horizontal trough containing a rotating double helical ribbon or paddle agitator.
• Clearance of 3-6 mm is maintained.
• Charging material is through top nozzles. Discharge through bottom valve.
• Blending time-15 to 20 minutes, 90 to 95 percent or better homogeneity.
• Ribbons are best suited for free flowing and cohesive products.

We have emerged in offering our customers a wide array of superior quality Chemical Blender. Our experienced professionals manufacture offered chemical blenders using advance technology and latest techniques.

Features :

• Sturdy construction
• Durability
• Fine finishing

In certain cases the mixing of solid powder is carried out with liquid and during the process lumps are formed and to overcome this, the use of chopper blades is provided to break the lumps and to carry out the operation.

The chopper blades are flanged on either side of the trough of the blender. The chopper consists of multiple sharp edged blades and rotates at high speed to carry out the operation.

A ball mill is partly filled with steel balls (some are cylindrical shaped cylpebs) that impart a tumbling and cascading action when the mill rotates around its horizontal axis. Material fed through the mill is crushed by impact and ground by attrition between the balls. The grinding media are usually made of high-chromium steel or manganese steel. The smaller grades are generally cylpebs.

Mill liners are generally of high chromium steel or manganese steel. The liners are selected based on the type and hardness of the material to be ground. The grinding media is also selected with the same principal and suitable to the material of the liners. The thickness and design of the liners largely effect the grinding efficiency of the mill and hence various improvements in the designs have been made from time to time.

• Closed-circuit with air classifier. Product size equivalent to 1.750 to 1.800 cm/gm
• Open circuit ; moisture less than 0.5%, average grind ability
• Feed temperature , 200 to 300F - Open circuit operation

The purpose of the refractory lining is to insulate the steel shell from the high temperatures inside the kiln and to protect it from the corrosive properties of the process material. It may consist of refractory bricks or cast refractory concrete. The refractory selected depends upon the temperature inside the kiln and the chemical nature of the material being processed. Mostly refractory is installed as solid block to fit in to different areas tightly in round formation from sliding or falling out. There are many types of bricks in different composition and have different properties such as insulation value, maximum temperature and resistance to wear. Areas where brick cannot be used liquid refractor called castables are used with anchor support. Also provided insulation material under the brick and this extra layer helps to reduce the heat transfer to the shell. A typical refractory will be capable of maintaining a temperature drop of 1000C or more between its hot and cold faces. The shell temperature needs to be maintained below around 350C in order to protect the steel from damage and continuous infrared scanners are used to give early warning of "hot-spots" indicative of refractory failure.

Rotary carbonisers (kilns) are used in Activated carbon units for the steam activation of carbon granules (charcoal) at a controlled temperature. The kiln is unique in design with a spiral wound cooling coil arrangement fixed over the discharge end of the shell to lower the product temperature during the discharge

Bearings are uniquely designed for this application. The most common are the anti-friction or spherical roller bearings. These bearings have become standardized and perform excellently in almost any condition.Rotary Kilns are normally gear driven through girth gear mounted over the shell on gear support base, assembled on a section of the shell away from the shell end where high temperature is encountered. To compensate the thermal expansion, the girth gear is mounted on a tangential spring plates attached to the shell.

Flue gas desulfurization is commonly known as fgd and is the technology used for removing sulfur dioxide (so2) from the exhaust combustion flue gases coming from the boilers to produce steam that burn coal /oil/ pet coke. The fgd offered is the dual- or double-alkali scrubbing process which contacts the flue gases with an alkaline sorbent of lime or limestone and a sodium-based alkali solution to remove so2 from combustion exhaust gas.

