INTRODUCTION

There are many places in our country, where we get different types of metallic substances as

raw material for industries. In these substances, the metals are present in compound form.

These substances are called as minerals. Minerals are mostly present as oxides, sulphides,

carbonates, chlorides and silicates. Those minerals from which we can get the metals

conveniently and at low cost are called ores. Less reactive metals, as gold, silver, platinum

etc. are obtained in free state in nature. Copper is basically obtained as copper pyrites

(CuFeS2). It is obtained from mainly the states Rajasthan, Bihar, Madhya Pradesh, Orissa,

Karnataka etc. Iron is obtained from Hametite (Fe2 O3 ), from the states Madhya Pradesh,

Andhra Pradesh,Tamil Nadu, Karnataka, Goa, Maharashtra. Zinc is mainly obtained from its

ore ZicsBlende (ZnS) available mainly in the states Rajasthan and Orissa.

Plenty of minerals are obtained in Rajasthan. The Jawara Mines in Udaipur are famous as a

source of zinc all over the world. Bhilwara , Beawar, Ajmer, Dungarpur, Banswara, and Tonk

are the famous places as a source of mica.

The minerals as obtained from these mines, after passing through various physical and

chemical processes in the zinc smelter plant give pure metal. The mines that have been

established for the extraction of these minerals are as follows:

Rajasthan,

Vishakhapatanam,

Tundu,(Bihar)

Sargipalli,

Agnikundala, and

Vijag zinc smelter.

There are mainly six plants of Hindustan zinc limited in Rajasthan, two of which are zinc

smelter and four are the mines for the raw material. These are as follows:

1

Chapter-1

1.1 Smelters:

1) Chanderia Lead Zinc Smelter,

2) Debari Lead Zinc Smelter,

1.2 Mines:

1) Jawara Mines

2) Rampura Agoocha Mines

3) Rajpura Dariba Mines

4) Maton Rock Phosphate Mines.

1.3 Aims of an industry:

1) To produce goods

2) To have continuous production

3) To produce goods at low cost

4) To produce goods of high quality

5) Have long life of equipment.

1.4 Problems/interruption with an industry:

1) Break Down

2) Power Failure

3) Industrial relation problem

4) Fire and Explosives.

1.5 Uses of Zinc:

1) Zinc Powder

2) Bras Items

3) GI pipes

4) CuSO4

2

1.6 Uses of Lead:

3

1) Die Casting

2) Powder Cable

3) Battery.

1.7 Mission of CLZS:

Be a lowest cost zinc producer on a global scale, maintaining market leadership.

One million tone zinc-lead metal capacity by 2010.

Be innovative, customer oriented and eco-friendly, maximizing stake holder value.

Refined zinc production capacity 69,000 tons per annum.

Refined lead production capacity 85,000 tons per annum.

4

Figure 1.1 Location Of HZL Plants

5

SAFETY

2.1 What is Safety:-

S- Sound thinking concerning the nature of job.

A- Alertness to anger.

F- Factorizing the entire operation into safe sequence.

E- Efficiency in carefully performing the work.

T- Thoughtfulness for the welfare of the group in which the worker is attached to.

Y- You and your protection at your job.

Accidents is most unwanted interruption because it involves human life and the main effects

of accidents are :

a. Stopping of production.

b. Human suffering.

c. Loss of good skilled employees.

d. Material loss.

e. Demoralizing effect on employees and society.

f. Legal proceeding.

g. Harassment to management.

h. Compensation.

2)

6

Chapter-2

2.2 Safety Materials:

1) Safety Belt.

2) Safety Shoes.

3) Ear Muff.

4) Face Shield.

5) Helmet.

6) Ear Plug.

7) Safety Glass

8) Breathing Set.

9) Acid proof glass.

10) Air stream helmet.

11) Dust and gas mask.

