Post on 13-Nov-2015
description
19/29/2014
DRI WASTE (CHAR) UTILIZATION IN POWER PLANT TO REDUCE POWER
GENERATION COST
BY T.M. DANDAPAT
29/29/2014
DRI PRODUCTION 390,000 MT PER ANNUM FROM 3 KILNS & 26 MW OF POWER PLANT
2
TATA SPONGE
DRI UNIT 26 MW POWER PLANT
39/29/2014
TATA SPONGE IRON LTD.Corporate Office
Coal Block in Angul
Bhubaneswar Office
TATA SPONGE IRON LTD.
In the Orissa province (Eastern part of India) 275 KMs from the State Capital Remote mining cum agriculture area
Location
49/29/2014
An associate company of Tata Steel Ltd., in the business of manufacturing of sponge iron. Based in Joda, in the district of Keonjhar, Odisha.
4
TATA SPONGE
59/29/2014
INTRODUCTIONIN DRI (SPONGE IRON ) PRODUCTION
RAW MATERIAL :A) IRON OREB) NON COKING COALC) DOLOMITE
PRODUCTS:A) SPONGE IRON (DRI)B) POWER FROM WASTE HEAT (WHRB)
SOLID WASTE: A) COAL CHAR , B) DE DUST, C) FLY ASH,
69/29/2014
BAGILTERS
DE DUST
FLOW CHART OF THE DRI PROCESS
79/29/2014
PER TON OF DRI SOLID WASTE GENERATION IS
0.5 MT
0.15 MT CHAR 30%
0.08MT DE DUST 16%
0.225 MT FLY ASH 45%
0.045 MT OTHERS 9%
GENERATION OF SOLID WASTE
89/29/2014
45
30
16
9
KILNS SOLID WASTE BREAKUP %
FLY ASH CHAR DE DUST OTHERS
99/29/2014
COOLER DISCHARGE CHAR & DE DUST
IN DRI MAKING THROGUH ROTARY KILNS NON MAGNETIC CHAR CONTAINS ALONG WITH FINISHED PRODUCT.
THIS NON MAGNETC CHAR HAVING GOOD F.C & GCV.
CHAR IS 30% OF TOTAL SOLID WASTE
DE DUST 16% OF TOTAL SOLID WASTE HAVING GOOD F.C & GCV
109/29/2014
SIZE ANALYSIS in %
CHAR
+6mm -6 +3mm 0 3mm
12.3 22.2 65.5
DE DUST
SIZE ANALYSIS in %
75 Mesh -75 to 100 Mesh
25 75
119/29/2014
COAL SOURCE V.M % ASH % F.C % GCV Kilo Calories/Kg.
IMPORTED COAL S.A
25 - 27 14 - 16 57 - 60 6500 - 6700
INDIGENIOUSCOAL
25 - 26 26 - 30 45 - 48 5000 - 5500
IN PUT COAL ANALYSIS
SOLID WASTE CHAR & DE DUST ANALYSIS V.M % ASH % F.C % GCV Kilo
Calories/Kg.
CHAR 1 2 55 - 60 35 - 40 3200 - 3400
DE DUST 2 4 60 - 65 30 - 35 2800 - 3000
129/29/2014
TYPEOF FUEL V.M ASH F.C GCV K.Cal./Kg.
F GRADE COAL 25 - 28 35 -40 30 - 35 3000 -3200
CHAR 1 2 55 - 60 35 - 40 3200 - 3400
DE -DUST 2 4 60 - 65 30 - 35 2800 - 3000
COMPARISION OF THE F- GRADE COALWITH
CHAR & DE DUST
139/29/2014
DEVELOPED A VALUE ADDED PRODUCT FROM SOLID WASTE, CHAR IS BEING UTILISED AS FUEL IN CFBC / AFBC BOILERS FOR POWER GENERATION
DE DUST GENERATES THROUGH BAG FILTERS FROM FINISHED PRODUCT CIRCUITS AND IT CONTAINS GOOD CARBON IN PULVERISED CONDITION (-75 to 100 MESH). IS ALSO BEING USED IN CFBC BOILERS (10% MIXED WITH F GRADE COAL 50 & 40% CHAR)
149/29/2014
FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBC BOILERS (100% F Grade coal @ Rs.3000/MT)
TYPE OF BOILER
BOILER CAPACITY
MAIN STEAM PRESSURE
MAIN STEAM TEMP.
COAL REQUIREQUIREMENTPER HOUR.
FUEL REQUIREMENT PER DAY
FUEL COSTPER DAY(Rs. Laks)
COST OF STEAM PER MT(Rs.)
AFBC15 MW 70 TPH 60Kgf/cm
2 500 0C 17 MT 410 MT 12.3 732
AFBC25 MW 110 TPH 60Kgf/cm2 500
0C 27 MT 648 MT 19.44 736
159/29/2014
FUEL REQUIREMENT FOR POWER GENERATION THROUGH CFBC BOILERS (100% F- GRADE COAL @ Rs.3000/MT )
TYPE OF BOILER
BOILER CAPACITY
MAINSTEAM
PRESSURE
MAIN STEAM TEMP.
COAL REQUIREQUIREME
NT /Hr.
