Technology

Real-time Condenser Cleaning System

Published

4 years ago

July 1, 2021

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U K Mullick is passionate about engineering innovations. So far he as an author has featured on two occasions on innovative products in our past issues. Here he provides information on condenser cleaning.

Various types and sizes of Condensers are widely being used in different types of Cement, Power and Chemical plant in India. All such Condensers, as a matter of conventional practice, are required to be cleaned at different time intervals depending on various input factors.

At present, mainly the following types of cleaning processes are used in cleaning such Condensers depending on various factors: (i) Ball Cleaning System, (ii) High Pressure Abrasive cleaning, (iii) Chemical Cleaning System, (iv) Ultrasonic De-scaling System.

Each of the above system requires shut down of the condenser or in other words, the Plant for 10 to 14 days, depending on the size and capacity of the condenser. Such shut down directly affects productivity and the efficiency of the complete Plant. Again, in case the condenser tube calls for any replacement due to any reason, the shutdown period may be even more than two weeks.

In the recent past, after continuous and relentless study and research, a new innovative way has been found out. This new system is not like the above conventional system. The Condenser cleaning is done by online Real-time basis. This system is termed as Real-time Condenser Cleaning System or in short RCCS.

The most important factor for which it has been found to be more popular in Plant abroad is that it does not require any shut down or stoppage of plant or Condenser for regular maintenance or cleaning. It is a real time online continuous cleaning process wherein any suspended particle carried by liquid water flowing through the Condenser tubes do not get any chance to get settled inside the tubes. This activity prevents any deposition of any suspended particle and thereby helps not form any layer inside the tube surface that may call for descaling later on. This system helps to improve the Heat Transfer of the Condenser considerably which may enhance the Heat transfer efficiency of the Heat Exchanger.

General Introduction of RCCS

The real-time online condenser cleaning and enhanced heat transfer system (RCCS) of condensers developed, has been successfully implemented in the Cement, thermal power plant, alumina, central air conditioner Plant, petroleum, metallurgical, paper making, sugar refinery, pharmaceutical and salt making industries.

It can greatly improve the heat exchanger efficiency more than 30% and make the heat transfer equipment to maintain best working state for long time.

RCCS

Principle of Operation

The Spiral (as shown above) is having at its one end Steel Adopter Housing with Ceramic Bearing while the other end is loose. The length of the Spiral is decided by the length of each tube of the condenser . The spiral is made of specially designed Multi-composite Polymer which withstands a wide range of temperature. This Spirals with its attachment is fixed at one end of each Condenser Tube.

Condenser Tube

When RCCS is installed into heat-exchanger tube, the circulating water affects the Spiral which initiates its continuous rotation at a speed of 300??,800 rpm. The rotation of Spirals is being maintained without any supplementary power supply. The circulating water flow gives the power to the Spirals to rotate. These rotating Spirals turn the laminar flow into the turbulent flow. Disturbances of stagnant boundary layers on sustained basis suppress the mechanism of fouling formation and prevent from deposit formation inside the tube walls. In opposition to traditional technologies of passive fouling cleaning, RCCS provides active in-service fouling prevention on continuous basis. Since all chances of formation of deposit inside the tube is fully prevented, the Condenser does not require any cleaning by taking shut down of the plant. The Spirals are made from some special quality of Plastic like material whose life is about 8 to 10 years.

Service Conditions

RCCS is suitable for straight tube and shell heat exchangers, condensers, evaporators used in energy, petroleum, chemical, metal, salt, refrigeration and other industries, including applications such as reactors, air pre-heating systems, etc. The system can be adapted to operational conditions of 20% sulfuric acid, 20% hydrochloric acid and 20% nitric acid solutions, solutions with up to 100% sodium hydroxide (caustic acid) and ammonia content. Operating temperature of the Spirals and its accessories is from ??00 ?C to +220 ?C.

