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Corporate Communication

Copyright © Transparent Technologies Pvt. Ltd. All rights reserved

New Generation

Super Efficient, Energy Conserving &

Eco-sustainable Solutions for WHR in

Cement Plants

1

www.tespl.com

13/6/2016 Corporate CommunicationCopyright © Transparent Technologies Pvt. Ltd. All rights reserved

Group companies

Company Name Business

Transparent Energy Systems Pvt. Ltd.

www.tespl.com

Waste Heat Recovery

Systems

Transparent Technologies Pvt. Ltd.

www.ttpl.co.in

Industrial Dryers, Flue

Gas Desulphurization

Systems etc

Transparent Pollution Control Pvt. Ltd.

www.transpol.co.inAir Pollution Control

Decimin Control Systems Pvt Ltd

www.decimin.comNoise Abatement

13/6/2016



Innovative Solutions for Cement

Industries.

• Waste Heat Recovery Systems

• FGD Plants for SOx removal and Gypsum making

• Wet Fly Ash Drying Plants

• Waste Water Recycling Plants

• Bag Filter

• Coal Dryer

• New Generation Captive Power Plants


• Pioneers in WHRS in cement plants.

• 11 WHRS Projects completed within 10 years – 2006-2016.

• More than 30 WHR Boilers installed in 11 projects

• Total installed capacity – 80 MW

• In-house R&D center with IP base of more than 40 patents

• Manufacturing facility with IBR, ASME and EN certifications

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Award from DSIR


Award from SIEMENS

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WHR Schemes Implemented

• Steam Rankine Cycle Power Plant

• Organic Rankine Cycle Power Plant (ORC)

• Steam Rankine Cycle with Co-firing

• Heat Injection into Captive Power Plant

13/6/2016Corporate Communication


Ultratech Cement Ltd., Tadipatri,

�Organic Rankine Cycle Power Plant

�Clinker Production – 2.5 Million TPA

�Source – Clinker Cooler

�Gross Power Generation – 4 MW

�Air cooled condensing

�Commissioned – March 2007

Note – WHR system supplied by TESPL to client & Organic Power Generator

sourced by client directly from ORC supplier

TESPL’s Experiences (cement WHR)

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The KCP Ltd., Macherla, AP

�Steam Rankine Cycle Power Plant

�Clinker Production – 0.5 Million TPA

�Source – Preheater and

Clinker

Cooler

�Gross Power Generation – 2.3 MW

�Water cooled condensing

�Commissioned – April 2007



Shree Cement Ltd., Beawar, Rajastan

Project - I

� Steam Rankine Cycle Power Plant

� Clinker Production – 1 Million TPA

� Source – Preheater

� Gross power generation – 5 MW

� Water cooled condensing

� Commissioned – March 2008


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Shree Cement Ltd., Beawar, Rajastan

Project – II


� Clinker Production – Kiln – 1 : 1 Million TPA

Kiln – 2 : 1.5 Million TPA

� Source – Preheaters & Clinker Coolers

� Gross power

generation – 13.2 MW on waste heat from

cement plant

& 3.0 MW on heat from other

sources

Total 16.2 MW

� Air cooled condensing

� Status : Commissioned June 2010



Ultratech Cement Ltd. Awarpur, MH


� Clinker Production – Kiln 1 – 1.30 Million TPA

Kiln 2 – 1.53 Million TPA

� Source – Preheaters and Clinker Coolers

� Gross power generation – 13.22 MW

� Air cooled condensing

� Status : commissioned on April 2014


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HOLCIM Rozonik – Slovakia

�Organic Rankine Cycle Power Plant

�Clinker Production – 1 Million TPA

�Source – Preheater and Clinker Cooler

�Gross Power Generation – 5 MW

�Water cooled condensing

�Status : commissioned on Sept 2013



Aditya Cement (Line III) – 6.5 MW


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Critical Review of Waste Heat

Recovery Projects


Need for Review –

1. Unsustainable Prices

2. Cost overruns and delays in execution

3. Performance Variations

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Critical Review of WHR Power Projects

• Most of the BUYERS in past had procured

Captive Power Plant under EPC contracts.

• There was natural preference to order the

WHR Power plant on the same EPC basis.

• However the WHR power plants were much

more complex as compared to a CPP.




• Each WHR Power plant is tailor made and

has complexities –

� Integration with process

� Execution is a running plant

� Layouts undergo change during execution

� Uncertainties on various cost heads

� Unanticipated delays in execution

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• Most of the over-eager bidders either

overlooked these complexities or were

too inexperienced to anticipate the

complexities.

• Such bidders offered the prices that did

not provide for any of these

complexities and uncertainties.




