SUMMER TRAINING REPORT(Observation based training)

INDIAN FARMER FERTILIZER COOPERATIVE LIMITED .

PHULPUR,ALLAHABAD U.P. INDIA

SUBMITTED BY

AJAY PANDEYB.TECH. (MECHANICAL ENGG.)

4th Year

Aktu Roll no.1313840009

BBSCET, ALLAHABAD

A

REPORT ON

SUMMER TRAINING

at

INDIAN FARMER FERTILIZER COOPERATIVE LIMITED.

Submitted as partial fulfillment of the requirement for the award of

Bachelor degree

In

Mechanical engineering(session: 2016-2017)

SUBMITTED TO SUBMITTED BY MR. AMIT KUMAR SRIVASTAV AJAY PANDEY

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INTRODUCTIONIFFCO is the largest producer and marketer of fertilizers in India with a membership of 37,276 Cooperative Societies and it turn 50 million farmers.

Presence of Cooperative in IndiaFirst legislation for cooperative in India i.e. Cooperative Societies Act, 1904, was enacted to cater to the requirement of credit societies.The National Cooperative Union of India (NCUI) was established in 1929 as an apex promotional organization for strengthening the cooperatives.National Cooperative Development and Warehousing board was set up in 1956.

Growth of Cooperatives in IndiaNational Cooperative Development Cooperation (NCDC) was established in 1963 under NCDC Act 1962 to promote production, marketing and export of agricultural produce.Number of Cooperative Societies increased from 35 thousand in 1965-1966 to 545 thousand in 2002-2003.

Role of Cooperatives in Indian EconomyDuring the year 2002-03, cooperative accounted for:46% of Agriculture Credit disbursement.36% of fertiliser distribution.59% of sugar production.65% of storage facility.

VISIONTo enable Indian farmers to prosper through timely supply of reliable, high quality agricultural inputs and services in an environmentally sustainable manner and to undertake other activities to improve their welfare

MISSION

Augment the incremental incomes of farmers by increasing their crop productivity Maintain environmental health

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Make cooperative societies economically and democratically strong Ensure an empowered rural India through professionalised service to the farming community

IFFCOOn 3 November 1967 Indian Farmers Fertiliser Cooperative Limited (IFFCO) was registered as a Multi-Unit Cooperative Society. It got deemed recognition under the provision of Multistate Cooperative Societies Act 1984 & 2002 later.

1967Membership57 cooperatives

TODAY(2014-15)

Turnover25,048 Crores

Total Production74.70 Lakh MT

Cooperative MembersOver 36,000

With our vast marketing network of over 36,000 cooperative societies we reach more than 5.5 Crores ( 55 million ) farmers in India.

ORIGIN OF IFFCO

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Till the mid 1960's, cooperatives in India had no production facility despite marketing nearly 70% of fertilisers.

There was a need of setting up production facility. IFFCO was established as the farmers' own initiative in Cooperative Sector

on 3rd Nov, 1967 with proposed plants at Kalol and Kandla in Gujarat. With the enactment of Multi State Co-operative Societies Act 2002, IFFCO

is registered as a Multi State Co-operative Society. Since inception, IFFCO has consistently followed transparent, democratic

and professional practices in Corporate Governance.

IFFCO has carved out a strong “Cooperative Identity” and is making sincere efforts to uphold the “Cooperative Values” by cherishing the “Cooperative Principles”.

IFFCO endeavours to achieve highest levels of transparency, accountability and full disclosure to its members to uphold the spirit of Cooperative Principles and Cooperative Values as laid down by the International Cooperative Alliance (ICA).

Initiative has been taken for strengthening IFFCO’s Member Cooperative Societies through a web based Member Portal for enabling them to access information relevant to them.

PLANTS

Initially, IFFCO commissioned an ammonia-urea complex at KALOL and the NPK/DAP plant at KANDLA both in state of Gujarat in 1975.Another ammoni9a-urea complex was set up at PHULPUR in the state of Uttar Pradesh in 1981.The ammonia-urea unit at AMLA was commissioned in 1988.Recently IFFCO has acquired an NPK/DAP and Phosphoric acid fertiliser unit at PARADEEP in Orissa in September 2005.The marketing of IFFCO’s products is channelled through cooperative societies and institutional agencies in over 29 states and union territories of India.

