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HINDALCO INDUSTRIES LIMITED

REPRESENT BY :- AMAN KUMAR PANDEY EN. NO.- 0502ME131010BRANCH- MECHANICAL

VOCATIONAL TRAINING PRESENTATION ON

“BOILER & CO-GENERATION”

SUBMITTED TO – ASHISH MUCHRIKAR SIR

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Content Introduction Coal Handling Plant(CHP) :- 1. Coal source 2. Type of coal 3. Size of coal 4. Banker capacity Boiler :- 1. Type of boiler 2. Auxiliaries of boilers 3. Details of boilers 4. Performance of boilers Turbine DM Plant (DEMINERALIZATION Plant) CO-Generation plant Ash handling plant (AHP)

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INTRODUCTION A flageship company of ADITYA BIRLA GROUP Located in RENUKOOT, Sonebhadra (Uttar Pradesh) Commenced its operarions in 1962 with initial capacity of 20,000 TPY Metal and 40,000 TPY Alumina Emergad as the largest integrated aluminium manufacturing company in INDIA Globally 12th largest Aluminium and Alumina Producer

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LAYOUT

DM water

Deaerator

BFP

Coal to feeders by Dozer

Coal Conveyors

Rotory Coal Feeders

Furnace

Coal Transporting Line

Steam Generation

Flue Gas to ESP

PA Fan

FD Fan

Economiser

Water Circuit

Coal Yard

Coal sizing circuit for

-6mm size coalCoal

Bunkers

ID Fan

Ash Recycling feeder-2

No.

Steam to Power Plant / Process

Exchange of Heat Energy

Feeder Running

YES

AshHopper

NOAsh drai

n

Ash Recycling feeder-2

No.

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Sources of coal in Hindalco - In coal auction held by Ministry of coal, Government of india, Hindalco has won the following four coal mines

1. Gare Palma 4 mine in Chattisgarh 2. Gare Palma 5 mine in Chattisgarh 3. Kathautia mine in Jharkhand 4. Dumri mine in Jharkhand Resources of coal – By road and by trains. Type of Coal- Semi Bituminous coal Coal size – 75mm max.

COAL HANDLING PLANT

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Proximate Analysis Values

QUALITY OF COAL

MOISTURE VOLATILEMATTER ASH FIXED

CARBONCALORIFIC

VALUE

10%-16% 21%-26% 35%-38% 25%-30%2900-3500

KCAL/KG

Coal Feed SizeBOILER #1, 3 & 4: 100% 20 MM TO MILLBOILER#2 : 6 MM WITH 20% FINES TO FURNACE

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Coal is unloading from WAGON TRIPPLER in two sizes i.e.- 1. +25mm and -75mm (Above 25mm and Below 75mm) 2. -25mm and +75mm(Below 25mm and Above 75mm)

After unloading of coal we fed the different size coal in different boilers. We have four boilers. Three are PF and one is FBC boiler. In PF boiler we have use the coal below the 20mm. In FBC boiler we have use the coal below the 6mm. For, which various eqipments have been installed in coal plant area.

To feed the coal in PF boilers(B# 1,3,&4) push the coal by dozers in rototry feeders grizzly situated in coal yards. Coal is coming from RECLAIM conveyer#64. Then vibrating screen having size of 20mm through vibro feeder. Less than 20mmcoal have fallen through screen directly to conveyer#70. And over size coal going to conveyer#70 through coal impactor having capacity 120TPH. Finally coal is going to the bankers of boilers(# 1,3 & 4) through conveyer#70 DABIN conveyer and TRIPPER conveyer.

