Mr. Rajesh Singla, M/s ISGEC Heavy Engg. Ltd. Best Solution to

Transcription

Engineering for Excellence
ISGEC HEAVY ENGINEERING LIMITED
Welcome
All Delegates
Presentation Road Map
Overview : Company
Isgec Slop Fired Boilers
Insights of Isgec
Isgec Heavy Engineering Limited
Overview
Who are we?
Corporate Data and Business
Founded & Incorporated
1933
Group Turnover
INR 4200 Crore*
Market Capitalization
INR 4700 Crore *
Headquarter
Noida (Delhi NCR)
International Offices
California, USA , Dusseldorf, Germany
Manufacturing Facilities
Plant – 1: Yamunanagar
Plant – 2: Ratangarh
Plant – 3: Dahej
Plant – 4: Muzafarnagar
Plant – 5: Bawal, Gurgaon
Engineering Offices
Noida (Delhi NCR)
Chennai
Pune
Yamunanagar
Global Footprints
85 Countries
* As on 31st March, 2015
ISGEC SLOP FIRED BOILERS
Next Generation Slop (Spent Wash)
Incineration Technology
What is Slop (Spent Wash) ?
Slop / Spent Wash
 An effluent (Process Waste) from molasses based Distillery.
 Hazardous for direct disposal to environment.
 Hence, there is a need for efficient disposal of this effluent.
Characteristics of Slop / Spent wash (Raw)
Effect
Acidic in Nature
Corrodes the surroundings and
contaminates the Soil.
Acidic
pH 4 - 4.5
BOD*
45000 – 60000 PPM
COD*
110000 – 135000 PPM
High Moisture
9 – 12 % w/w depending
Difficult to handle and store
on plant configuration
Odour
Pungent
It pollutes rivers and ground water.
Water becomes unfit for human
consumption and for sustaining
aquatic life.
Unbearable
BOD - Biological Oxygen Demand
COD - Chemical Oxygen Demand
Effluent Treatment Method
Concentrated Slop/ Spent Wash is directly fired in the Boiler to meet
Zero Liquid Discharge
a. To Meet the Statutory Norm of Zero Discharge:
• By Firing Concentrated Distillery Effluent spent wash (Slop) in a boiler.
b. By Product:
• Steam Generation to meet the process requirement of Distillery.
c. Benefits:
• Reduction in production cost per liter of alcohol.
• Power Generation to meet captive requirement.
• Potash rich ash is saleable, generates good revenue and also eliminates
disposal problem.
Solutions for Firing Slop
Travelling Grate Furnace with Slop Atomization
Solutions for Firing Slop
Travelling Grate Furnace with Slop Atomization
General Arrangement of Slop Fired Boiler
Spent Wash Boilers Executed
Spent Wash Fired Boilers Executed
32 TPH, 35 Kg/cm2, 380 Deg C at Dharani Sugars, Villupuram
Slop with Bagasse / Coal as supporting fuel
Brief Report
DHARANI SUGARS & CHEMICALS LTD.
Site : Kalyanpur Village, Villupuram District, TN
Commissioned – Sep’
DESIGN PARAMETERS
UNIT
VALUES
TPH
Steam flow at MCR
32
kg/cm2(g)
Steam pressure at MSSV Outlet
35
Steam temperature at MSSV Outlet
°C
380
Feed water temp. at economiser Inlet
Main Fuel/s (Percentage on Heat Basis)
− 50% Slop + 50% Bagasse
− 50% Slop + 50% Coal (Indian / Imported)
− 100% Bagasse
− 100% Coal (Indian / Imported)