KANDLAInitiated on 24th June 1971 and commissioned for commercial production in January 1975 ,Kandla is one of the oldest IFFCO plant and also a center

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of innovation - R & D Laboratory, at IFFCO Kandla, has taken up the work for development of various new fertilizers.IFFCO Kandla is also an ISO 14001:2004/ OHSAS 18001:2007/ISO 9001:2015 Certified Organization with an established Environmental Management System / Health and Safety Management System /Quality Management System.

PRODUCTION DATAKandla Plant Capacity is 2.42 MMTPA of NPK/DAP Production

PHULPURCommissioned in 1981, this facility has two Urea and two Ammonia production facilities. The IFFCO Phulpur plant is known for taking up and successfully completing many R&D projects. It is a leader when it comes to technology and innovation. The Phulpur facility has many awards and laurels to its name due to its quality and efficient performance. Some of these include the Rajiv Ratna National Award, national productivity council award and many more.

PRODUCTION DATAIn 2014-15 IFFCO's Phulpur plant produced a total of 0.824 MTPA Ammonia and 1.416 MTPA of urea, reaching a new height. It achieved lowest yearly energy consumption for both Ammonia and Urea Plants

ANOLA

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Commissioned in 1988, this 260 hectares’ facility produces ammonia and urea. The facility has been winning a number of awards since 1989 and continues to do so. IFFCO Aonla Unit has received FAI Award for Best Production Performance (Winner) of an operating fertiliser unit for nitrogen (Ammonia and Urea) for Aonla-II for the year 2012-13 from The Fertiliser Association of India.

PRODUCTION DATAThe facility has a capacity of producing 1.148 Million MTPA of Ammonia and 2.000 Million MTPA of Urea.

PARADEEPAcquired from Oswal Chemicals and Fertilisers plant, the plant was commissioned in April 2000.It can produce 2 million tonnes of the fertiliser a year.

PRODUCTION DATAThe plant can produce 2 Million TPA DAP/NPK, 7000 TPD of Sulphuric Acid and 2650 TPD of Phosphoric Acid

Product of IFFCO

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Urea NPK DAP Bio-Fertilizer

UREAUrea is the most important nitrogenous fertilizer in the country because of its high N content (46%N). Besides its use in the crops, it is used as a cattle feed supplement to replace a part of protein requirements. It has also numerous industrial uses notably for production of plastics.If urea is applied to bare soil surface significant quantities of ammonia may be lost by volatilization because of its rapid hydrolysis to ammonium carbonate. The hydrolysis of urea can be altered by the use of several compound called urease inhibitors. These inhibitors inactivate the enzyme and thereby prevent the rapid hydrolysis of urea when it is added to soil. The rapid hydrolysis of urea in soils is also responsible for ammonia injury to seedlings if large quantities of this material placed with or too close to the seed. Proper placement of fertilizer urea with respect to seed can eliminate this difficulty

NPKNPK complex fertilisers produced at Kandla are DAP based grades. At present two grades Grade I - 10:26:26 and Grade II - 12:32:16 are produced.Granular NPK complexes are free flowing and do not pose any problem during handling and storage. However, exposure of material for long period to very high humidity may cause caking. Therefore, NPK complexes are bagged in quality tested HDPE bags to prevent ingress of moisture.

Technical specifications:NPK complex as per Fertiliser Control Order

  NPK-10:26:26

NPK-12:32:16

Moisture % by weight, maximum 1 1

Total N % by weight, minimum 10 12

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  NPK-10:26:26

NPK-12:32:16

Ammoniacal N % by weight, minimum 7 9

N in the form of urea, % by weight, maximum 3 3

Neutral ammonium citrate soluble phosphates (as P2O5) % by weight, minimum

26 32

Water soluble phosphates (as P2O5) % by weight, minimum

22.1 27.2

Water soluble potash (as K2O) % by weight, minimum 26 16

Particle size    

Atomic WeightC=12, H=1, O=16, N=14, P=31, K=39, Ca=40, S=32, C1=35

DIAMMONIOUM PHOSPHATEAs far as Indian farmer is concerned, IFFCO's DAP is not just a source of crucial nutrients N, P for the crops, but is an integral part of his/her quest for nurturing mother earth. The bountiful crop that results from this care is an enough reason for the graceful bags of IFFCO DAP bags to be an integral part of the farmers’ family. The Indian farmer's confidence and trust stems from the fact that IFFCO's DAP is a part of a complete package of services, ably supported by a dedicated team of qualified personnel. This fertiliser is useful for all kinds of crops.Diammonium PhosphateIt is the most popular phosphatic fertiliser because of its high analysis and good physical properties. The composition of DAP is N-18% and P2O5 -46%.