Safety precautions should be taken by Electrical Engg. trainees at CLZS are as follows:

a. Always wear the protective helmet in plant.

b. Do not wear the loose and nylon clothes.

c. Always wear rubber and strength shoes.

d. Do not roam in the plant without any supervision of instructor.

e. Do not touch any machine or switching parts.

f. Always keep distance from fast moving machine.

g. Do not visit silver refinery and acid plant without any written permission.

h. Always wear ear mask in plant because heavy machines produces huge noise

which is very harmful to ears.

i. Always wear mouth mask in plant because certain poisonous gases like CO,

SO2, CO2, smoke dust etc. are very harmful for human health.

8

9

Chapter-3

CAPTIVE POWER PLANT

4.1 What Is Cpp :

Captive power plants (CPP) are those power plants which operate independent of wheeling to

grid! They are mostly meant by in-house power generation for industry and not selling the

power to grid of electricity boards.

In Hindustan Zinc there are many plants running like hydro plant, pyro plant, NZP (new zinc

plant) and other required huge amount of electric energy. So to fulfill their requirement CPP

is setup which provide amount of required electricity to this plant and in certain cases excess

electricity is produced which is to be sold to the market.

4.2 Need Of Cpp :

There is a huge shortfall in power and an even bigger gap when it comes to peak power. With

an installed generation capacity of 1,43,000 MW, more than 400 million have no access to

energy. To meet the ever growing demand from industry, and to cater to those with no access,

India has to double its capacity in the next four years.

A quicker way to address the problem would be to bring in innovative regulations. For

instance, make all large industrial units employing over 5000 people compulsorily build

captive power plants (CPPs) for their requirements.

4.3 Electricity Sector in India:

The electricity sector in India is predominantly controlled by government of India’s public

sector (PSU). Major PSU’S:

National Thermal Power Corporation (NTPC).

National Hydroelectric Power Corporation (NHPC).

Nuclear Power Corporation of India (NPCI).

The intra state distribution is managed by the state Electricity board (SEB).

INDIA is world’s 6th largest energy consumer, accounting for 3.4% of global energy

consumption.

10

Chapter-4

4.4 National Capacity% :

Thermal : 75%

Hydel : 20%

Nuclear : 4%

Others : 1%

4.5 CPP Chanderiya :

A power plant is an industrial facility for the generation of electric power.The power

produced in Hindustan zinc Limited is for its own production purposes,and is known

as a Captive Power Plant(CPP).

While supplying uninterrupted and reliable power to Chanderiya Lead Zinc Smelter,

the CPP has been additionally wheeling power to its Agucha, Debari and Dariba units

of Hindustan Zinc Limited.

Recently sale of power has also been initiated with both RSEB and power exchange.

Captive Power Plant in Chanderiya consists of 3 units (2X77 MW + 1X80 MW).

All three units are supplied by BHEL, Hyderabad.

Figure 4.1 Captive Power Plant

11

THERMAL POWER PLANT

Figure 5.1 Thermal Power Plant

Thermal Power Station produce electricity by burning fuel in a boiler to heat water to

produce steam. This steam at high pressure rotates the blades of a turbine which spins

a generator to produce electricity. The steam further cooled in a condenser to form

water and sent again to boiler. And the gases produced are sending in to the

atmosphere with the help of chimney.

12

Chapter-5

BASIC OPERATION OF THERMAL POWER PLANT

Coal conveyor

Stoker

Pulverizer

1) Ball and Tube Mill

2) Ring and Ball

Boiler 

1) Fire tube boilers

2) Water tube boilers

Condenser 

Air Preheater

Electrostatic precipitator

Smoke stack

Cooling Towers

6.1 Coal conveyor:

This is a belt type of arrangement. With this coal is transported from coal storage place in

power plant to the place nearby boiler.

6.2 Stoker:

The coal which is brought nearby boiler has to put in boiler furnace for combustion. This

stoker is a mechanical device for feeding coal to a furnace.

6.3 Pulverizer:

The coal is put in the boiler after pulverization. For this pulverizer is used. A pulverizer is a

device for grinding coal for combustion in a furnace in a power plant. 