• The BUYER had a compulsive

preference for L1 bidder, with a belief

that –

“Once locked in legally enforceable fixed

price contract, the vendor has no

escape but to complete the project

whether affordable or not.”

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• The BUYER’s compulsive preference for

L1 bidder, forced even experienced

bidders to make unsustainable

compromise on price to at least stay in

business.

• The BUYER could thus draw a

satisfaction of having made a

competitive procurement contract.




• The experienced players having long term

interest patiently tolerated cost over runs,

but completed the projects.

• The inexperienced players with no long term

vision abandoned the projects half way,

forcing BUYERS to complete the project by

themselves with heavy cost over run and

inordinate delays.

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• The loss of projected savings due to

delayed projects proved to be much

higher than the satisfaction of

competitive procurement.




Performance Variations –

1. Variance in actual exhaust gas parameters

2. Absence of online measurement performance

monitoring instrumentation.

3. Absence of a Standardized Performance Test

Procedure

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Fundamental decisions for next WHR

Power Projects for each BUYER –

• Is EPC Model of Procurement really most

beneficial?

• Does the policy of compulsive preference for

L1 Bidder needs a review?



New Generation WHR Plants

• Improve the accuracy of cost estimation before entering into firm price contract

• Thorough planning for imely project completion.

• Provide facility for online measurement of all vital parameters.

•Evolve a Performance Test Procedure based on a universally accepted standard.

26

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New Generation WHR Projects in Cement Plants

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Prominent Features of New Generation WHR Projects in Cement Plants

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13/6/2016

•Three Phase Execution Methodology

•Online Real time measurement & logging of Vital process parameters

•Innovative Mid Tap Control System.

•Steam Dryness improvement at Super-heater Inlet



EPC Business Methodology for Successful Projects

Project is divided in Critical Phases of the project with milestones for both EPC / Managed EPC Contract

▪Phase -1 : System Optimization, Detailed Engineering, Accurate Project Cost Estimation,

▪Phase -2 : Actual Procurement

▪Phase -3 : Site Activities, Erection & Commissioning, Performance Trials

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13/6/2016



Phase -1 Activities

•Work jointly with End User

•Conceptual Engineering & System Optimization

•Facility planning

•Performance test procedure

•Real time on line recording of all vital input-output

parameters at different locations in the system

3013/6/2016



Phase -1 Activities

•G.A. Drawings / Layouts, P+I diagrams.

•Engineering Specifications / BOM / BOQ.

•Detailed engineering.

•BOM / BOQ / Material costs / Fabrication costs.

•Packing & forwarding transport.

•Unloading / shifting to foundation / site work / cabling /

insulation, piping, structural etc.

31

13/6/2016



Advantages of Phase-1

•Finally reach a stage in Phase-I where in Accurate Cost Estimation is possible for procurement process to be initiated.

•This eliminates surprises with reference to quantity & specifications of materials, their costs, project schedules etc.

•Performance Test Procedures are also prescribed. – No Disputes related to Input & Output parameters.

32

13/6/2016



Phase – 2 Procurement Activities

1. Waste Heat Recovery Boiler

2. Steam Turbine Generator Module

3. Air Cooled Condenser

4. Balance of Plant

5. Site Work (including Civil Work)

33

13/6/2016



Phase – 3 Activities

•Site Work Management

• Commissioning

• Performance trials

•Trouble shooting & Warrantee Services

• Post warrantee services

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Performance –Assurance and Monitoring

•Online Real-time Flue Gas Flow Measurement

•Online Real Time Dust Measurement System

•Dual Mid Tap Control System

•Steam Dryness improvement at Super-heater Inlet

35


Measurement of Vital Parameters

•Online Real-time Flue Gas Flow Measurement

▪One of the most important parameter in Validation of WHR Project Performance.

▪Indirect method for Flue Gas Flow measurement is recommended by ASME-PTC-4.4 and it is universally accepted

▪The new generation WHR from TESPL will include a separate elaborate system to measure the online and real-time flue gas flow rates by indirect method.

36

13/6/2016



Measurement of Vital Parameters

• Online Real Time Dust Measurement System

▪One of the most important parameter in Validation of WHR ProjectPerformance.

▪The Dust Content in Flue gas may affect WHR System Performance.

▪New generation WHR Project from TESPL will include online dust measurement system.

▪TESPL has applied for the Patent for online dust measurement system.

37

13/6/2016



Innovative Mid Tap Control System

•Dual Mid Tap Control System▪Without Booster Fan▪With Booster Fan

•Using this control system consistency in Flue gas temperature at Boiler inlet can be achieved.