The Steps Involved In The Process Is As Follows

The so2 in the flue gas passing through the absorber column / scrubber reacts with the alkaline solution ( naoh, caustic soda) sprayed from top through distributor nozzles to primarily form sodium sulfite and sodium bisulfite (nahso3). The following are the main absorption reactions :

2 NaOH + SO2 --> Na2SO3+ H2O
NaOH + SO2 --> NaHSO3

In addition to the above reactions, some of the so3 present may react with alkaline components to produce sodium sulfate-
2NaOH + SO3--> Na2SO4+ H2O

Throughout the system, some sodium sulfite is oxidized to sulfate by:
2Na2SO3+ O2-->2Na2SO4

Later the sodium bisulfite and sodium sulfate are reacted with lime or limestone ( caco3) slurry solution to produce a calcium sludge in the form of calcium sulphate ( gypsum ) and a regenerated sodium solution. This regenerated sodium solution is re-used in the absorption column and the sludge from the reactor is then sent to a clarifier, or thickener, where the calcium sludge is drawn off the bottom, filtered, and washed with water. From the filter, the sodium solution is recycled to the clarifier, and the sludge is discarded. From the clarifier, the regenerated sodium solution is sent to a mixing tank where the sodium compounds and makeup water are added.

The sodium alkali solution absorbs so2 , and the spent absorbing liquor is regenerated with lime or limestone. Using both sodium- and calcium-based compounds is where the name dual or double-alkali comes from. Calcium sulfites and sulfates are re-precipitated and discarded as sludge. The regenerated sodium scrubbing solution is returned to the absorber loop. The dual-alkali process has reduced plugging and scaling problems in the absorber because sodium scrubbing compounds are very soluble. Dual-alkali systems are capable of 95% so2 reduction.

Induced draft fan (ID fan) is located between dust collector and chimney of Rotary Dryer. ID fan will take the hot flue gases from Rotary Dryer via dust collector (dust separation system or Fume Extraction system) and will deliver to chimney. ID fan will handle the flue gases i.e. hot air. ID fan will produce the negative pressure in the Rotary Dryer to remove the flue gases from Dryer via Cyclone and bag Filter and to push the flue gases to chimney.

The hot gases may be generated in an external furnace, Hot Air Generator (HAG), or may be generated by a flame inside the kiln. Such a flame is projected from a burner-pipe. The fuel for this may be gas, oil or pulverized coal. The fuel could be mixed with air before or in the burner. The flame temperature is a factor of fuel type, fuel/air ratio and other burning conditions.

Exhaust gases from an oil fired kiln contain certain proportion of very fine dust, entrained in the air stream while in contact with materials being calcined and there may be undesirable constituents such as sulfur dioxide or hydrogen chloride. Equipment is installed to scrub these out before the exhaust gases pass to atmosphere.

A Dust Collector of high efficiency cyclone type is used to trap the fine dust. Very fine particles which escape the dry collector may be recovered by means of a wet collector in the form of a sludge or alternatively by means of Bag Filter.

ROTARY COOLER is a part of Rotary kiln system used to lower the temperature of the hot products discharged from the kiln to a temperature approaching ambient. The Rotary Cooler is installed beneath the Rotary Kiln and interconnected with the kiln discharge hood. The construction is similar to Rotary kiln with a cylindrical shell inclined to the horizontal with tyres, support rollers, feed hood and driven by girth gear & pinion. A part of the cooler shell is castable lined to take care of the shell from the hot discharge.

The Rotary Cooler operates in counter-flow, the hot gases being substituted by ambient or chilled air, which is in direct contact with the hot material. For high temperature applications the material is cooled to a temperature approaching ambient by continuous water spray over the shell and operates on the principle of heat transfer through the rotating cylinder wall which is continuously irrigated by a series of external water sprays mounted over the unit. The water is partially evaporated as steam while the excess is collected from the bottom of the unit and re-circulated. The material thus cooled is discharged from the other end of the shell.

In co-current and counter-current systems, the material when drying or pre-heating which are unaffected by heat or exposure to a flame, anOil or Gas Burneris used to fire directly into the drum. For low temperature and heat sensitive applications, indirectly heated air can be supplied viaFinned Tube Heat Exchangersand induced by a centrifugal fan located at up steam of the air heater with filter at fan inlet.

Tyres, sometimes called riding rings, usually consist of a single annular steel casting, machined to a smooth cylindrical surface, which attach loosely to the kiln shell through wedge arrangements. These require some ingenuity of design, since the tyre must fit the shell snugly, but also allow thermal movement. The tyre rides on pairs of steel support rollers, also machined to a smooth cylindrical surface and set about half a kiln-diameter apart. The rollers must support the kiln and allow rotation that is as nearly frictionless as possible. Depend on size and capacity an additional tyre can be provided with a set of support rollers. Kilns usually rotate at 0.5 to 2 rpm. The bearings of the support rollers must be capable of withstanding the large static and live loads involved, and must be carefully protected from the heat of the kiln and the ingress of dust. In addition to support rollers, there are usually upper and lower "retaining (or thrust) rollers" bearing against the side of tyres, that prevent the kiln from slipping off the support rollers.