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Technical specifications:

 

Moisture % by weight, maximum 1.5%

Total N % by weight, minimum 18%

Being readily soluble in water, Water soluble fertilisers (WSF) help fertigation* by releasing essential plant nutrients at the root zone from where they are readily absorbed and used elsewhere in the plant system. (Information of the product to be take from the website)*Fertigation is a method of fertiliser application in which fertiliser is incorporated within the irrigation water by the drip system

BIO FERTILISERBiofertilisers are capable of fixing atmospheric nitrogen when suitable crops are inoculated with them. Biofertilisers are low cost, effective, environmental friendly and renewable source of plant nutrients to supplement fertilizers. Integration of chemical, organic and biological sources of plant nutrients and their management is necessary for maintaining soil health for sustainable agriculture. The bacterial organisms present in the biofertiliser either fix atmospheric nitrogen or solubilize insoluble forms of soil phosphate. The range of nitrogen fixed per ha/year varies from crop to crop; it is 80 - 85 kg for cow pea, 50 - 60 kg for groundnut, 60 - 80 kg for soybean and 50 - 55 kg for moong bean.

Phosphate Solubilizing Micro OrganismSeveral soil bacteria and fungi possess the ability to bring insoluble phosphates into soluble forms by secreting organic acids. They can be applied to and recommended for all crops

RhizobiumIt is the most important nitrogen fixing organism. It live symbiotically in the root nodules of leguminous plants and supply nitrogen to the plant through nitrogen fixation. Besides, supplying nitrogen to the crop, nitrogen fixed by legume - Rhizobia association would also leave residual nitrogen for the succeeding crops. The beneficiary crops are Groundnut,

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Soybean, Red-gram, Green-gram, Black-gram, Lentil, Cow pea, Bengal-gram and Fodder legumes.

AzotobacterIt is non symbiotic nitrogen fixing bacteria recommended for non leguminous crops like Paddy, Wheat, Millets, Cotton, Tomato, Cabbage, Mustard, Safflower and Sunflower. The Azotobacter performs well if the soil organic matter content is high.

AcetobacterIt is a symbiotic bacteria capable of fixing atmospheric nitrogen by living within the sugar plant. They are found in all parts of plant body. It is suitable for sugarcane cultivation.

PERFORMANCE OF IFFCOProduction – 6 million tonne fertilizer.Sales – 6 million tonne fertilizerTurnover of Rs. 60.9 billionProfit before tax of Rs. 8.1 billionNet worth as on 31/3/2003 – Rs. B32.7 billion

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Investment in Joint Ventures of IFFCO Rs. 9.7 billion equivalents to US$ 0.2 billion in KRIBHCO. Rs. 0.8 billion in Godavary Fertilizer & Chemical Ltd. Rs. 0.3 billion in Indian Potash Ltd.

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US$ 80.68 million in Oman Indian Fertilizer Company. Rs. 903 billion in Industries Chemique-Du Senegal (ICS). Rs. 501 billion in IFFCO-TOKIO General Insurance Co. Ltd.

UX

POWER PLANT A power plant is a place  in which heat energy is converted to  electric power. In IFFCO phulpur INDIA the turbine is steam-driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated; this is known as a Rankine cycle.

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Fig. POWER PLANT

Following two are the main products in a thermal power plant .

1) Electricity: Electricity is produced after which it is stepped grid for supply in iffco phulpur allahabad.

2) Ash: Ash is by product of coal after its combustion. It can be categorized into two parts

A) Fly ash, which is sold to cement manufacturing organization. B) Ash slurry, it is a waste product which is generally provided to construction

companies for road filling etc.