6.4 Types of pulverizer:

Ball and Tube Mill.

13

Chapter-6

Ring and Ball.

6.5 Boiler:

Now that pulverized coal is put in boiler furnace. Boiler is an enclosed vessel in which water

is heated and circulated until the water is turned in to steam at the required pressure. 

Coal is burned inside the combustion chamber of boiler. The products of combustion are

nothing but gases. These gases which are at high temperature vaporize the water inside the

boiler to steam. Sometimes this steam is further heated in a super heater as higher the steam

pressure and temperature the greater efficiency the engine will have in converting the heat in

steam in to mechanical work. This steam at high pressure and temperature is used directly as

a heating medium, or as the working fluid in a prime mover to convert thermal energy to

mechanical work, which in turn may be converted to electrical energy.

6.6 Classification of Boilers:

Fire tube boilers:

Figure 6.1 Fire Tube Boilers

14

In fire tube boilers hot gases are passed through the tubes and water surrounds these

tubes.  These are simple, compact and rugged in construction. Depending on whether

the tubes are vertical or horizontal these are further classified as vertical and

horizontal tube boilers. In this since the water volume is more, circulation will be

poor. High pressures of steam are not possible, maximum pressure that can be

attained is about 17.5kg/sq cm. Due to large quantity of water in the drain it requires

more time for steam raising.

Water tube boilers:

Figure 6.2 Water Tube Boilers

In these boilers water is inside the tubes and hot gases are outside the tubes. They

consist of drums and tubes. Feed water enters the boiler to one drum (here it is drum

below the boiler).This water circulates through the tubes connected external to drums.

Hot gases which surround these tubes will convert the water in tubes in to steam. This

steam is passed through tubes and collected at the top of the drum since it is of light

weight. So the drums store steam and water (upper drum).The entire steam is

collected in one drum and it is taken out from there (see in layout fig).As the

15

movement of water in the water tubes is high, so rate of heat transfer also becomes

high resulting in greater efficiency. They produce high pressure, easily accessible and

can respond quickly to changes in steam demand.

6.7 Condenser:

Steam after rotating steam turbine comes to condenser. Condenser refers here to the shell and

tube heat exchanger (or surface condenser) installed at the outlet of every steam turbine in

Thermal power stations of utility companies generally. These condensers are heat exchangers

which convert steam from its gaseous to its liquid state, also known as phase transition. In so

doing, the latent heat of steam is given out inside the condenser. Where water is in short

supply an air cooled condenser is often used. An air cooled condenser is however

significantly more expensive and cannot achieve as low a steam turbine backpressure (and

therefore less efficient) as a surface condenser. 

6.8 Economizer:

Flue gases coming out of the boiler carry lot of heat. Function of economizer is to recover

some of the heat from the heat carried away in the flue gases up the chimney and utilize for

heating the feed water to the boiler. It is placed in the passage of flue gases in between the

exit from the boiler and the entry to the chimney. The use of economizer results in saving in

coal consumption, increase in steaming rate and high boiler efficiency but needs extra

investment and increase in maintenance costs and floor area required for the plant.

6.9 Air Preheater:

The remaining heat of flue gases is utilized by air preheater. It is a device used in steam

boilers to transfer heat from the flue gases to the combustion air before the air enters the

furnace. Also known as air heater, air-heating system.

6.10 Electrostatic precipitator:

16

It is a device which removes dust or other finely divided particles from flue gases by charging

the particles inductively with an electric field, then attracting them to highly charged collector

plates. Also known as precipitator. 

6.11 Cooling Towers:

Figure 6.3 Cooling Towers

The condensate (water) formed in the condenser after condensation is initially at high

temperature. This hot water is passed to cooling towers. It is a tower- or building-like

device in which atmospheric air (the heat receiver) circulates in direct or indirect

contact with warmer water (the heat source) and the water is thereby cooled.