Heat exchanger with finned heating surfaces, so-called finned tube heat exchangers are widely used in Rotary Dryer which offers the possibility of heat transfer between Air and liquids significantly space-saving and is more. Finned tube heat exchangers are designed to transfer heat from clean air and gases with high efficiency on liquids or vapors. In this way the Air can be heated in a closely space.

It is an essential component of the air intake system of Rotary Dryer and is tasked with trapping any dirt or debris in the air entering the intake system. It is important that foreign material is not allowed to enter the Rotary Dryer.

Heavy duty, continuous type ball mill is with three compartment and screen. Replaceable Liners are fixed inside entire mill. Liners material and shape is selected based on material to be grind. Input material is fed in two primary grinding compartments. Large diameter balls for reduce particle size are laying inside first compartment. Material comes into second compartment for further grinding. Small size Balls are laying inside second compartment. Material comes into third for fine grinding. Smaller size media are laying inside third compartment for fine grinding. Diaphragms may place to regulate material level and control retention time. Material is feed and discharged through hollow trunnion at opposite end. Accessories like air classifier, cyclone, blower, return air circuit or dust collector can also be placed for close loop system. Girth gear is fixed on shell, which driven mating gear, gearbox and motor, which are fixed on heavy drive base.

NSI Equipments Pvt. Ltd. Continuous Ball Mill is useful for grinding coarse feed to get fine powder in single continuous operation. It is for grinding Ceramics, Cement, Pencil, Paint, Chemical, Ink, Marble, Coal, minerals, Ferro Alloys etc.

In a Bag Lifting type Centrifuge a chain pulley block and hoist is required to lift the bag out of the centrifuge and there are chances of product contamination in these devices, instead for a clean room application a specially designed hydraulic lifting device is used for lifting the basket top with filter bag along with solids after filtration.

This arrangement consists of a central pillar with hydraulic ram movement inside the pillar attached to the lifting arm. These ram aides the movement of arm up and down with hydraulic power pack controlled through a control panel. After filtration the basket top cover with filter bag and solids are hooked to the arm of the bag lift arrangement to lift the bag vertically upwards and to turn around through its pillar centre pivot point, mounted on bearings and the solids are unloaded. This system eliminates the usage of any chain pulley block.

The system is also available confirming to cGMP standards.

Hydro-Extractors are also called Centrifuges. Centrifuges are for water extraction (dewatering, pre-drying) of textile materials. Values of approx. 15% for residual moisture content can be achieved depending on the type of textile fiber. Centrifuges with perforated drums or baskets ( up to approx. 2000 mm) which oscillate vertically in ball-and-socket joints suspended on three points are produced in various designs as pendulating, suspension, cage and vertical centrifuges, also with so called gliding support bearings as gliding support centrifuges or in horizontal resp.

vertical arrangements as open-width, horizontal and warp-beam centrifuges, etc. Most centrifuges have electric drives for speeds of approx. 750-1200 rpm and are generally provided with automatic control over various ranges.

For safety reasons, an interlocking lid is essential on a centrifuge so that the motor cannot be started until the lid is locked, nor the lid rose until the basket is stationary again after the machine has been stopped.

We are a profound manufacturer ofMS Rubber Lined Centrifugesthat utilized for corrosive services. Manufacture using MS or rubber-lined MS or SS (AISI 304 or 316) at the contact surfaces, these ergonomically engineered centrifuges find applications in diverse industries such as Pharmaceutical, Chemical Plants and Fertilizer Plants owing to their superior quality.

Apart from this, ourMS Rubber Lined Centrifugesare based upon advanced technology, and can be customized as per specific requirements of the customers.