FUEL REQUIREMENT /
DAY
FUEL COST
PER DAYRs. Laks
COST OF STEEM
PER TON (Rs)
CFBC15 MW 75 TPH 66Kgf/cm
2 480 0C 20 MT 480 MT 14.40 800
CFBC25 MW 110 TPH 66Kgf/cm
2 480 0C 28 MT 672 MT 20.16 763
169/29/2014
FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBE BOILERS (15 MW PLANT)
(IN COMBINATION OF F- GRADE COAL AND CHAR) CONSIDERING THE STEEM GENERATION FROM 15MW AFBC BOILER
IS 1680 MT
FUEL COMBINATION IS 60% F- GRADE COAL & 40% CHAR
REQUIREMENT OF F GRADE COAL = 24*10.9 =261 MT/DAYREUIREMENT OF CHAR = 24*8 = 192 MT/DAY
COST OF THE F-GRADE COAL = 3000*261= Rs.7.83 LAKHCOST OF THE CHAR = 1300*192= Rs.2.496 LAKH
TOTAL FUEL COST IS 10.326 LAKHS
SO THE COST SAVINGS BY USING THE CHAR COMBINATION FUEL IS = 12.3 10.326 = 1.974 LAKH /DAY
179/29/2014
TYPE OF BOILER
STEAMGENERATION /DAY MT
FUEL COSTFOR F-GRADE COAL 100% IN
(Rs. LAKH) (A)
FUEL COMBINATION
COAL AND CHAR 60:40 IN
(Rs.LAKH)(B)
COST SAVINGS IN STEEM /TON (Rs.) (C) =A-B
AFBC15 MW 1680 12.3 10.326 117.50
AFBC25 MW 2640 16.44 16.147 124.74
FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBC BOILERS (60% F Grade coal @ Rs.3000/MT & 40% char
@Rs.1300/MT)
189/29/2014
FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBE BOILERS (25 MW PLANT)
(IN COMBINATION OF F- GRADE COAL AND CHAR) CONSIDERING THE STEEM GENERATION FROM 25MW AFBC BOILER
IS 2640 MT/DA
FUEL COMBINATION IS 60% F- GRADE COAL & 40% CHAR
REQUIREMENT OF F GRADE COAL = 24*17.4 =417.6 MT/DAYREUIREMENT OF CHAR = 24*11.6 = 278.4 MT/DAY
COST OF THE F-GRADE COAL = 3000*417.6= Rs.12.528 LAKHCOST OF THE CHAR = 1300*278.4= Rs. 3.619 LAKH
TOTAL FUEL COST IS 16.147 LAKHS
SO THE COST SAVINGS BY USING THE CHAR COMBINATION FUEL IS = 19.44 16.147 = 3.293 LAKH /DAY
199/29/2014
TYPE OF BOILER
STEAMGENERATION /DAY MT
FUEL COSTFOR F-GRADE COAL 100% IN
(Rs. LAKH) (A)
FUEL COMBINATION
COAL AND CHAR 60:40 IN
(Rs.LAKH)(B)
COST SAVINGS IN STEEM /TON (Rs.) (C) =A-B
CFBC15 MW 1800 14.40 11.136 181.33
CFBC25 MW 2640 20.16 15.590 173.10
FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBC BOILERS (60% F Grade coal @ Rs.3000/MT & 40% char
@Rs.1300/MT)
YEARLY SAVINGS
AFBC 15 MW: 06.31 Cr. AFBC 25 MW: 10.54 Cr. CFBC 15 MW: 10.44 Cr. CFBC 25 MW: 14.62 Cr.
219/29/2014
LIST OF THE PARTIES USING CHAR M/S ADHUNIC METALIKS Ltd., M/S MSP STEEL & POWER LTD. M/S VISA STEEL LTD. M/S SHREE GANESH METALIKS LTD M/S SHYAM METALIKS AND ENERGY LTD M/S K P TRADING M/S VIKASH COAL COMPANY M/S SHREE JAGANNATH METALLIC INDUSTRIES
229/29/2014
AN APEAL TO THE GOVT. OF INDIA INORDER TO DECLARE CHAR IS NOT A WASTE
IT IS TO BE MANDATED TO UTILISE THE CHAR GENERATED FROM DRI PLANTS IN AFBC /CFBC BASED PLANTS.
ADVISE RAILWAYS TO GIVE SUBSIDY IN FRAIGHT FOR TRANSPORTING.
GIVING TAX EXEMPTIONS ON UTILISING THE CHAR IN POWER PLANTS.
239/29/2014
CONSERVE NATURAL RESOURCES BY USINGCHAR GENERATED FROM COAL BASED DRIPLANTS IN AFBC / CFBC BOILER BASED POWERPLANT WHICH OTHERWISE CALLED AS WASTE.
GENERATE WEALTH FROM CHAR (ENERGYSOURCE) WHICH OTHERWISE DECLARED ASWASTE
249/29/2014
CORPORATE OFFICE : 202,2nd Floor HMP HOUSE ,4 FAIRLEY PLACE , KOLKATA-711101
REGISTERED OFFICE : 206, 2nd Floor SHREENIKETAN APARTMENT,BARBIL,KEONJHAR ,ODISHA
CONTACT NO : +91 9007819992 ; +91 9830870011 ; +91 9937754992 ; +91 9668423900
CONTACT PERSON - SHAKEEL ANSARI (DIRECTOR)EMAIL ID : aryavarta.mn @gmail.com
259/29/2014
269/29/2014