17

TURBINE

7.1 Principle of Turbine:

Steam is allowed to expand through narrow orifice, the kinetic energy is converted into

mechanical energy through the reaction of steam against the blade.

Steam moves continuously through blades as a result pressure exerted on the blade.

7.2 Steam Turbine:

A turbine is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. A turbine is a turbo machine with at least one moving part called a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades so that they move and impart Rotational energy to the rotor. 

7.3 Types of Turbines:

a. Impulse Turbine:

An impulse turbine has fixed nozzles that orient the steam flow into high speed jets. These

jets contain significant kinetic energy, which the rotor blades, shaped like buckets, convert

into shaft rotation as the steam jet changes direction. A pressure drop occurs across only the

stationary blades, with a net increase in steam velocity across the stage.As the steam flows

through the nozzle its pressure falls from inlet pressure to the exit pressure (atmospheric

pressure, or more usually, the condenser vacuum). Due to this higher ratio of expansion of

steam in the nozzle the steam leaves the nozzle with a very high velocity. The steam leaving

the moving blades is a large portion of the maximum velocity of the steam when leaving the

nozzle. The loss of energy due to this higher exit velocity is commonly called the "carry over

velocity" or "leaving loss".

18

Chapter-7

b. Reaction Turbine:

In the reaction turbine, the rotor blades themselves are arranged to form convergent nozzles.

This type of turbine makes use of the reaction force produced as the steam accelerates

through the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of

the stator. It leaves the stator as a jet that fills the entire circumference of the rotor. The steam

then changes direction and increases its speed relative to the speed of the blades. A pressure

drop occurs across both the stator and the rotor, with steam accelerating through the stator

and decelerating through the rotor, with no net change in steam velocity across the stage but

with a decrease in both pressure and temperature, reflecting the work performed in the

driving of the rotor.

7.4 Turbine Specification:

Type of turbine : high press, high temp

Rotation speed : 3000 rpm

Rated power : 77MW

Main steam inlet pressure

: 90kg/cm2

Rated steam flow inlet : 286.4 T/hr

19

Stage of heaters : 2LP, 1deaerator&2HP

Heat rate : 2640 kcal/kwhr

MOTORS

An electric motor is an electric machine that converts electrical energy into

mechanical energy.

Motor one part is known is non driving part as it is not a rotating part or functioning

any work.

2nd part is known as driving part as it is rotating some part of the motor

there is a standard vibration value given for each machine, at this value the machine

will function properly after crossing that limit there may be any damage arises in the

machine like fans break etc.

These standard values are set according to the size of the machine.

These motors are having radiators which are used to cool the heat produced inside the

motor. These are made in the form of plates as to increase the cooling faster

applicable for small motors.

20

Chapter-8

Large motors outer surface is round as it is having inbuilt pipes which take the heat

from the motor and through it out from the other end.

8.1 Types of Motor:

1) Low Tension Motor:

Low tension motors may be define as it connected to low voltage source in three

phase or single phase for three phase voltage 440V ac or less and for single phase

220V ac or less .Drive may be required depended your application for speed to adjust.

You can use dc motors also for your application. We can use these different

applications for blower, pump, drive mechanical load, etc.

In this motor having voltage less than 415v.

2) High Tension Motor:

High tension motors may be define as it connected to high voltage source in three

phase or single phase for three phase voltage 440V or greater and for single phase

220V ac or more.

In this motor having voltage greater than 415V.

21

ELECTRIC GENERATORS

An electric generator is a device that converts mechanical energy to electrical

energy. A generator forces electric current to flow through an external circuit. The

source of mechanical energy may be a reciprocating or turbine steam engine, water

falling through a turbine or waterwheel, an internal, a wind turbine, a

hand crank, compressed air, or any other source of mechanical energy. Generators

provide nearly all of the power for electric power grids.

9.1 Generator Working:

22

Chapter-9

The turbine is attached by a shaft to the turbo generator. The generator has a long,

coiled wire on its shaft surrounded by a giant magnet. You can see the inside of the

generator coil with all its wires in the picture on the right.