• The hollow rotating agitator shaft imparts heat to the product, scrapes the shell wall, and tumbles the product for maximum heat transfer and discharge product when required.
• The large heat transfer area available on the wide paddles and hollow shaft give maximum heat transfer efficiency to the product.
• The scrapers have minimum calculates clearance from the shell to keep the shell clean and increase heat transfer co-efficient.
• Unique condensate removal mechanism employed in the shaft.
• Mechanical seal are offered for high vacuum.
• Shaft is hardened and ground when gland packing is used.

• User friendly discharge valve design provides vacuum tight closing when the material is processed and quick opening lever facilitates filling of bags when material is discharge and packed.
• Pneumatically closing, opening, locking and cleaning mechanism is offered for automation.

These are most efficient axial flow impeller. It is recommended for blending, solid suspension, heat transfer etc. It provides maximum flow at minimum power. Mostly available in three blade version. But different number & width of bade are also common in special applications. This is also called as fabricated propeller.

These are axial mixing impeller with considerable amount of radial flow. It produces suction when placed near the liquid surface. Hence used for blending of immiscible liquids, solid incorporation etc. It is also a preferred choice for applications where the viscosity change during the process is large. These are mostly available in four blades @ 45 degree. But different numbers of blade with various angles are also used depending on application.

Mostly used for gas dispersion application. Curve blade (Concave, parabolic etc.) disc can handle 2 to 6 times more gas than flat blade disk turbine. Power drop between gassed and un-gassed condition is very less than conventional flat blade disk impellers. Hence it is preferred choice for gas dispersion application viz. Fermentation, Hydrogenation, Oxidation, Carbonisation, Ethylation etc.

Anchor/Gate type impellers are close-clearance impeller. This impeller provides adequate mixing under the laminar flow conditions encountered viscosity applications for heat transfer. These are many applications that other type of impellers is integrated with the anchor.

This impeller sweeps the whole wall surface of the vessel and agitates most of the fluid batch through physical contact. Anchor impellers are used for liquid viscosities between 5, 000 and 50, 000 cP. When reaction /mixing homogeneity is required, other type of impellers are recommended.

Disperser disk provides large amount of shear and mostly used for liquid-liquid dispersion and powder dissolution or de-agglomeration etc.

A single mechanical seal consists of two very flat surfaces that are pressed together by a spring and slide against each other. Between these two surfaces is a fluid film generated by the product. This fluid film prevents the mechanical seal from touching the stationary ring. An absence of this fluid film (dry running of the pump) results in frictional heat and ultimate destruction of the mechanical seal.

Mechanical seals tend to leak a vapor from the high pressure side to the low pressure side. This fluid lubricates the seal faces and absorbs the heat generated from the associated friction, which crosses the seal faces as a liquid and vaporizes into the atmosphere. So, it's common practice to use a single mechanical seal if the product poses little to no risk to the environment.

We are a prominent organization that manufactures supplies a vast spectrum of Chemical Reactors. Available in various specifications, these products are extensively used in chemical and pharmaceutical industries.

The offered range is manufactured using premium quality material following standards and norms of the industry.

To mix dry powder & granules, this Industrial Powder Blender is considered very suitable and effective.

These ribbon blenders are extensively used for cosmetic powder, food, chemicals. It is an efficient and versatile machine used for mixing powder and granules homogeneously. All the contact parts of the blender are made from materials with grades as required by customers. Our blender offers uniform mixing and easy discharge of material.

Features :

• U-shaped horizontal trough containing a rotating double helical ribbon or paddle agitator.
• Clearance of 3-6 mm is maintained.
• Charging material is through top nozzles. Discharge through bottom valve.
• Blending time-15 to 20 minutes, 90 to 95 percent or better homogeneity.
• Ribbons are best suited for free flowing and cohesive products.

We have emerged in offering our customers a wide array of superior quality Chemical Blender. Our experienced professionals manufacture offered chemical blenders using advance technology and latest techniques.

Features :

• Sturdy construction
• Durability
• Fine finishing

In certain cases the mixing of solid powder is carried out with liquid and during the process lumps are formed and to overcome this, the use of chopper blades is provided to break the lumps and to carry out the operation.

The chopper blades are flanged on either side of the trough of the blender. The chopper consists of multiple sharp edged blades and rotates at high speed to carry out the operation.