Functions and Benefits

RCCS uniqueness relies on simultaneous implementation of the two major functions:

enhanced heat transfer coefficient and real-time cleaning of heat-exchanger equipment during the actually long-life operation. Benefits are:

(i) Heat transfer efficiency increases more than 30%

(ii) No additional equipment required for Routine shutdown and cleaning activities

(iii) Easy to install the Spirals and its accessories (RCCS)

(iv) No separate power supply is required to rotate the Spirals

(v) No spare-parts required and hence no additional operational cost.

(vi) No effect on environmental safety

(vii) Improved heat transfer helps to save power on sustained basis.

Enhancement of Heat Transfer Indicators

RCCS has an obvious effect on enhancing flow disturbance. Steady laminar flow is turned into turbulent flow, which results in disturbance of the stagnant boundary layer, maintenance of even temperature distribution within the tubes and significant increase of heat transfer coefficient.

Such effect is proved with both theoretical calculation and operational characteristics of the heat-exchanger equipment currently being operated.

Heat Transfer Indicators

heat-exchanger equipment

A 20?0.6 austenic steel tube has been used for tests. Considerable heat exchange improvement has been proved under low and high flow rate values and Reynolds number values.

RCCS technical advantages are explained by its principle of function. If compared with traditional methods of cleaning, such as ball cleaning systems and ultrasonic de-scaling systems, RCCS improves heat transfer co-efficient considerably and prolongs heat exchanger equipment service life.

Author: Authored by: U K Mullick, who is a Mechanical Engr, worked at L& T; WIRTGEN INDIA,Tata Motors, AMW MOTORS (ESSAR Group), Mahindra & Mahindra. A total of 40 years of experience in Sales, Marketing and Business Development.

Technology

ARAPL Reports 175% EBITDA Growth, Expands Global Robotics Footprint

Affordable Robotic & Automation posts strong Q2 and H1 FY26 results driven by innovation and overseas orders

Published

3 weeks ago

October 15, 2025

admin

Affordable Robotic & Automation Limited (ARAPL), India’s first listed robotics firm and a pioneer in industrial automation and smart robotic solutions, has reported robust financial results for the second quarter and half year ended September 30, 2025.
The company achieved a 175 per cent year-on-year rise in standalone EBITDA and strong revenue growth across its automation and robotics segments. The Board of Directors approved the unaudited financial results on October 10, 2025.

Key Highlights – Q2 FY2026
• Strong momentum across core automation and robotics divisions
• Secured the first order for the Atlas AC2000, an autonomous truck loading and unloading forklift, from a leading US logistics player
• Rebranded its RaaS product line as Humro (Human + Robot), symbolising collaborative automation between people and machines
• Expanded its Humro range in global warehouse automation markets
• Continued investment in deep-tech innovations, including AI-based route optimisation, autonomy kits, vehicle controllers, and digital twins
Global Milestone: First Atlas AC2000 Order in the US

ARAPL’s US-based subsidiary, ARAPL RaaS (Humro), received its first order for the next-generation Atlas AC2000 autonomous forklift from a leading logistics company. Following successful prototype trials, the client placed an order for two robots valued at Rs 36 million under a three-year lease. The project opens opportunities for scaling up to 15–16 robots per site across 15 US warehouses within two years.
The product addresses an untapped market of 10 million loading docks across 21,000 warehouses in the US, positioning ARAPL for exponential growth.

Financial Performance – Q2 FY2026 (Standalone)
Net Revenue: Rs 25.7587 million, up 37 per cent quarter-on-quarter
EBITDA: Rs 5.9632 million, up 396 per cent QoQ
Profit Before Tax: Rs 4.3808 million, compared to a Rs 360.46 lakh loss in Q1
Profit After Tax: Rs 4.1854 lakh, representing 216 per cent QoQ growth
On a half-year basis, ARAPL reported a 175 per cent rise in EBITDA and returned to profitability with Rs 58.08 lakh PAT, highlighting strong operational efficiency and improved contribution from core businesses.
Consolidated Performance – Q2 FY2026
Net Revenue: Rs 29.566 million, up 57% QoQ
EBITDA: Rs 6.2608 million, up 418 per cent QoQ
Profit After Tax: Rs 4.5672 million, marking a 224 per cent QoQ improvement