The shaft that comes out of the turbine is connected to the generator. When the

turbine turns, the shaft and rotor is turned. As the shaft inside the generator turns, an

electric current is produced in the wire. The electric generator is converting

mechanical, moving energy into electrical energy.

The generator is based on the principle of "electromagnetic induction"  .

23

DIESEL GENERATORS

A diesel generator is the combination of a diesel engine with an electric

generator (often an alternator) to generate electrical energy. Diesel generating sets are

used in places without connection to the power grid, as emergency power-supply if

the grid fails, as well as for more complex applications such as peak-lopping, grid

support and export to the power grid. Sizing of diesel generators is critical to avoid

low-load or a shortage of power and is complicated by modern electronics,

specifically non-linear loads.

There is always a standby for the generators. There are 2 DG in every plant as if the

1st one due to some fault or any other problem get stopped working then the 2nd one

act as a standby takes the place of the 1st one and automatically get started.

Diesel generators, sometimes as small as 200 kW (250 KVA) are widely used not

only for emergency power, but also many have a secondary function of feeding power

to utility grids either during peak periods, or periods when there is a shortage of large

power generators.

10.1 Generator Size:

Generating sets are selected based on the Electrical load they are intended to supply,

the electrical loads total characteristics ( KVA, VAR's and Harmonic)

Content including starting currents (normally from motors) and loads. There are 2

types of winding used in the generators as well as motors

10.2 Armature Winding:

Armature winding is generally is in the rotator which is in the rotating part.

10.3 Field Winding:

Field winding is generally in the stator which is in the stationary part.

24

Chapter-10

TRANSFORMERS

Electrical Power Transformer is a static device which transforms electrical energy from one

circuit to another without any direct electrical connection and with the help of mutual

induction between to windings. It transforms power from one circuit to another without

changing its frequency but may be in different voltage level. 

Figure 11.1 Transformer

11.1 Working Principle:

Say you have one winding which is supplied by an alternating electrical source. The

alternating current through the winding produces a continually changing flux or alternating

flux surrounds the winding. If any other winding is brought nearer to the previous one,

obviously some portion of this flux will link with the second. As this flux is continually

changing in its amplitude and direction, there must be a change in flux linkage in the second

winding or coil. According to Faraday’s laws of Electromagnetic Induction, there must be an

EMF induced in the second. If the circuit of the latter winding is closed, there must be

25

Chapter-11

electric current flows through it. This is the simplest form of electrical power transformer and

this is most basic of working principle of transformer.

Figure 11.2 Principle of Transformer

26

DISTRIBUTIVE TRANSFORMER

A distribution transformer is a transformer that provides the

final voltage transformation in the electric power distribution system, stepping down

the voltage used in the distribution lines to the level used by the customer. If mounted

on a utility pole, they are called pole-mount transformers. If the distribution lines

are located at ground level or underground, distribution transformers are mounted on

concrete pads and locked in steel cases, thus known as pad-mount transformers.

12.1 Major Components:

1) Silica Gel Breather:-

This is a black box placed below the conservative tank. The functioning of this box is to

remove the moisture from the conservative tank. Containing oil.

And make the air inside moisture free. And its work generally its color is blue and when

some moisture contain is there its color changes to pink.

2) Conservative Tank:

This tank contains the oil .and the oil it is containing is the transformer oil. It’s the storage of

the transformer oil.

3) Radiator:

This is the plates placed at the outer side of the transformer for cooling the heat produced

inside the transformer.

Cooling can be done with the help transformer oil and the air.

27

Chapter-12

12.2 Types of Cooling:

1) Oil Natural Air Natural:

In this type of cooling natural oil flowed naturally through the pipes and the natural

atmospheric air passing through the radiator and cooling it.

2) Oil Natural Air Forced:

In this type of cooling naturally oil is flowed but the air is flowing forcefully by the fans

placed under it.