COAL PLANT OPERATION

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To feed the coal in FBC boiler (B#2) push the coal by dozers in roratry feederd grizzly situated in coal yards. Coal is coming from RECLAIM conveyer to conveyer#64, Vibro feeder then coal impactor(240TPH) to two numebrs vibrating screen having capacity of 120TPH each through two vibro feeders. Coal has fallen through screen directly to conveyer#69(Size less than 6mm) and over size coal (Above 6mm) going to conveyer#64 through the BUCKET ELEVATOR having capacity 65TPH for recrushing in coal impactor with fress coal. Close coal cricut is running during coal feeding in B#2. Finally coal is going to the bunkers through conveyer#70. DAVBIN conveyer and TRIPPER conveyer.

COAL PLANT OPERATION

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BOILER#1:- 750 mt. ton BOILER#2:- 1120 mt. ton BOILER#3:- 1640 mt. ton BOILER#4:- 1400 mt. ton

STEAM GENERATED :- 450 ton/hr COAL USED :- 125 ton/hr ( In which 40% ash contains ) 3000 ton/day

BUNKER CAPACITY

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A BOILER is a closed vessel in which water or other fluid is heated.

 Boilers produce steam to be used at saturation temperature.

AUXILIARIES OF BOILERS 1. Fans - Induced Draft fans Primary Air Fans Forced Draught Fans 2. Air Preheater 3. Economiser 4. Mill 5. Superheater 6. ESP( Electrostatic precipitator)

BOILER

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ID Fans - The function of this fan is to maintain draft in the furnace and carry out flue gas of the furnace and maintain the negative value of the pressure in side the furnace PA FANS - The function of this fan is to heat and carry coal from mill to the furnace FD FANS - This fan is used for the purpose of supplying excess air in the furnace for complete combustion of coalAIR PREHEATER - The function of air preheater is to heat the incoming air from the Primary air fan which is supplied to the mills, Basically we are using this air as the medium for heating and conveying the Pulverized coal. The air preheater is located in the second pass of the Boiler and it gains its heat by the flue gases and gives the heat to the incoming air.

ECONOMISER- The Economizer is the located in the second pass of the Boiler its function is to utilize the heat of flue gases coming out of the first pass of the Boiler which have done their work of producing steam from the Boiler. The economizer utilizes this heat of Flue gases which would otherwise be wasted to the atmosphere resulting in dry flue gas loss and reducing the efficiency of the Boiler.

Auxiliaries details

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MILL - The function of the mill is to grind the coal in the required size, like the size of coal required in the Pulverized fuel fired Boilers is of 75 microns so to achieve that size the mills are used. The mills used in the cogeneration plant are of Ball mill and Bowl mill type.

SUPERHEATER- The function of super heater is to superheat the Dry saturated steam coming from the drum and convert it into the superheated from so that chances of moisture is totally eliminated and the Enthalpy of steam is increased

ESP - The function of the Electrostatic Precipitator is to collect the ash coming out of the Boiler and send it to the ash silo from where it is further utilized as per requirement. The ESP works on the principle of Corona where the Ash particles are charged by Direct Current and further collected at the collecting electrodes and than removed with the help of rappers and collected in the ash silos.

Auxiliaries details

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Details of boilers

BOILERS TYPE CAPACITY PR. KG/CM2

TEMP. 0 C

YEAR OF COMMISSI

ONINGMAKE

BOILER # 1 FRONT FIRING (PF) 80 (TPH) 52.5 450 1986 WIL PUNE

BOILER # 2 AFBC 80 (TPH) 52.5 450 1989 BHEL, TRICHI

BOILER # 3 TANGENTIAL FIRING (PF) 140 (TPH) 111 535 1996 BHEL,

TRICHI

BOILER # 4 TANGENTIAL FIRING (PF) 150 (TPH) 111 535 2004 BHEL,

TRICHI

STEAM GENERATION PER HOUR = 450 MTSTEAM RECEIVED FROM HI-TECH = 25-35 MT / HR

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Performance of boilers

Boiler Efficiency: Direct MethodBoiler efficiency () = Heat output

Heat inputx 100 Q sx (hg – hf)

Q x GCVx 100=

hg -the enthalpy of saturated steam in kcal/kg of steam hf -the enthalpy of feed water in kcal/kg of water