PROCEDURE IN POWER PLANT

Procedure for production of electricity is based on modified Rankine cycle. The four processes of Rankine cycle is used in thermal power plant are as fallows :-

1) Heat addition in boiler.2) Adiabatic expansion in turbines.3) Heat rejection in condenser and,4) Adiabatic compression in boiler feed pumps.

This may seem to be a simple enough process, but every step employs various circuits to accomplish the required conditions for the four told steps. Certain are follows fuel and Ash circuit. Air and Gas circuits feed water and steam circuit. Cooling water circuit.

Various methods are employed to increase a efficiency of classical rankine cycle by adding devices like air preheater, economizer, super heater etc.

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RANKINE CYCLE

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The Rankine cycle is a model that is used to predict the performance of steam turbine systems. The Rankine cycle is an idealized thermodynamic cycle of a heat engine that converts heat into mechanical work. The heat is supplied externally to a closed loop, which usually uses water as the working fluid. It is named after William John Macquorn Rankine, a Scottish polymath and Glasgow University professor.

The Rankine cycle closely describes the process by which steam-operated heat engines commonly found in thermal power generation plants generate power. The heat sources used in these power plants are usually nuclear fission or the combustion of fossil fuels such as coal, natural gas, and oil.

The efficiency of the Rankine cycle is limited by the high heat of vaporization of the working fluid. Also, unless the pressure and temperature reach super critical levels in the steam boiler, the temperature range the cycle can operate over is quite small: steam turbine entry temperatures are typically around 565 °C and steam condenser temperatures are around 30 °C. This gives a theoretical maximum Carnot efficiency for the steam turbine alone of about 63,8% compared with an actual overall thermal efficiency of up to 42% for a modern coal-fired power station. This low steam turbine entry temperature (compared to a gas turbine) is why the Rankine (steam) cycle is often used as a bottoming cycle to recover otherwise rejected heat in combined-cycle gas turbine power stations.

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The working fluid in a Rankine cycle follows a closed loop and is reused constantly. The water vapor with condensed droplets often seen billowing from power stations is created by the cooling systems (not directly from the closed-loop Rankine power cycle) and represents the means for (low temperature) waste heat to exit the system, allowing for the addition of (higher temperature) heat that can then be converted to useful work (power). This 'exhaust' heat is represented by the "Qout" flowing out of the lower side of the cycle shown in the T/s diagram below. Cooling towers operate as large heat exchangers by absorbing the latent heat of vaporization of the working fluid and simultaneously evaporating cooling water to the atmosphere. While many substances could be used as the working fluid in the Rankine cycle, water is usually the fluid of choice due to its favorable properties, such as its non-toxic and unreactive chemistry, abundance, and low cost, as well as its thermodynamic properties. By condensing the working steam vapor to a liquid the pressure at the turbine outlet is lowered and the energy required by the feed pump consumes only 1% to 3% of the turbine output power and these factors contribute to a higher efficiency for the cycle. The benefit of this is

offset by the low temperatures of steam admitted to the turbine(s). Gas turbines, for instance, have turbine entry temperatures approaching 1500°C. However, the thermal efficiency of actual large steam power stations and large modern gas turbine stations are similar.

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Processes in rankine cycle

There are four processes in the Rankine cycle. These states are identified by numbers (in brown) in the above T-s diagram.

Process 1-2: The working fluid is pumped from low to high pressure. As the fluid is a liquid at this stage, the pump requires little input energy.

Process 2-3: The high pressure liquid enters a boiler where it is heated at constant pressure by an external heat source to become a dry saturated vapour. The input energy

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required can be easily calculated graphically, using an enthalpy-entropy chart (aka h-s chart or Mollier diagram), or numerically, using steam tables.

Process 3-4: The dry saturated vapour expands through a turbine, generating power. This decreases the temperature and pressure of the vapour, and some condensation may occur. The output in this process can be easily calculated using the chart or tables noted above.

Process 4-1: The wet vapour then enters a condenser where it is condensed at a constant pressure to become a saturated liquid.

In an ideal Rankine cycle the pump and turbine would be isentropic, i.e., the pump and turbine would generate no entropy and hence maximize the net work output. Processes 1-2 and 3-4 would be represented by vertical lines on the T-s diagram and more closely resemble that of the Carnot cycle. The Rankine cycle shown here prevents the vapor ending up in the superheatregion after the expansion in the turbine, [1] which reduces the energy removed by the condensers.