3) Oil Forced Air Forced:

in this type of cooling the oil is flowed forcefully through the pipes and the air which is

produced by the fans placed below it. This type is used for the transformer of 11kv or more.

28

MCC ROOM

MCC is motor control center room . A motor controller is a device or group of

devices that serves to govern in some predetermined manner the performance of an

electric motor. A motor controller might include a manual or automatic means for

starting and stopping the motor, selecting forward or reverse rotation, selecting and

regulating the speed, regulating or limiting the torque, and protecting against

overloads and faults.

The switch may be manually operated, or may be a relay or contactor connected to

some form of sensor to automatically start and stop the motor. The switch may have

several positions to select different connections of the motor. This may allow

reduced-voltage starting of the motor, reversing control, or selection of multiple

speeds. Overload and over current protection may be omitted in very small motor

controllers, which rely on the supplying circuit to have over current protection. Small

motors may have built-in overload devices to automatically open the circuit on

overload. Larger motors have a protective overload relay or temperature sensing relay

included in the controller, and fuses or circuit breakers for over current protection. An

automatic motor controller may also include limit switches or other devices to protect

the driven machinery.

Figure 13.1 MCC Room

29

Chapter-13

13.1 Relays:

A relay is an electrically operated switch,  Relays are used where it is necessary to

control a circuit by a low-power signal (with complete electrical isolation between

control and controlled circuits), or where several circuits must be controlled by one

signal.

Figure 13.2 Relays

30

SWITCH GEARS

In an electric power system, switchgear is the combination of electrical disconnects

switches, fuses or circuit breakers used to control, protect and isolate electrical

equipment. Switchgear is used both to de-energize equipment to allow work to be

done and to clear faults downstream. This type of equipment is important because it is

directly linked to the reliability of the electricity supply.

the switchgear in substations is located on both the high voltage and the low voltage

side of large power transformers. The switchgear on the low voltage side of the

transformers may be located in a building, with medium-voltage circuit breakers for

distribution circuits, along with metering, control, and protection equipment. For

industrial applications, a transformer and switchgear line-up may be combined in one

housing, called a unitized substation or USS.

14.1 Function:

One of the basic functions of switchgear is protection, which is interruption of short-circuit

and overload fault currents while maintaining service to unaffected circuits. Switchgear also

provides isolation of circuits. from power supplies. Switchgear is also used to enhance system

availability by allowing more than one source to feed a load.

14.2 Types:

1) Oil

2) Gas

3) Vacuum

4) Air

31

Chapter-14

UPS ROOM

Uninterruptible power supply (UPS), a power supply that includes a battery to

maintain power in the event of a power outage.

In the power plant there is a UPS ROOM which is having 6-7 inverters of big size.

That are placed in that room, so that if there is a power cut in the power plant due to

some reason,then at that time office computers, control room computers and other

systems require power at that time, then the UPS room supply power to that area or

to that system for a particular time period. So that they should work properly.

There are other parts also of it:

15.1 Battery Charger Room:

The inverters placed in the UPS room get charged in the battery charger room. Here many

panels are there. Which are connected to different systems. From here we can decide which

system actually need the power and give supply to it and which is not require power at that

time cut the supply of it to save the power.

There are 2 types of dc inverters:-

15.2 Float Inverter:

Float is used keep/maintain a level of voltage.

15.3 Booster Inverter:

Boosters are used to boost the voltage so that it gain its level back and function smoothly.

15.4 Battery Room:

In this room large number of batteries are get charged.

31

Chapter-15

Charging of the batteries depend on the load. If the load is high then the batteries will charge

at high rate and if the load is low then the will charge normally .they require 10A to get

charge.

