A journey towards excellence of sap
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Transcript of A journey towards excellence of sap
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 1
A JOURNEY TOWARDSEXCELLENCE OF
SULPHURIC ACID PLANT
S.K. GHOSH, DGM(CCD)
ATUL GOSWAMI,SM(CCD)
BHILAI STEEL PLANT
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 2
SULPHURIC ACID PLANT, BSP
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 3
SULPHURIC ACID PLANT, BSP
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 4
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 5
CAPACITY : 140 TPD COMMISSIONED IN THE YEAR 1993 DOUBLE CONTACT DOUBLE ABSORPTION
SYSTEM. DE-MINERALIZATION WATER TREATMENT
PLANT FOR BOILERS . STACK HEIGHT : 40 METER . SULPHUR CONSUMPTION 330 KG /TON
SALIENT FEATURES
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 6
ENVIRONMENT FRIENDLY FEATURES
• START UP SCRUBBER SYSTEM.
• SO2 IN FLUE GAS < 2.5 KG/TON
• SO3 / ACID MIST IN FLUE GAS < 90 MG/NM3.
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 7
PROBLEMS EMERGED
• SULPHUR STREAM -- DELAY IN WAGON UNLOADING -- QUALITY OF SULPHUR -- HEALTH OF MELTERS -- SULPHUR GUN
• AIR STREAM -- AIR BLOWER -- RESTRICTED AIR FLOW
• GAS STREAM -- HOT GAS FILTER -- CONVERTER
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 8
PROBLEMS EMERGED
• ACID STREAM -- CIRCULATION TANK -- PHE -- LIMITED STORAGE CAPACITY
• BOILER STREAM -- PROBLEMS IN DM PLANT -- WHB 1& 2 -- ECONOMISER -- SUPERHEATER
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 9
PROBLEMS EMERGED
• PROBLEMS DURING START UP -- INEFFICIENT SCRUBBER -- CHOCKING OF GAS LINES -- LIMITED SODA FACILITIES
• EROSION OF CONCRETE STRUCTURES & FLOORS
• INADEQUATE INSTRUMENTATION
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 10
PROBLEMS RESULTED IN
• DOWNFALL IN ACID PRODUCTION
• MISMATCH WITH REQUIREMENT
• COKE OVEN GAS BYPASSING.
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 11
PROBLEMS RESULTED IN
• PURCHASE OF ACID
• TIME LIMITATIONS FOR CAPITAL REPAIRS.
• ENVIRONMENTAL PROBLEMS DURING START UP
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 12
YEAR QUANTITY (MT)
2003-04
2004-05
2005-06
2006-07
2007-08
2008-09
192
1500* IPT (1000RSP;500BSL)
4718
NIL
1350
132
PURCHASE OF ACID
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 13
INNOVATIONS IN ACID PLANT
SULPHUR STREAM
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 14
EXTENDED SULPHUR GODOWN
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 15
EXTENDED SULPHUR GODOWN
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 16
NEW CLEAN COMPARTMENT
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 17
SLUDGE SETTLING CHAMBERS
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 18
SLUDGE SETTLING CHAMBERS
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 19
SULPHUR GUN MODIFICATION
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 20
SULPHUR GUN MODIFICATION
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 21
INNOVATIONS IN ACID PLANT
• AIR STREAM -- AIR BLOWER IN SERIES -- INCREASING DIA OF AIR
STREAM
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 22
INSTALLATION OF NEW BLOWER
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 23
INNOVATIONS IN ACID PLANT
GAS STREAM
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 24
REPAIR OF CONVERTER
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 25
INSTALLATION OF NEW HGF
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 26
INNOVATIONS IN ACID PLANT
BOILER STREAM
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 27
REPLACEMENT OF WHB & SUPERHEATER
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 28
REPLACEMENT OF ECONOMISER
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 29
INNOVATIONS IN ACID PLANT
ACID STREAM
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 30
COMMON ACID CIRCULATION TANK
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 31
REPLACEMENT OF PHE WITH S&T HE
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 32
REPLACEMENT OF STORAGE TANK
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 33
REPLACEMENT OF STORAGE TANK
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 34
ADDITIONAL STORAGE TANK
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 35
INNOVATIONS IN ACID PLANT
SCRUBBING SYSTEM
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 36
ADDITIONAL CAUSTIC SODA TANKS
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 37
ADDITIONAL CAUSTIC SODA TANKS
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 38
REPLACEMENT OF SCRUBBER GAS LINES
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 39
REPAIR OF FLOOR & DYKES
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 40
REPAIR OF FLOOR & DYKES
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 41
REPAIR OF FLOOR & DYKES
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 42
IMPROVEMENT IN INSTRUMENTATION
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 43
IMPROVEMENT IN INSTRUMENTATION
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 44
DESPATCHES OF ACID TO OTHER UNITS
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 45
DESPATCHES OF ACID TO OTHER UNITS
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 46
PLANT 2009-10 2010-11
RSP
BSL
DSP
IISCO
502 932----361
4891350 500-----
DESPATCHES OF ACID
CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 47