Slop quantity to be fired (55 – 65 Brix)
°C
150
Slop GCV (at 55 Brix)
Dust concentration at the ESP outlet
100% MCR
Kg/hr
10000
Kcal/kg
mg/Nm3
1750
100
22 TPH, 45 Kg/cm2, 400 Deg C at Mumias Sugar, Kenya
Slop with Bagasse / Coal as supporting fuel
Commissioned in September- 2012
Brief Report
MUMIAS SUGARS & CHEMICALS LTD.
Commissioned – Sep’
Site : KENYA
DESIGN PARAMETERS
UNIT
VALUES
TPH
kg/cm2(g)
22
45
°C
400
Main Fuel/s (Percentage on Heat Basis)
− 50% Slop + 50% Bagasse
− 50% Slop + 50% Coal (Indian / Imported)
− 100% Bagasse
°C
150
Steam flow at MCR
100% MCR
Kg/hr
6000
Kcal/kg
mg/Nm3
1750
100
What Competitors Said
Total 8 Slides
40 TPH, 45 Kg/cm2, 400 Deg C at Balrampur Chini Mills, U.P.
Slop with Bagasse as supporting fuel
Brief Report
BALRAMPUR CHINI MILLS LIMITED
Site : BALRAMPUR, UTTAR PRADESH
DESIGN PARAMETERS
Commissioned – Nove ber’
UNIT
VALUES
TPH
40
kg/cm2(g)
45
°C
400
°C
140
Main Fuel/s
− Slop + Bagasse
− Bagasse
MCR
100%
Kg/hr
13000
Kcal/kg
mg/Nm3
1700
50
Steam flow at MCR
Brief Report
BALRAMPUR CHINI MILLS LIMITED
Site : BALRAMPUR, UTTAR PRADESH
SITE PARAMETERS
UNIT
VALUES
TPH
39 - 42
kg/cm2(g)
43 - 45
°C
395 - 402
°C
130 - 140
MCR
100%
Steam flow at MCR
Fuel Fired
− Slop + Bagasse
Avg. (TPH)
TPD
Slop quantity fired (52 – 62 Brix)
13.00
300 – 315
Bagasse fired
7.00
170 – 175
Fuel Parameters
mg/nm3
29 - 42
Brief Report
18 TPH, 45 Kg/cm2, 400 Deg C at Dalmia Sugars, Kolhapur
Slop with Coal as supporting fuel
Brief Report
DALMIA SUGARS LIMITED
Site : KOLHAPUR, MAHARASHTRA
DESIGN PARAMETERS
UNIT
VALUES
TPH
kg/cm2(g)
18
45
°C
400
°C
150
MCR
100%
MCR
80%
Kg/hr
5500
Kcal/kg
mg/Nm3
1750
50
Steam flow at MCR
Main Fuel/s
− Slop + Indian / Imported Coal
− 100% Imported Coal
− 100% Indian Coal
24 TPH, 45 Kg/cm2(a), 390 °C at Madhucon Sugar & Power, Telangana
Slop with Coal as supporting fuel
Brief Report
MADHUCON SUGAR & POWER LIMITED
Site : TELANGANA
DESIGN PARAMETERS
Commissioned – Ja uary’
UNIT
VALUES
TPH
kg/cm2(a)
24
45
°C
390
Feed water temp. at economizer Inlet
Main Fuel/s
− Slop + Bagasse
− 100% Bagasse
− Slop + Coal (Indian / Imported)
°C
150
MCR
100%
MCR
100%
Kg/hr
6500
Kcal/kg
mg/Nm3
1750
50
Steam flow at MCR
Reference Installations for Slop Fired Boilers
Customer
TPH Ata Deg C
Fuels
Commissioned /
Commissioning
Shri Sai Priya Sugars Ltd., Karnataka
52
45
400
Slop + Bagasse
February” 2017
Balrampur Chini Mills, Uttar Pradesh
40
45
400
Slop + Bagasse
November’ 2015
Dharani Sugars & Chemicals, Tamil
Nadu
35
35
380
Slop + Bagasse
/ Coal
2012
Madhucon Sugar & Power, Telangana
24
45
390
Slop + Bagasse
/ Coal
January’ 2016
23.5
40
400
Slop + Bagasse
February’ 2016
Mumias Sugars, Kenya
22
45
400
Slop + Bagasse
/ Wood Chips
2012
Dalmia Sugar, Kolhapur
18
45
400
Slop + Coal
Indreswar Sugar Mills, Maharashtra
November’ 2015
Advantages of Isgec Design
Proven Travelling Grate technology
