Case Studies
Real-world engineered solutions successfully delivered across complex industrial environments.
1. Two-stage classifier dispatched to Maharashtra
Fly Ash Classification in Beed, Maharashtra
Challenge: Low recovery (40–52%), bag filter clogging, rain-related output drop, and high wear.
TNBi Solution: Two-stage classifier with closed-loop air, bag filter integration, and ultra-fine tuning
Result
- Recovery increased to 55–63%
- Capacity improved ~10%
- No monsoon disruption
- Enabled new product line with <10µm separation
2. Venturi scrubber installed in the Pharma industry
Proven Performance in Pharma
Challenge: High emissions, severe corrosion causing leaks, pressure drop of up to 750 mm Wg, and foaming back to the tablet coater.
TNBi Solution: Replaced the legacy scrubber with an SS304 Venturi-based unit featuring:
- Horizontal gas entry
- Open recirculation tank
- Adjustable venturi
- Higher liquid flow rate
- Foam-resistant spray system
Result
- Pressure drop reduced to 300 mm Wg
- No foam backflow
- Zero corrosion-related failures since installation
3. Cyclone Separator deployed to a polymer processing facility
High-Efficiency Cyclone Replaces Fire-Prone Bag Filter
Challenge: A polymer processing facility handling ultra-fine powder after milling faced major operational setbacks due to an overloaded bag filter system. With dust loading at 8750 mg/Nm³ and over 90% of particles smaller than 9.1 µm, the existing setup couldn’t manage the fine particulate burden. This led to frequent fires, 18-hour downtimes, and repeated filter bag failures under heat and pressure.
TNBi Solution: To replace the breakdown-prone filter system, TNBi deployed a cyclone separator designed for high dust loads, eliminating the need for filter bags. The system featured a no-moving-parts design, which prevents choking, reduces maintenance, and ensures safe, spark-free operation. Its compact configuration also minimized noise and simplified integration into the plant’s layout.
Result
- Emission level brought down to <25 mg/Nm³
- 99.72% collection efficiency achieved
- Zero fire incidents
- Higher product recovery and uptime