CarbonFree™ APCD
Hybrid Air Pollution Control Device — Engineered for 50 mg/Nm³ Compliance
CarbonFree™ APCD
Engineered Cleaner Stack Emissions. Verified Compliance.
At Novorbis, we built CarbonFree™ APCD as a complete, indigenously engineered air pollution control system for India’s most demanding industrial stacks — boilers, thermic fluid heaters, furnaces, and kilns operating under high particulate loads.
Combining a cyclone pre-separator with a tubular shell-pipe ESP and automated water-assisted cleaning, CarbonFree™ APCD is a filter-less, low-OPEX system engineered to help industries meet CAQM Direction No. 98 and the uniform 50 mg/Nm³ PM emission standard.
It is purpose-built for plants that need reliable compliance without the recurring cost of bag replacements or the operational risk of conventional plate-wire ESPs.
Boiler & Furnace Emissions: A Growing Compliance Problem
Six issues every plant head sees on the ground today.
High PM Emissions
Boilers and furnaces routinely emit far above prescribed limits when systems are poorly designed or under-maintained.
PM up to 500 mg/Nm³ against a 50 mg/Nm³ ceilingFilter Choking
Conventional bag filters and rapper-based ESPs fail under real-load conditions and varying fuel quality.
Pressure drops cross 200 mmWC, choking the draftMaintenance Downtime
Frequent shutdowns for cleaning and consumable replacement directly hit plant utilisation.
Unplanned outages cost 5–8% of annual productionFuel Variability
Switching between coal, biomass, husk, or briquettes causes large swings in PM load and characteristics.
Fuel changes trigger ±40% surges in emissionsCompliance Risk
Repeat non-compliance with CPCB / State PCB stack norms triggers fines, show-cause notices and closure threats.
Penalties reaching ₹50,000/day — and risingHigh Operating Costs
Replacement filter bags, frequent manpower, and unscheduled outages keep inflating OPEX year after year.
Traditional filtration inflates budgets by ~20%What You Gain with CarbonFree™ APCD
Advanced engineering benefits designed to deliver cleaner emissions, reliable compliance, and lower operational costs.
High Collection Efficiency
Hybrid cyclone + tubular ESP technology efficiently captures fine particulate matter even under fluctuating load conditions.
Filter-less Architecture
No filter bags or cartridges required — eliminating recurring consumable replacement costs completely.
50 mg/Nm³ Compliance Ready
Purpose-built to support compliance with CAQM Direction No. 98 and CPCB particulate emission norms.
Stable Emission Control
Delivers consistent outlet PM performance without re-entrainment or rapper-related operational instability.
Automated Cleaning System
Integrated water-assisted cleaning reduces manual intervention and keeps performance stable over long operating hours.
Compact & Modular Design
Retrofit-ready modular construction allows easy installation within existing plant layouts and stack systems.
Lower Lifecycle Cost
Reduced maintenance, no filter replacement, and lower power consumption significantly reduce long-term operating costs.
Tested & Verified Technology
Backed by indigenous engineering, field validation, and third-party emission testing across industrial applications.
How CarbonFree™ APCD Works
A six-stage hybrid process engineered to reduce particulate emissions and deliver clean, compliant stack discharge.
1. Gas Inlet
Flue gas enters the APCD unit directly from the boiler, furnace, kiln, or industrial exhaust system.
2. Centrifugal Removal
The cyclone separator removes coarse particulate matter through centrifugal and inertial separation.
3. ESP Charging
Fine particles enter the tubular ESP chamber, where corona discharge electrically charges the particulate matter.
4. Particle Migration
Charged particles migrate toward grounded collection surfaces inside the tubular ESP shell.
5. Auto Cleaning
Periodic water-assisted flushing removes deposited dust automatically without manual cleaning or rapper cycles.
6. Clean Gas Exit
Treated flue gas exits through the stack with significantly reduced particulate matter levels.
Ten Reasons It Stands Out
Unique engineering advantages designed for reliable compliance, operational efficiency, and long-term cost savings.
Filter-less Technology
No filter bags or cartridge replacements required throughout operation.
Minimal Maintenance
Automated cleaning minimizes manual intervention and downtime.
Retrofit Ready
Easily integrates into existing industrial ducting and stack systems.