The actual vapor power cycle differs from the ideal Rankine cycle because of irreversibilities in the inherent components caused by fluid friction and heat loss to the surroundings; fluid friction causes pressure drops in the boiler, the condenser, and the piping between the components, and as a result the steam leaves the boiler at a lower pressure; heat loss reduces the net work output, thus heat addition to the steam in the boiler is required to maintain the same level of net work output.

Coal Fired Thermal Power Plant

The Basic Steps and Facts

The conversion from coal to electricity takes place in three stages.

Stage 1The first conversion of energy takes place in the boiler. Coal is burnt in the boiler furnace to produce heat. Carbon in the coal and Oxygen in the air combine to produce Carbon Dioxide and heat.

Stage 2The second stage is the thermodynamic process.

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1. The heat from combustion of the coal boils water in the boiler to produce steam. In modern power plant, boilers produce steam at a high pressure and temperature. 

2. The steam is then piped to a turbine. 3. The high pressure steam impinges and expands across a number of sets of blades in the

turbine. 4. The impulse and the thrust created rotates the turbine. 5. The steam is then condensed and pumped back into the boiler to repeat the cycle.

Stage 3In the third stage, rotation of the turbine rotates the generator rotor to produce electricity based of Faraday’s Principle of electromagnetic induction.

Steam GenerationIn fossil-fueled power plants, steam generator refers to a furnace that burns the fossil fuel to boil water to generate steam. In the nuclear power plant field, steam generator refers to a specific type of large heat exchanger used in a pressurized water reactor (PWR) to thermally connect the primary (reactor plant) and secondary (steam plant) systems, which of course is used to generate steam. In a nuclear reactor called a boiling water reactor (BWR), water is boiled to generate steam directly in the reactor itself and there are no units called steam generators. In some industrial settings, there can also be steam-producing heat exchangers called heat recovery steam generators (HRSG) which utilize heat from some industrial process. The steam generating boiler has to produce steam at the high purity, pressure and temperature required for the steam turbine that drives the electrical generator. A fossil fuel steam generator includes an economizer, a steam drum, and the furnace with its steam generating tubes and superheater coils. Necessary safety valves are located at suitable points to avoid excessive boiler pressure. The air and flue gas path equipment include: forced draft (FD) fan, air preheater (APH), boiler furnace, induced draft (ID) fan, fly ash collectors (electrostatic precipitator or baghouse) and the flue gas stack.

Fuel preparation system

In coal-fired power plants, the raw feed coal from the coal storage area is first crushed into small pieces and then conveyed to the coal feed hoppers at the boilers. The coal is next pulverized into a very fine powder. The pulverizers may be ball mills, rotating drum grinders, or other types of grinders.

Some power plant burn fuel oil rather than coal. The oil must kept warm (above its pour point) in the fuel oil storage tanks to prevent the oil from congealing and becoming unpumpable. The oil is usually heated to about 100 °C before being pumped through the furnace fuel oil spray nozzles.

Boilers in some power stations use processed natural gas as their main fuel. Other power stations may use processed natural gas as auxiliary fuel in the event that their main fuel

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supply (coal or oil) is interrupted. In such cases, separate gas burners are provided on the boiler furnaces.

Air path

External fans are provided to give sufficient air for combustion. The forced draft fan takes air from the atmosphere and, first warming it in the air preheater for better combustion, injects it via the air nozzles on the furnace wall.

The induced draft fan assists the FD fan by drawing out combustible gases from the furnace, maintaining a slightly negative pressure in the furnace to avoid backfiring through any opening.

Boiler furnace and steam drum

Once water inside the boiler or steam generator, the process of adding the latent heat of vaporization or enthalpy is underway. The boiler transfers energy to the water by the chemical reaction of burning some type of fuel.

