Engineering for Excellence
Presentation Road Map
Overview : Company
Isgec Slop Fired Boilers
Insights of Isgec
Engineering for Excellence
Who are we?
Corporate Data and Business
Founded & Incorporated 1933
Group Turnover INR 4200 Crore*
Market Capitalization INR 4700 Crore *
Headquarter International Offices
Noida (Delhi NCR) 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
Engineering for Excellence
ISGEC SLOP FIRED BOILERS
Next Generation Slop (Spent Wash) Incineration Technology
Engineering for Excellence
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 pH 4 - 4.5 Acidic in Nature Corrodes the surroundings and contaminates the Soil.
BOD* 45000 – 60000 PPM It pollutes rivers and ground water. Water becomes unfit for human consumption and for sustaining aquatic life. COD* 110000 – 135000 PPM
High Moisture 9 – 12 % w/w depending on plant configuration
Difficult to handle and store
Odour Pungent Unbearable
BOD - Biological Oxygen Demand COD - Chemical Oxygen Demand
What is Slop (Spent Wash) ?
Slop / Spent Wash
Engineering for Excellence
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.
Effluent Treatment Method
Engineering for Excellence
Solutions for Firing Slop
Travelling Grate Furnace with Slop Atomization
General Arrangement of Slop Fired Boiler
Engineering for Excellence
32 TPH, 35 Kg/cm2, 380 Deg C at Dharani Sugars, Villupuram Slop with Bagasse / Coal as supporting fuel
Spent Wash Fired Boilers Executed
Engineering for Excellence
DHARANI SUGARS & CHEMICALS LTD.
Site : Kalyanpur Village, Villupuram District, TN Commissioned – Sep’
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 32
Steam pressure at MSSV Outlet kg/cm2(g) 35
Steam temperature at MSSV Outlet °C 380
Feed water temp. at economiser Inlet °C 150 Main Fuel/s (Percentage on Heat Basis)
− 50% Slop + 50% Bagasse
− 50% Slop + 50% Coal (Indian / Imported)
− 100% Bagasse
− 100% Coal (Indian / Imported)
100% MCR
Slop quantity to be fired (55 – 65 Brix) Kg/hr 10000
Slop GCV (at 55 Brix) Kcal/kg 1750 Dust concentration at the ESP outlet mg/Nm3 100
Brief Report
Engineering for Excellence
22 TPH, 45 Kg/cm2, 400 Deg C at Mumias Sugar, Kenya Slop with Bagasse / Coal as supporting fuel
Commissioned in September- 2012
Spent Wash Fired Boilers Executed
Engineering for Excellence
MUMIAS SUGARS & CHEMICALS LTD.
Site : KENYA Commissioned – Sep’
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 22
Steam pressure at MSSV Outlet kg/cm2(g) 45
Steam temperature at MSSV Outlet °C 400
Feed water temp. at economiser Inlet °C 150 Main Fuel/s (Percentage on Heat Basis)
− 50% Slop + 50% Bagasse
− 50% Slop + 50% Coal (Indian / Imported)
− 100% Bagasse
− 100% Coal (Indian / Imported)
100% MCR
Slop quantity to be fired (55 – 65 Brix) Kg/hr 6000
Slop GCV (at 55 Brix) Kcal/kg 1750 Dust concentration at the ESP outlet mg/Nm3 100
Brief Report
Engineering for Excellence
Spent Wash Fired Boilers Executed
40 TPH, 45 Kg/cm2, 400 Deg C at Balrampur Chini Mills, U.P. Slop with Bagasse as supporting fuel
Engineering for Excellence
BALRAMPUR CHINI MILLS LIMITED
Site : BALRAMPUR, UTTAR PRADESH Commissioned – Nove ber’
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 40
Steam pressure at MSSV Outlet kg/cm2(g) 45
Steam temperature at MSSV Outlet °C 400
Feed water temp. at economiser Inlet °C 140
Main Fuel/s
− Slop + Bagasse
− Bagasse
MCR 100%
Slop quantity to be fired (55 – 65 Brix) Kg/hr 13000
Slop GCV (at 55 Brix) Kcal/kg 1700 Dust concentration at the ESP outlet mg/Nm3 50
Brief Report
Engineering for Excellence
BALRAMPUR CHINI MILLS LIMITED