A ball mill is partly filled with steel balls (some are cylindrical shaped cylpebs) that impart a tumbling and cascading action when the mill rotates around its horizontal axis. Material fed through the mill is crushed by impact and ground by attrition between the balls. The grinding media are usually made of high-chromium steel or manganese steel. The smaller grades are generally cylpebs.

Mill liners are generally of high chromium steel or manganese steel. The liners are selected based on the type and hardness of the material to be ground. The grinding media is also selected with the same principal and suitable to the material of the liners. The thickness and design of the liners largely effect the grinding efficiency of the mill and hence various improvements in the designs have been made from time to time.

• Closed-circuit with air classifier. Product size equivalent to 1.750 to 1.800 cm/gm
• Open circuit ; moisture less than 0.5%, average grind ability
• Feed temperature , 200 to 300F - Open circuit operation

The purpose of the refractory lining is to insulate the steel shell from the high temperatures inside the kiln and to protect it from the corrosive properties of the process material. It may consist of refractory bricks or cast refractory concrete. The refractory selected depends upon the temperature inside the kiln and the chemical nature of the material being processed. Mostly refractory is installed as solid block to fit in to different areas tightly in round formation from sliding or falling out. There are many types of bricks in different composition and have different properties such as insulation value, maximum temperature and resistance to wear. Areas where brick cannot be used liquid refractor called castables are used with anchor support. Also provided insulation material under the brick and this extra layer helps to reduce the heat transfer to the shell. A typical refractory will be capable of maintaining a temperature drop of 1000C or more between its hot and cold faces. The shell temperature needs to be maintained below around 350C in order to protect the steel from damage and continuous infrared scanners are used to give early warning of "hot-spots" indicative of refractory failure.

Rotary carbonisers (kilns) are used in Activated carbon units for the steam activation of carbon granules (charcoal) at a controlled temperature. The kiln is unique in design with a spiral wound cooling coil arrangement fixed over the discharge end of the shell to lower the product temperature during the discharge

Bearings are uniquely designed for this application. The most common are the anti-friction or spherical roller bearings. These bearings have become standardized and perform excellently in almost any condition.Rotary Kilns are normally gear driven through girth gear mounted over the shell on gear support base, assembled on a section of the shell away from the shell end where high temperature is encountered. To compensate the thermal expansion, the girth gear is mounted on a tangential spring plates attached to the shell.

Flue gas desulfurization is commonly known as fgd and is the technology used for removing sulfur dioxide (so2) from the exhaust combustion flue gases coming from the boilers to produce steam that burn coal /oil/ pet coke. The fgd offered is the dual- or double-alkali scrubbing process which contacts the flue gases with an alkaline sorbent of lime or limestone and a sodium-based alkali solution to remove so2 from combustion exhaust gas.

The Steps Involved In The Process Is As Follows

The so2 in the flue gas passing through the absorber column / scrubber reacts with the alkaline solution ( naoh, caustic soda) sprayed from top through distributor nozzles to primarily form sodium sulfite and sodium bisulfite (nahso3). The following are the main absorption reactions :

2 NaOH + SO2 --> Na2SO3+ H2O
NaOH + SO2 --> NaHSO3

In addition to the above reactions, some of the so3 present may react with alkaline components to produce sodium sulfate-
2NaOH + SO3--> Na2SO4+ H2O

Throughout the system, some sodium sulfite is oxidized to sulfate by:
2Na2SO3+ O2-->2Na2SO4

Later the sodium bisulfite and sodium sulfate are reacted with lime or limestone ( caco3) slurry solution to produce a calcium sludge in the form of calcium sulphate ( gypsum ) and a regenerated sodium solution. This regenerated sodium solution is re-used in the absorption column and the sludge from the reactor is then sent to a clarifier, or thickener, where the calcium sludge is drawn off the bottom, filtered, and washed with water. From the filter, the sodium solution is recycled to the clarifier, and the sludge is discarded. From the clarifier, the regenerated sodium solution is sent to a mixing tank where the sodium compounds and makeup water are added.