PARAMETERS TO BE MONITORED: - QUANTITY OF STEAM GENERATED PER HOUR (QS) IN KG/HR - QUANTITY OF FUEL USED PER HOUR (Q) IN KG/HR- THE WORKING PRESSURE (IN KG/CM2(G)) AND SUPERHEAT

TEMPERATURE (OC), IF ANY - THE TEMPERATURE OF FEED WATER (OC) - TYPE OF FUEL AND GROSS CALORIFIC VALUE OF THE FUEL

(GCV) IN KCAL/KG OF FUEL

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STEAM TURBINE A turbine in which a high-

velocity jet of steam rotates a bladed disc or drum.

A steam turbine is a device that extracts thermal energy from pressurized steam and uses it to do mechanical work on a rotating output shaft.

TURBINE

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LAYOUT OF DM PLANT PUMP PUMP AIR BLOWER PUMP FLOW CHART OF D. M. PLANT

CW TANK

DYNA- -SAND FILTER

M G F

A C F

S A C DEGASSED

WATER TANK

S B A

COLD DM TANK

F W TANK

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DEMINIRALIZATION OF WATER

• THE PROCESS OF DEMINERALIZATION RESULTS IN REMOVAL OF MINERALS FROM WATER,. CLEAR WATER IS RECEIVED FROM CLEAR WATER TANK AND THE MONITORING OF PH AND CONDUCTIVITY (BELOW 150 MICRO SIEMENS/CM) ON DAILY BASIS IS MADE.ACTIVATED CARBON FILTER THIS IS USED TO ABSORB EXCESS CHLORINE, REMOVAL OF ORGANIC MATTER AND OIL & GREASE IF ANY. AND CHARCOAL IS USED AS ACTIVATED CARBON IN THE ACTIVATED CARBON FILTER.

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COGENERATION PLANT VIEW

20 A

TA

11 A

TA

3.9

ATA

11 A

TA

3.9A

TA

CONDENSER

CONDENSER

M~

20 A

TA

~~

~

H.P.HTR

35 MW

6 MW

31.4 MW

5.6 MW

54 ATA COMMON HEADER

43 A

TA H

EA

DE

R

54 ATA COMMON HEADER

To Economiser

From BFP

B#4 150 TPH

Reynolds

B#3 140 TPH

B#2 80 TPH

B#1 80 TPH

~

Auxiliary Steam

4 BAR STEAM

6 MW

600/

250

7 B

ar H

dr

250 PSI from Hi-Tech

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• CO-GENERATION MEANS SIMULTANEOUSLY PRODUCTION OF POWER & USEFUL THERMAL ENERGY FOR PROCESS FROM THE SAME PRIMARY ENERGY SOURCE. AS PER MINISTRY OF POWER CO- GENERATION IS DEFINED AS ONE WHICH SIMULTANEOUSLY PRODUCES TWO OR MORE FORMS OF USEFUL ENERGY SUCH AS ELECTRIC POWER AND STEAM, ELECTRIC POWER & SHAFT (MECHANICAL) POWER ETC... IT ALSO DEFINES ANY FACILITY THAT USES WASTE INDUSTRIAL HEAT FOR POWER GENERATION BY SUPPLEMENTING HEAT, NOT MORE THAN 50%, FROM ANY FOSSIL FUEL.

• AT HINDALCO WE ARE HAVING THE COGENERATION PLANT IN WHICH WE USE THE STEAM FOR THE PROCESS REQUIREMENT AS WELL AS POWER GENERATION

COGENERATION PLANT

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When the Coal combustion takes place in the boiler, some part of the coal remains unburnt and that un-burnt particles are called the ash.

In Hindalco ash is collected in a ash pond The hight of the Ash pond is 20-25 ft. The ash pond of hindalco is filled by the ash

in 30-35 days After that those ash will used bye the bricks

mills

ASH HANDLING PLANT

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PRESNTER

THANKS