Site : BALRAMPUR, UTTAR PRADESH Commissioned – Nove ber’
SITE PARAMETERS UNIT VALUES
Steam flow at MCR TPH 39 - 42
Steam pressure at MSSV Outlet kg/cm2(g) 43 - 45
Steam temperature at MSSV Outlet °C 395 - 402
Feed water temp. at economiser Inlet °C 130 - 140
Fuel Fired
− Slop + Bagasse MCR 100%
Fuel Parameters Avg. (TPH) TPD
Slop quantity fired (52 – 62 Brix) 13.00 300 – 315
Bagasse fired 7.00 170 – 175
Dust concentration at the ESP outlet mg/nm3 29 - 42
Brief Report
Engineering for Excellence
Spent Wash Fired Boilers Executed
18 TPH, 45 Kg/cm2, 400 Deg C at Dalmia Sugars, Kolhapur Slop with Coal as supporting fuel
Engineering for Excellence
DALMIA SUGARS LIMITED
Site : KOLHAPUR, MAHARASHTRA Commissioned – Nove ber’
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 18
Steam pressure at MSSV Outlet kg/cm2(g) 45
Steam temperature at MSSV Outlet °C 400
Feed water temp. at economiser Inlet °C 150
Main Fuel/s
− Slop + Indian / Imported Coal
− 100% Imported Coal
MCR 100%
− 100% Indian Coal MCR 80%
Slop quantity to be fired (55 – 65 Brix) Kg/hr 5500
Slop GCV (at 55 Brix) Kcal/kg 1750 Dust concentration at the ESP outlet mg/Nm3 50
Brief Report
Engineering for Excellence
Spent Wash Fired Boilers Executed
24 TPH, 45 Kg/cm2(a), 390 °C at Madhucon Sugar & Power, Telangana Slop with Coal as supporting fuel
Engineering for Excellence
MADHUCON SUGAR & POWER LIMITED
Site : TELANGANA Commissioned – Ja uary’
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 24
Steam pressure at MSSV Outlet kg/cm2(a) 45
Steam temperature at MSSV Outlet °C 390
Feed water temp. at economizer Inlet °C 150 Main Fuel/s
− Slop + Bagasse
− 100% Bagasse
MCR 100%
− Slop + Coal (Indian / Imported)
− 100% Coal (Indian / Imported) MCR 100%
Slop quantity to be fired (55 – 65 Brix) Kg/hr 6500
Slop GCV (at 55 Brix) Kcal/kg 1750 Dust concentration at the ESP outlet mg/Nm3 50
Brief Report
Engineering for Excellence
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
Indreswar Sugar Mills, Maharashtra 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 November’ 2015
Reference Installations for Slop Fired Boilers
Engineering for Excellence Proven Travelling Grate technology
• Flexibility of fuels : Wide variety of support fuels such as Bagasse / Rice husk / Wood Chips / Coal etc.
• Minimum Maintenance : Familiar, proven and easy to operate technology
• Enhanced Up Time: Online removal of clinkers with continuous ash discharge ensuring no stoppage of Boiler.
3 pass design
• in tall furnace due to adequate time availability for mixing of slop and support fuel.
• Ash bridging Eliminated in third pass due to wide transverse pitch of heating surfaces.
• Better Combustion through Tall Furnace. Lower flue gas temperature at superheater inlet to avoid fouling due to alkalies in ash (Na2O + K2O) and corrosion of SH due to chlorides in ash.
Advantages of Isgec Design
Flexibility of Fuels :
Minimum Maintenance :
Enhanced Uptime :
Better Combustion
Efficient Combustion :
Ash bridging eliminated
Better Combustion
Engineering for Excellence Online Cleaning System
• Easy removal of gun for cleaning.
• Reliable & Efficient On-Load Cleaning: Steam operated soot blowers for super heater and other convective heating surfaces in horizontal pass to ensure cleaning without any stoppage.
Advantages of Isgec Design
Easy removal of gun for Cleaning
Reliable & Efficient On-Load Cleaning
Engineering for Excellence
Slop firing system
• Complete combustion : high pressure atomization (spray) of slop thru Specially designed Nozzles.