Multi-fuel Compatibility
Efficiently handles coal, biomass, briquettes, husk, pet coke, and more.
Temperature Resilient
Stable performance even under fluctuating load and temperature conditions.
Compact Footprint
Space-efficient tubular design suitable for constrained industrial layouts.
High Collection Efficiency
Delivers superior PM reduction across a wide range of industries.
Continuous Operation
Supports uninterrupted plant operation with minimal shutdown requirements.
Lower Lifecycle Cost
Significantly reduces long-term operating and maintenance expenses.
Custom-Engineered
Tailored solutions designed around your fuel, stack, and emission profile.
Industries We Serve
CarbonFree™ APCD is engineered for diverse industrial sectors dealing with high particulate emissions and stringent compliance requirements.
Cement & Lime
Rotary kilns, clinker coolers, and lime kilns operating on coal, pet coke, and RDF fuels.
Steel & Metallurgy
Blast furnaces, reheating furnaces, foundries, and cupola-based industrial operations.
Power Plants
Coal-fired and biomass-fired boilers in captive and commercial power generation facilities.
Chemical & Petrochemical
Process heaters, calciners, and fired systems handling fine and reactive particulate emissions.
Glass & Ceramics
Glass melting furnaces, tunnel kilns, and ceramic manufacturing operations with high PM loads.
Textile & Paper
Thermic fluid heaters and industrial boilers operating on coal, biomass, and briquettes.
Brick & Refractory
Zig-zag kilns, bull trench kilns, and refractory manufacturing processes requiring emission control.
Food & Pharma
Industrial ovens, process heaters, and food-grade manufacturing plants with boiler-based operations.
Built for Every Boiler Capacity
Modular CarbonFree™ APCD configurations engineered for every industrial boiler, furnace, and flue gas volume requirement.
Small Manufacturing Units
Compact APCD systems designed for low-flow industrial boilers, ovens, and small furnace operations.
Textile, Food & Chemical
Mid-range configurations optimized for thermic fluid heaters, process boilers, and manufacturing plants.
Process Industries
High-efficiency systems engineered for cement, metallurgy, paper, and medium-scale industrial operations.
Large Industrial Plants
Heavy-duty APCD solutions for power plants, integrated steel units, and large-scale continuous process industries.
CarbonFree™ APCD vs. Conventional Technologies
How the hybrid Cyclone + Tubular ESP system compares with common alternatives.
| Parameter | Bag Filter | Wet Scrubber | Standalone Cyclone | CarbonFree™ APCD |
|---|---|---|---|---|
| Working Principle | Fabric filtration | Gas–liquid contact | Centrifugal separation | Cyclone + Tubular ESP + Auto-clean |
| Fine PM Efficiency | High | Moderate | Low | High — engineered for 50 mg/Nm³ |
| Consumable Cost | High — bag replacements | High — water + effluent | Very low | Negligible — filter-less |
| Pressure Drop | High | Moderate | Low | Low — reduced fan power |
| Sticky / Moist Dust | Difficult to handle | Suitable | Limited | Suitable via water-assisted cleaning |
| Maintenance Intensity | High | High — effluent handling | Low | Low — automated cleaning |
| Lifecycle Cost | High over time | High over time | Inadequate for compliance | Lowest TCO over 10 years |
Engineered for CAQM Direction No. 98
CarbonFree™ APCD is purpose-built to help Delhi-NCR industries meet the uniform 50 mg/Nm³ PM emission standard with reliable, long-term compliance.
Industries Falling Under the New Norm
The 50 mg/Nm³ particulate emission standard applies to multiple industrial sectors operating in Delhi-NCR and surrounding regions.
- 17 CPCB-identified highly polluting industry categories
- Red-category medium and large air-polluting industries
- Food & food-processing units with boilers or thermic fluid heaters
- Textile industries operating boilers or TFHs
- Metal industries operating furnaces in Delhi-NCR
Two Critical Deadlines to Plan For
Industries are required to install or upgrade APCD systems within the timelines proposed under CAQM Direction No. 98.
- 31 July 2026 — Medium and large industries
- 30 September 2026 — Remaining covered industries
Fits Every Industrial Boiler, Furnace & Kiln — No Exceptions
Talk to Our Engineering Team
Request a site assessment, technical consultation, or a custom APCD quote tailored to your fuel type, flue gas characteristics, and stack requirements.