The water enters the boiler through a section in the convection pass called the economizer. From the economizer it passes to the steam drum. Once the water enters the steam drum it goes down the downcomers to the lower inlet waterwall headers. From the inlet headers the water rises through the waterwalls and is eventually turned into steam due to the heat being generated by the burners located on the front and rear waterwalls (typically). As the water is turned into steam/vapor in the waterwalls, the steam/vapor once again enters the steam drum. The steam/vapor is passed through a series of steam and water separators and then dryers inside the steam drum. The steam separators and dryers remove water droplets from the steam and the cycle through the waterwalls is repeated. This process is known as natural circulation.

The boiler furnace auxiliary equipment includes coal feed nozzles and igniter guns, soot blowers, water lancing and observation ports (in the furnace walls) for observation of the furnace interior. Furnace explosions due to any accumulation of combustible gases after a trip-out are avoided by flushing out such gases from the combustion zone before igniting the coal.

The steam drum (as well as the superheater coils and headers) have air vents and drains needed for initial startup. The steam drum has internal devices that removes moisture from the wet steam entering the drum from the steam generating tubes. The dry steam then flows into the superheater coils.

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Superheater

Fossil fuel power plants can have a superheater and/or reheater section in the steam generating furnace. Nuclear-powered steam plants do not have such sections but produce steam at essentially saturated conditions. In a fossil fuel plant, after the steam is conditioned by the drying equipment inside the steam drum, it is piped from the upper drum area into tubes inside an area of the furnace known as the superheater, which has an elaborate set up of

tubing where the steam vapor picks up more energy from hot flue gases outside the tubing and its temperature is now superheated above the saturation temperature. The superheated steam is then piped through the main steam lines to the valves before the high pressure turbine.

Reheater

Power plant furnaces may have a reheater section containing tubes heated by hot flue gases outside the tubes. Exhaust steam from the high pressure turbine is rerouted to go inside the reheater tubes to pickup more energy to go drive intermediate or lower pressure turbines. This is what is called as thermal power.

Auxiliary systems1) FLY ASH SYSTEM

Fly ash is captured and removed from the flue gas by electrostatic precipitators or fabric bag filters (or sometimes both) located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators or bag filters. Generally, the fly ash is pneumatically transported to storage silos for subsequent transport by trucks or railroad cars.

2) Bottom ash collection and disposal

At the bottom of the furnace, there is a hopper for collection of bottom ash. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement is included to crush the clinkers and for conveying the crushed clinkers and bottom ash to a storage site.

3) Boiler make-up water treatment plant and storage

Since there is continuous withdrawal of steam and continuous return of condensate to the boiler, losses due to blowdown and leakages have to be made up to maintain a desired water level in the boiler steam drum. For this, continuous make-up water is added to the boiler water system. Impurities in the raw water input to the plant generally consist of calcium and magnesium salts which impart hardness to the water. Hardness in the make-up water to the

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boiler will form deposits on the tube water surfaces which will lead to overheating and failure of the tubes. Thus, the salts have to be removed from the water, and that is done by a water demineralising treatment plant (DM). A DM plant generally consists of cation, anion, and mixed bed exchangers. Any ions in the final water from this process consist essentially of hydrogen ions and hydroxide ions which recombine to form pure water. Very pure DM water becomes highly corrosive once it absorbs oxygen from the atmosphere because of its very high affinity for oxygen.

The capacity of the DM plant is dictated by the type and quantity of salts in the raw water input. However, some storage is essential as the DM plant may be down for maintenance. For this purpose, a storage tank is installed from which DM water is continuously withdrawn for boiler make-up. The storage tank for DM water is made from materials not affected by corrosive water, such as PVC. The piping and valves are generally of stainless steel. Sometimes, a steam blanketing arrangement or stainless steel doughnut float is provided on top of the water in the tank to avoid contact with air. DM water make-up is generally added at the steam space of the surface condenser (i.e., the vacuum side). This arrangement not only sprays the water but also DM water gets deaerated, with the dissolved gases being removed by an air ejector attached to the condenser.

Pollutant Hard coal Brown coal Fuel oil Other oil Gas

CO2 (g/GJ) 94,600 101,000 77,400 74,100 56,100

SO2 (g/GJ) 765 1,361 1,350 228 0.68

NOx (g/GJ) 292 183 195 129 93.3

CO (g/GJ) 89.1 89.1 15.7 15.7 14.5

Non methane organic compounds (g/GJ) 4.92 7.78 3.70 3.24 1.58

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