• Slop nozzles : located at Strategic height on furnace water wall to ensure complete combustion and minimum carry over.
• Slop Pumps : high pressure pumps are provided to ensure adequate pressure of slop for atomization.
Advantages of Isgec Design
Complete Combustion :
Slop nozzles
Slop Pumps
Engineering for Excellence 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.
Advantages of Isgec Design
Engineering for Excellence
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.
Advantages of Isgec Design
Engineering for Excellence
Improvements in Design
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.
Special Designed I-Grate
Engineering for Excellence
Specially Designed-I Grate for Slop Fired Boiler 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
Improvements in Design
Engineering for Excellence
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
Specially Designed-I Grate for Slop Fired Boiler
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.
Improvements in Design
Engineering for Excellence
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.
Low Dust Loading
Improvements in Design
Engineering for Excellence 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.
Improvements in Design
Engineering for Excellence With Above Design & Features,
minimum 60 days Continuous Operation of this boiler
Engineering for Excellence
1 x 220 TPH Travelling Grate Boiler for Ingenio Magdalena, SA, Guatemala
Delighted Customers : Cogeneration Boilers
Engineering for Excellence
190 TPH Travelling Grate boiler for 40 MW Bagasse / Coal based Power Plant for Kesar Enterprises, Baheri, U.P.
Delighted Customers : Cogeneration Boilers
Engineering for Excellence
3 x 150 TPH Travelling Grate Boilers for Kamphaengphet Bioenergy Company, Thailand
Delighted Customers : Cogeneration Boilers
Engineering for Excellence
130 TPH Travelling Grate Boiler at Coregreen Sugars Limited, Karnataka, India
Delighted Customers : Cogeneration Boilers
Engineering for Excellence
36 MW Bagasse / Coal based Power Plant with 1 x 180 TPH Travelling Grate Boiler for Shree Dutta SSK, Kolhapur, India
Delighted Customers : Cogeneration Boilers
Engineering for Excellence
28 TPH Biomass Fired Boiler for 8 MW Power Plant for Aldebran, Spain
Delighted Customers : Biomass Fired Boilers
Engineering for Excellence
Pulverized coal fired boilers
Oil & Gas Fired HRSGs CFBC AFBC Traveling Grate Reciprocating Grate WHRB Waste to Energy Vinasse / Slop
Utility Boilers
Industrial Boilers
Process Equipment: Pressure Vessels & Heat Exchangers Presses: Mechanical & Hydraulic Castings: Steel & Iron Contract Manufacturing Trading
Others
Turnkey Power Plants
Sugar Machinery
Air Pollution Control
Equipment
ESP Dust Collectors
O&M services Spares & R&M
Special Products
EPC
Turnkey Sugar Plants
ISGEC HEAVY ENGINEERING LIMITED
Business Verticals
Engineering for Excellence
Noida HO
Yamunanagar
Muzaffarnagar
Chennai
Kolkata Dahej
Mumbai
INDIA
International Offices: • California, USA • Dusseldorf, Germany
70 International Agents
New Delhi
Pune
Bawal
Ratangarh
Noida
Dahej
Ratangarh
Our Locations
Engineering for Excellence
• 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 Ratangarh
Engineering for Excellence
170 TPH TG Boiler for Mumias Sugar Company Ltd., Kenya
100 TPH CFBC Boiler for Nirma, India.
105 TPH AFBC Boiler at Gujarat Flurochemicals Limited, India
140 TPH Oil Fired Boiler for Kochi Refinery, India
Boilers
Engineering for Excellence
25 MW Core Green, Mahrashtra 1x30.4 MW Power Plant for Zambia Sugar ( part of British Sugars)
1x25 MW Power Plant for Core Green Pvt Ltd, Karnataka
1x30 MW KPR Sugar Mills, Karnataka
2 x 20 MW Grasim Industries Ltd., Karnataka
Power Plants
Engineering for Excellence
• 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
Quality, Safety and Environment
Engineering for Excellence
ISGEC HEAVY ENGINEERING LIMITED A-5, Sector 63, Noida - 201 301 (U.P.) India
Tel.: +91 - 120 – 4085900 Fax: +91 - 120 – 4085999 Email: [email protected] / [email protected]
Thank you
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