The sodium alkali solution absorbs so2 , and the spent absorbing liquor is regenerated with lime or limestone. Using both sodium- and calcium-based compounds is where the name dual or double-alkali comes from. Calcium sulfites and sulfates are re-precipitated and discarded as sludge. The regenerated sodium scrubbing solution is returned to the absorber loop. The dual-alkali process has reduced plugging and scaling problems in the absorber because sodium scrubbing compounds are very soluble. Dual-alkali systems are capable of 95% so2 reduction.

Induced draft fan (ID fan) is located between dust collector and chimney of Rotary Dryer. ID fan will take the hot flue gases from Rotary Dryer via dust collector (dust separation system or Fume Extraction system) and will deliver to chimney. ID fan will handle the flue gases i.e. hot air. ID fan will produce the negative pressure in the Rotary Dryer to remove the flue gases from Dryer via Cyclone and bag Filter and to push the flue gases to chimney.

The hot gases may be generated in an external furnace, Hot Air Generator (HAG), or may be generated by a flame inside the kiln. Such a flame is projected from a burner-pipe. The fuel for this may be gas, oil or pulverized coal. The fuel could be mixed with air before or in the burner. The flame temperature is a factor of fuel type, fuel/air ratio and other burning conditions.

Exhaust gases from an oil fired kiln contain certain proportion of very fine dust, entrained in the air stream while in contact with materials being calcined and there may be undesirable constituents such as sulfur dioxide or hydrogen chloride. Equipment is installed to scrub these out before the exhaust gases pass to atmosphere.

A Dust Collector of high efficiency cyclone type is used to trap the fine dust. Very fine particles which escape the dry collector may be recovered by means of a wet collector in the form of a sludge or alternatively by means of Bag Filter.

ROTARY COOLER is a part of Rotary kiln system used to lower the temperature of the hot products discharged from the kiln to a temperature approaching ambient. The Rotary Cooler is installed beneath the Rotary Kiln and interconnected with the kiln discharge hood. The construction is similar to Rotary kiln with a cylindrical shell inclined to the horizontal with tyres, support rollers, feed hood and driven by girth gear & pinion. A part of the cooler shell is castable lined to take care of the shell from the hot discharge.

The Rotary Cooler operates in counter-flow, the hot gases being substituted by ambient or chilled air, which is in direct contact with the hot material. For high temperature applications the material is cooled to a temperature approaching ambient by continuous water spray over the shell and operates on the principle of heat transfer through the rotating cylinder wall which is continuously irrigated by a series of external water sprays mounted over the unit. The water is partially evaporated as steam while the excess is collected from the bottom of the unit and re-circulated. The material thus cooled is discharged from the other end of the shell.

In co-current and counter-current systems, the material when drying or pre-heating which are unaffected by heat or exposure to a flame, anOil or Gas Burneris used to fire directly into the drum. For low temperature and heat sensitive applications, indirectly heated air can be supplied viaFinned Tube Heat Exchangersand induced by a centrifugal fan located at up steam of the air heater with filter at fan inlet.

Tyres, sometimes called riding rings, usually consist of a single annular steel casting, machined to a smooth cylindrical surface, which attach loosely to the kiln shell through wedge arrangements. These require some ingenuity of design, since the tyre must fit the shell snugly, but also allow thermal movement. The tyre rides on pairs of steel support rollers, also machined to a smooth cylindrical surface and set about half a kiln-diameter apart. The rollers must support the kiln and allow rotation that is as nearly frictionless as possible. Depend on size and capacity an additional tyre can be provided with a set of support rollers. Kilns usually rotate at 0.5 to 2 rpm. The bearings of the support rollers must be capable of withstanding the large static and live loads involved, and must be carefully protected from the heat of the kiln and the ingress of dust. In addition to support rollers, there are usually upper and lower "retaining (or thrust) rollers" bearing against the side of tyres, that prevent the kiln from slipping off the support rollers.

Heat exchanger with finned heating surfaces, so-called finned tube heat exchangers are widely used in Rotary Dryer which offers the possibility of heat transfer between Air and liquids significantly space-saving and is more. Finned tube heat exchangers are designed to transfer heat from clean air and gases with high efficiency on liquids or vapors. In this way the Air can be heated in a closely space.

It is an essential component of the air intake system of Rotary Dryer and is tasked with trapping any dirt or debris in the air entering the intake system. It is important that foreign material is not allowed to enter the Rotary Dryer.