Flexibility of Fuels
• Flexibility
fuels :: Wide variety of support fuels such as Bagasse / Rice
husk / Wood Chips / Coal etc.
Minimum Maintenance
Maintenance : : Familiar, proven and easy to operate technology
• Minimum
Enhanced Uptime
: Online removal of clinkers with continuous ash
• Enhanced
Up Time:
discharge ensuring no stoppage of Boiler.
3 pass design
•
Efficient Combustion : in tall furnace due to adequate time availability
for mixing of slop and support fuel.
• Ash
Eliminated in third pass due to wide transverse pitch of
Ash bridging
bridging eliminated
heating surfaces.
Better
BetterCombustion
Combustion through Tall Furnace. Lower flue gas temperature at
• Better
Combustion
superheater inlet to avoid fouling due to alkalies in ash (Na2O + K2O)
and corrosion of SH due to chlorides in ash.
Online Cleaning System
• Easy
Easyremoval
removalof
ofgun
gunfor
forcleaning.
Cleaning
• Reliable
Efficient On-Load
On-LoadCleaning
Cleaning:
Reliable & Efficient
Steam operated soot blowers for super
heater and other convective heating
surfaces in horizontal pass to ensure
cleaning without any stoppage.
Slop firing system
• Complete
Complete combustion
Combustion : high pressure
atomization (spray) of slop thru
Specially designed Nozzles.
• Slop
Slop nozzles
nozzles
: located at Strategic
height on furnace water wall to ensure
complete combustion and minimum
carry over.
SlopPumps
Pumps: high pressure
• Slop
pumps are provided to ensure
adequate pressure of slop for
atomization.
Specially Designed Air Pollution Control Equipment
• Combination of Pre-Dust Collector and Electrostatic Precipitator / Bag
Filter.
• Higher Spacing between Electrodes of ESP
• Special Type TR Set Controllers of ESP.
• Shorter Length of Electrodes for Effective rapping in ESP.
• Bag filters with optimum air to cloth ratio.
• Special material of filter bags to withstand corrosive flue gas.
• Cleaning of filter bags with reverse air pulses.
• Proper Gas distribution in Bag filter to promote better release of Dust.
100% Steam Generation possible with support fuels
• Even if slop is not available, Power & Steam demand can be met at all
times.
Low Gas Velocity in Furnace, hence eliminates tube erosion.
Cost effective due to lower power consumption and negligible
maintenance.
Eliminates requirement of additional consumables like bed material.
Avoids manual poking due to self sustained and efficient combustion.
Improvement in Design
Improvements in Design
Special Designed I-Grate
Specially Designed-I Grate for Slop Fired Boiler
No Gaps B/w Grate Bars to avoid
Jamming due to entrapment of Foreign
Material
Minimum Gaps between Adjacent bars
No gap between Grate bars in new TG.
The Uniform distribution of air across the Grate take place to
avoid local combustion due to ash accumulation.
Practically no Gap between Grate bar &
partition plate in new TG