•TESPL has applied for the Patent for innovative Mid Tap Control System

38

13/6/2016



Steam Dryness improvement at Super-heater Inlet

•Super efficient, Cyclonic type Drum Internals are provided to minimize droplets carried over in the saturated steam.

•Additional external cyclonic separator is provided at super-heater inlet to remove carried moisture / condensate at the super heater inlet.

•This reduces moisture load on super-heater, reduces scale formation in super-heater and also maintains the designed gas temperature profile in the WHRS.

39

13/6/2016



New Generation WHR Projects

•Cost effective project implementation.

•Timely bound completion of project

• No variance in performance

• Online performance monitoring

NEXT

40

13/6/2016



Flue Gas Desulfurization (FGD)

Plant for Captive Power Plants

CII - WEbinar

byMr. Ajit Apte

Next



Flue Gas Desulfurization (FGD)

•Removal of Sulfur Emissions

from Exhaust Gases

•Source of Sulfur Emissions –

Sulfur in fuel burns with coal

to form sulfur dioxide (SO2)

13/6/2016



Need of FGD Plants

• Use of Low Cost Fuels – Pet Coke, Imported Coal,

Lignite

• These fuels have high sulfur content (3 to 8%)

• High sulfur pyrites in limestone

• SO2 emissions from combustion of these fuel and

pyrites in the kiln

• Recent SO2 norms published by MOEF -

• FGD process – absorption of SO2 and generation of

bi products



What is FGD?

• Exhaust gas is scrubbed with wet reagent

• SO2 reacts with the reagent to form by-

product

• By-product is separated and un-reacted

reagent is recycled.

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FGD Processes

13/6/2016

Processes Reagent used By-Product Formed

I. Wet FGD Processes

Limestone Gypsum Process Limestone Gypsum

Soda ash / Caustic Soda ProcessSoda Ash or Caustic

SodaSodium Bisulfite

Ammonia Process Ammonia Ammonium Sulfate

Seawater Process Seawater None

II. Semi-dry FGD Processes

Flash Absorption Process (FAP) Lime or Hydrated LimeCalcium Sulfite and

Sulfate

Spray Dryer Absorber (SDA)

ProcessLime or Hydrated Lime

Calcium Sulfite and

Sulfate



Selection Criteria

•Cost and availability of reagent

•Revenue / Disposal of by-Product

•SO2 content in exhaust gas

•SO2 emissions regulations

•Utility consumption – Power and Water

•Type of user Industry

13/6/2016



Choice of FGD for Cement Plants

Wet Limestone Gypsum Process

• Limestone - Low cost & Easy Availability

• By-product – Gypsum for Captive Use

• Most effective for high sulfur fuels

including pet coke

• Output Emissions < 600 mg

• No solid waste generation & disposal

• Negligible Effluent Generation



WET LIMESTONE GYPSUM PROCESS

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Chemical Reactions

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Wet FGD - Limestone Gypsum Process

1 CaCO3 (s) + SO2 (g) + ½ H2O (l) CaSO3. ½ H2O (s) + CO2 (g)

Limeston

e

Sulphur

Dioxide

Water Calcium Sulphite

Hemihydrate

Carbon

Dioxide

2 CaSO3. ½ H2O (s) + 3/2 H2O (l) + ½ O2 (g) CaSO4.2H2O (s)

Calcium Sulphite

Hemihydrate+ Water + Oxygen Gypsum


Copyright © Transparent Technologies Pvt. Ltd. All rights reserved 13/6/2016

Schematic Diagram



FGD PLANT - LIVE CASE STUDY



Key parameters

• Power Plant Capacity: 44 MW (22 MW x 2 nos)

• Fuel: Petroleum Coke with 7-8 % Sulphur

• Reagent Used: Low Purity Limestone (78%)

• By-product: Gypsum (Purity – 73%, 15%

Moisture)

• Status: Commissioned in Feb 2012

• Exhaust Gas Flow: 280000 m3 / hr

• Temperature: 140 Deg C

• Inlet SO2: 11420 mg / Nm3

• SO2 removal Efficiency: 92 %

13/6/2016



Key parameters

• Electricity Consumption: 950kW

• Lime Stone (78% purity) Consumption: 4300 kg / hr

• Water Consumption: 18 m3 / hr

• Gypsum Generation (73% purity on dry basis):

� On Wet Basis (12-15% moisture) : 7500 kg/hr

� On Dry Basis (approx) : 6500 kg/hr



Installation Photographs

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FGD Economics for typical CPP