Milind Padole, Managing Director, ARAPL said, “Our Q2 results reflect the success of our innovation-led growth strategy and the growing global confidence in ARAPL’s technology. The Atlas AC2000 order marks a defining milestone that validates our engineering strength and accelerates our global expansion. With a healthy order book and continued investment in AI and autonomous systems, ARAPL is positioned to lead the next phase of intelligent industrial transformation.”
Founded in 2005 and headquartered in Pune, Affordable Robotic & Automation Ltd (ARAPL) delivers turnkey robotic and automation solutions across automotive, general manufacturing, and government sectors. Its offerings include robotic welding, automated inspection, assembly automation, automated parking systems, and autonomous driverless forklifts.
ARAPL operates five advanced plants in Pune spanning 350,000 sq ft, supported by over 400 engineers in India and seven team members in the US. The company also maintains facilities in North Carolina and California, and service centres in Faridabad, Mumbai, and San Francisco.

Technology

M.E. Energy Bags Rs 490 Mn Order for Waste Heat Recovery Project

Second major EPC contract from Ferro Alloys sector strengthens company’s growth

Published

3 weeks ago

October 15, 2025

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M.E. Energy Pvt Ltd, a wholly owned subsidiary of Kilburn Engineering Ltd and a leading Indian engineering company specialising in energy recovery and cost reduction, has secured its second consecutive major order worth Rs 490 million in the Ferro Alloys sector. The order covers the Engineering, Procurement and Construction (EPC) of a 12 MW Waste Heat Recovery Based Power Plant (WHRPP).

This repeat order underscores the Ferro Alloys industry’s confidence in M.E. Energy’s expertise in delivering efficient and sustainable energy solutions for high-temperature process industries. The project aims to enhance energy efficiency and reduce carbon emissions by converting waste heat into clean power.

“Securing another project in the Ferro Alloys segment reinforces our strong technical credibility. It’s a proud moment as we continue helping our clients achieve sustainability and cost efficiency through innovative waste heat recovery systems,” said K. Vijaysanker Kartha, Managing Director, M.E. Energy Pvt Ltd.

“M.E. Energy’s expansion into sectors such as cement and ferro alloys is yielding solid results. We remain confident of sustained success as we deepen our presence in steel and carbon black industries. These achievements reaffirm our focus on innovation, technology, and energy efficiency,” added Amritanshu Khaitan, Director, Kilburn Engineering Ltd

With this latest order, M.E. Energy has already surpassed its total external order bookings from the previous financial year, recording Rs 138 crore so far in FY26. The company anticipates further growth in the second half, supported by a robust project pipeline and the rising adoption of waste heat recovery technologies across industries.

The development marks continued momentum towards FY27, strengthening M.E. Energy’s position as a leading player in industrial energy optimisation.

Technology

NTPC Green Energy Partners with Japan’s ENEOS for Green Fuel Exports

NGEL signs MoU with ENEOS to supply green methanol and hydrogen derivatives

Published

3 weeks ago

October 15, 2025

admin

NTPC Green Energy Limited (NGEL), a subsidiary of NTPC Limited, has signed a Memorandum of Understanding (MoU) with Japan’s ENEOS Corporation to explore a potential agreement for the supply of green methanol and hydrogen derivative products.

The MoU was exchanged on 10 October 2025 during the World Expo 2025 in Osaka, Japan. It marks a major step towards global collaboration in clean energy and decarbonisation.
The partnership centres on NGEL’s upcoming Green Hydrogen Hub at Pudimadaka in Andhra Pradesh. Spread across 1,200 acres, the integrated facility is being developed for large-scale green chemical production and exports.

By aligning ENEOS’s demand for hydrogen derivatives with NGEL’s renewable energy initiatives, the collaboration aims to accelerate low-carbon energy transitions. It also supports NGEL’s target of achieving a 60 GW renewable energy portfolio by 2032, reinforcing its commitment to India’s green energy ambitions and the global net-zero agenda.