MINIMUM GAPS BETWEEN ADJACENT BARS

WIDER GRATE BARS AND SHOTER IN LENGTH

SELF LUBRICATING SHAFT BEARINGS

ONLINE REPLACEMENT OF LAST ROW GRATE BAR BY SIMPLY REMOVING
ONE BOLT ……………… EASY MAINTAINANCE……………. LESS DOWN TIME
Grate Bar is wider and shorter in length. Grate bar consists of number of orifice shaped inline holes
through which air passes and Fuel burns over the grate bar.
Low Dust Loading
Economizer and APH are constructed in Vertical arrangement instead of
Horizontal in order to reduce the dust load in economizer and APH. It also leads to
easy cleaning of Economizer and APH.
Effective Soot Blowing
Providing the More effective Short Retractable Soot Blowers for On-line cleaning of
Evaporator, economizer and APH.
It provide more blowing radius and better cleaning action even against the flue gas
flow.
With Above Design & Features,
minimum 60 days Continuous
Operation of this boiler
Delighted Customers : Cogeneration Boilers
1 x 220 TPH Travelling Grate Boiler for
Ingenio Magdalena, SA, Guatemala
190 TPH Travelling Grate boiler for 40 MW Bagasse /
Coal based Power Plant for Kesar Enterprises, Baheri, U.P.
3 x 150 TPH Travelling Grate Boilers for
Kamphaengphet Bioenergy Company, Thailand
130 TPH Travelling Grate Boiler at
Coregreen Sugars Limited, Karnataka, India
36 MW Bagasse / Coal based Power Plant with 1 x 180 TPH
Travelling Grate Boiler for Shree Dutta SSK, Kolhapur, India
Delighted Customers
Delighted Customers : Biomass Fired Boilers
28 TPH Biomass Fired Boiler for 8 MW Power
Plant for Aldebran, Spain
Isgec Heavy Engineering Limited
MORE ABOUT ISGEC
Business Verticals
Industrial Boilers









Oil & Gas Fired
HRSGs
CFBC
AFBC
Traveling Grate
Reciprocating Grate
WHRB
Waste to Energy
Vinasse / Slop
Utility Boilers
 Pulverized coal
fired boilers
EPC
 Turnkey Power Plants
Sugar Machinery
 Turnkey Sugar Plants
Air Pollution Control
Equipment
 ESP
 Dust Collectors
Others
 Process Equipment:
Pressure Vessels &
Heat Exchangers
 Presses: Mechanical &
Hydraulic
 Castings: Steel & Iron
 Contract Manufacturing
Trading
Special Products
 O&M services
 Spares & R&M
Global Experience
Our Locations
Noida
International Offices:
• California, USA
• Dusseldorf, Germany
Yamunanagar
70 International Agents
Ratangarh
Noida HO
New
Delhi
Bawal
Dahej
Muzaffarnagar
INDIA
Dahej
Mumbai
Pune
Chennai
Ratangarh
Kolkata
Isgec Yamunanagar
Isgec Ratangarh
•
Automatic Plant
•
TUBES in PRODUCT out.
•
100 % Shot blasting
•
Online real time inspection.
•
Multihead SAW moving panel welding machines
•
PLC operated heat-treatment furnace
•
Hydro testing up to 600 Kg/ sq.cm g.
Isgec Dahej
Isgec Muzaffarnagar
Boilers
170 TPH TG Boiler for Mumias Sugar
Company Ltd., Kenya
105 TPH AFBC Boiler at Gujarat
Flurochemicals Limited, India
100 TPH CFBC Boiler for Nirma, India.
140 TPH Oil Fired Boiler for Kochi
Refinery, India
Power Plants
25 MW
Green, Mahrashtra
1x30.4 MW Power
PlantCore
for Zambia
Sugar
( part of British Sugars)
2 x 20 MW Grasim Industries Ltd., Karnataka
1x30 MW KPR Sugar Mills, Karnataka
1x25 MW Power Plant for
Core Green Pvt Ltd, Karnataka
Quality, Safety and Environment
•
ISO 9001:2008 Approval by Lloyds Register of Quality Assurance
•
ASME ‘S’ ‘U’ ‘U-2’ & ‘U-3’ Stamps
•
ASME ‘N’ Stamp
•
‘R’ Stamp
•
‘NB’ Stamp
•
Approval by Lloyds as a Class I fabricator of Fusion Welded Pressure Vessels
up to 200 mm (8”) thickness
•
China Safety Quality License
•
ISO 14001 : 2004
•
OHSAS 18001 : 1999
Thank you
A-5, Sector 63, Noida - 201 301 (U.P.) India
Tel.: +91 - 120 – 4085900 Fax: +91 - 120 – 4085999
Email: [email protected] / [email protected]

Mr. Rajesh Singla, M/s ISGEC Heavy Engg. Ltd. Best Solution to

Transcription

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