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Power Plant Capacity MW 27

Total Fuel Consumption TPH 15

Sulphur Content in Pet Coke (75 %) Wt% 7

Sulphur Content in Lignite (25 %) Wt% 3.0

SO2 in exhaust gas

kg / hr 1800

mg / Nm3 12077

ppm 4227

SO2 Removal Efficiency required to achieve

< 600 mg/Nm3% 95

Gypsum Generation on wet Basis (15 %

moisture )kg / hr 6600

Limestone Consumption ( 80 % Purity ) kg / hr 3674



FGD Economics for Typical CPP

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Limestone Cost ( 300 Rs / ton ) Rs / hr 1102

Power Consumption kWh 1150

Power cost (3.0 Rs / kWh) Rs / hr 3450

Water Consumption m3 / hr 13

Water Cost (25 Rs/m3 ) Rs / hr 325

FGD Plant Running Cost Rs / hr 4877



FGD Economics for Typical CPP

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FGD Gypsum Cost Rs / Ton 740

Equivalent Market Price for mineral

Gypsum ( 73% Purity )Rs / Ton 4000

Revenue Generation from FGD Gypsum

(benefit of pet coke against coal is to be

considered separately)

Rs / Ton 3260

Rs / Hr 21516

Lacs / Annum

(8000 hrs)1721.3

Investment Rs in Lacs 2700

Pay Back Period Years < 2



Project Execution Project Execution

Methodologies for FGD plantsMethodologies for FGD plants

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Copyright © Transparent Technologies Pvt. Ltd. All rights reserved 61

FGD plant executionFGD plant execution

� Engineering

� Procurement

� Construction


13/6/2016

Schematic Diagram



FGD Plant Site Activities

� FGD Tower manufacturing & erection

� Oxidation tank manufacturing & erection

� All ducting fabrication & erection

� All piping (Slurry circulation, Slurry transfer, filtrate

return etc)

� Anti corrosive lining on FGD tower & Oxidation tank

� Erection assembly, & testing of all bought out

components

� Wiring, Cabling & instruments fitting


64

Proposed execution optionsProposed execution options

Option I- Engineering Services for FGD Plant (All

procurement to be done by CLIENT)

Option II- Engineering & Procurement Services

for FGD Plant (Procurement by TTPL, Payment

Directly by CLIENT to suppliers)

Option III- EPC (Turn Key - Engineering,

Procurement & Construction) excluding civil

13/6/2016



Option I- Engineering Services

� Basic Engg, P & I Diagrams, G.A. Drawings/ Layouts

� Specifications of equipments & Bought outs

� Specifications for Electrical components & wiring, All

input specifications & battery limits, Specifications of

anticorrosive lining

Phase II- Execution Services

� Detail engineering, manufacturing drawings,

assembly drawings, hook up drawings, electrical wiring

drawings, load data for civil design

Phase I- Design & Engg Services


66


� Support to client for procurement planning

� Participation in procurement process, summarization

of vendor offers, Due diligence and selection of vendors,

techno commercial discussion and negotiation

� Project Supervision and inspection services

� Overall project coordination

� Stage wise inspection, Inspection after installation

� Site work supervision, monitoring & controlling

Phase II- Execution Services Continued..

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� Pre Commissioning & commissioning of individual

equipments

� Commissioning of the plant

� Provisional performance trials

� Final Performance trials

� Operation & Maintenance manual, training & handing

over

Phase III- Pre-Commissioning & Commissioning Services


68

Option II- Engineering Services & Procurement

�In addition to engineering services provided on option

I, TTPL will also do actual ordering & co-ordination

� Fund provision for the project, payment to suppliers,

freight & insurance shall be arranged by client directly

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Option III- EPC (Excluding Civil)

� Engineering, Procurement & construction shall be

done by TTPL

� Entire civil work will have to be carried out by Client.


70

Initial Investment with all 3 options

All Prices are Rs. in Lacs

Sr.

No.

Description Option I

(Engineering

Services)

Option II

(Engineering &

Procurement

Services)

Option III

(EPC)

Major

Bough

t Outs

Indian

Make

Major

Bough

t Outs

Chine

se

Make

Major

Bough

t Outs

Indian

Make

Major

Bough

t Outs

Chine

se

Make

Major

Bough

t Outs

Indian

Make

Major

Bough

t Outs

Chine

se

Make

1 Estimated Cost of Raw Material & Bought out

Components, Site

Activities

1320 1095 1320 1095 1320 1095

2 Cost of Services for TTPL 716 716 765 765 1360 1283

3 Total Project Cost 2036 1811 2085 1860 2680 2378

4 Cost of Civil Budget Estimate

70-90 70-90 70-9013/6/2016



THANK YOU!visit us www.tespl.com

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new generation group companies super efficient, energy ...€¦ · organic rankinecycle power plant...

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