Figure 15.1 UPS Room

32

ELECTROSTATIC PRICEPITATOR

Figure 16.1 Electrostatic Precipitator

An electrostatic precipitator (ESP), or electrostatic air cleaner is

a particulate collection device that removes particles from a flowing gas (such as air)

using the force of an induced electrostatic charge. Electrostatic can precipitators are

highly efficient filtration devices that minimally impede the flow of gases through the

device, and can easily remove fine particulate matter such as dust and smoke from the

air.

We can recover of valuable material like Lead, tin.

Removal of dirt from gases in steam plant.

33

Chapter-16

16.1 Parts:

1) Gas Distributor screen

2) Collecting system

3) Emitting system

4) Insulator housing

16.2 Working Principle:

Electrostatic precipitation is a method of dust collection that uses electrostatic forces, and

consists of discharge wires and collecting plates. A high voltage is applied to the discharge

wires to form an electrical field between the wires and the collecting plates, and also ionizes

the gas around the discharge wires to supply ions. When gas that contains an aerosol (dust,

mist) flows between the collecting plates and the discharge wires, the aerosol particles in the

gas are charged by the ions. The Coulomb force caused by the electric field causes the

Figure 16.2 working of ESP

34

charged particles to be collected on the collecting plates, and the gas is purified. This is the

principle of electrostatic precipitation, and Electrostatic precipitator apply this principle on an

industrial scale. 

16.3 Process:

First of all we use gas distributor screen for separating gases.

We use electrodes for ionization of the gases to get positive and negative ions.

The negative ions and free electrons travel towards positive electrode and positive

ions travel towards negative electrode.

Negative charge attached to dust particles and thus the dust particles are electrically

charged.

The positive and negative particles are collected at the electrodes.

After it the charged dust particles are collect into hoppers.

35

ASH HANDLING SYSTEM

There is a air pressure is given to the ash for moving in pipe line.

We add a filter between air line for removing dust and humidity from air, filter has

oil.

The fly ash is removed from the collection hopper below the precipitator.

Figure 17.1 Ash Handling Plant

Fly ash is captured and removed from the flue gas by electrostatic precipitator located

at the outlet of the furnace.

36

Chapter-17

COOLING TOWER

Figure 18.1 Cooling System

Cooling tower is used to extracts waste heat from the water discharged from the

condenser.

These towers used large fans to force air through circulating water.

There are many pipes which carries hot water from condenser to cooling tower.

37

Chapter-18

The water falls downward over fill surfaces which help increase the contact time

between water and time. From this the heat transfer is maximum.

This process is called mechanical draft cooling tower.

There are some water lose 3%.

The main types of cooling towers are natural draft and induced draft cooling towers

and the classification is based on the type of air induction into the tower.

18.1 De-Mineralization Plant:

De-

mineralization is the process of removing minerals salts from water by using ion

FIGURE 18.2 DE-MINERALIZED

Exchange process which produces pure water used in the boiler

38

COAL SYSTEM

Figure 19.1 Coal System

First small sized raw coal is separated and big sized coal is fed to primary crusher via

conveyor belt.

At primary crusher the size of coal is reduced.

Here is magnetic separator present, which separates the iron particles.

Now the coal is fed to secondary crushes via conveyor belt, here the size of coal is more

reduced to 20mm.

Here a vibrating screen present which is allows only 20mm sized coal to drier through

trolley.

A system is here which is separate other things and a metal detector which detects and

alarmed.

20mm sized coal passes over coal bunker.

Here the pulverizer is present which works as a crusher device through volumetric feeder.

The pulverized coal sized is in micro unit.

It is mixed with air furnace burners.

39

Chapter-19

CONCLUSION

The summer training at Hindustan Zinc Chittorgarh has been a unique experience for

me as it helped me to acquire practical knowledge and trends which is not possible in

practical lab of college.

The practical training at Hindustan Zinc Chittorgarh provided me a golden

opportunity of increase my knowledge in power generation and distribution and to

understand wide application of different types of transformers their design

installation, testing and maintenance of electrical equipment and I had a chance to

watch carefully how the generation of power from thermal plants. I had chance t see

the control operation of different equipments from the control room.

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