PROCESS LEVEL ENERGY MANAGEMENT TEAM ON ASH HANDLING PLANT - - PowerPoint PPT Presentation

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May 11, 2023 384 likes •580 views

PROCESS LEVEL ENERGY MANAGEMENT TEAM ON ASH HANDLING PLANT MEMBERS: R K OJHA, LEADER ROMIT MOHAPATRA, MEMBER K V REDDI, MEMBER DILIP DAS, MEMBER NALCO AT A GLANCE SOLAR POWER PLANT CORPORATE OFFICE WIND POWER PLANT BAUXITE MINES

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PROCESS LEVEL ENERGY MANAGEMENT TEAM ON ASH HANDLING PLANT

MEMBERS: R K OJHA, LEADER K V REDDI, MEMBER ROMIT MOHAPATRA, MEMBER DILIP DAS, MEMBER

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NALCO AT A GLANCE

CORPORATE OFFICE

BAUXITE MINES ALUMINA REFINERY ALUMINIUM SMELTER CAPTIVE POWER PLANT ROLLED PRODUCT UNIT PORT FACILITIES WIND POWER PLANT SOLAR POWER PLANT

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SALIENT FEATURES

BAUXITE MINES:

 Area od deposit – 16Sq.KM  Resource – 310 MT  Capacity – 68.25 Lakh TPA  Transport – 14.6KM long cable belt conveyor

ALUMINA REFINERY:

 Capacity – 22.75 Lakh TPA  Atmospheric pressure digestion  Pre-desilication & inter-stage cooling for higher productivity  Co-generation –4X18.5MW power

ALUMINIUM SMELTER:

 Capacity – 4.60 Lakh TPA  180KW Cell technology  Micro-processor based pot regulation system  Ingot, wire rod, billet, strip casting

CAPTIVE POWER PLANT:

 Capacity – 1200 MW  Micro-processor based burner management system  Automatic turbine run-up system  Specially designed barrel type high pressure turbine

ROLLED PRODUCT UNIT:

 Capacity – 50000 MT/ annum  Products – Cold rolled sheets, coils from continuous caster route  Technology – FATA Hunter of Italy

PORT FACILITIES:

 Location: Visakhapatnam  Export - Alumina  Import – Caustic Soda  Mechanised storage and ship handling facilities

WIND POWER PLANT:

 Capacity – 50.4 MW, A.P., commissioned in Dec’2012  Capacity – 47.6 MW, Rajastan, commissioned in Jan’2014

SOLAR POWER PLANT:

 Capacity – 260 KW  Commissioned roof top solar power plant at Corporate Office

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ALUMINA REFINERY

ALUMINA MAKING PROCESS STEAM GENERATION PROCESS

BOILERS:

Make – M/s BHEL Capacity – 4 Boilers of 200TPH – 1 Boiler of 250TPH Type - VU40, Bi-drum, natural circulation, oil/ p.f. fired, fixed tangential corner fired

TURBOGENERATORS:

Make – M/s BHEL Capacity – 4 TGs’ of 18.5MW Type - Extraction back pressure TG Higher cycle efficiency due to co-generation

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BOILER

AIR PRE-HEATER ESP

AIR

FUEL

WET ASH SYSTEM ASH POND

DM WATER

PROCESS FLOW DIAGRAM

STEAM DRY ASH COLLECTION FLY ASH SILO CHIMNEY FLUE GAS

PRAYASH QC 6

ECONOMISER

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WET ASH DISPOSAL SYSTEM

BLR #3

BLR #2

BLR #1

BLR #4 BLR #5

BOTTOM ASH HOPPER

LINE - 1 5 2 3 4

STAGE 1 STAGE 2 STAGE 3

STREAM#6

AIR PREHEATER ECONOMISER

BOILER BLOW DOWN ESP PRAYASH QC 7

STREAM#5 STREAM#4 STREAM#3 STREAM#2 STREAM#1

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ASH POND

ASH DISPOSAL PUMP HOUSE

ASH SLURRY PIT ASH SLURRY PUMP

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UPGRADATION OF ASH SLURRY PUMPS

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ASH DISPOSAL PUMP HOUSE

NO. OF STREAMS : 03
ASH SLURRY PUMPS: 09NOS
SERIES PUMPING
CAPACITY: 635M3/HR
HEAD: 44MTRS
MOTOR: 150KW
NO. OF STREAMS : 03
ASH SLURRY PUMPS: 09NOS
SERIES PUMPING
CAPACITY: 350M3/HR
HEAD: 50MTRS
MOTOR: 110KW

ADPH-I ADPH-II

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ADPH-I

ORIGINAL PUMP
EFFICIENCY : 67%
POWER CONS : 120KW
UPGRADED PUMP
EFFICIENCY : 76%
POWER CONS : 106KW

UPGRADATION OF ASH SLURRY PUMP IN STREAM-1 OF OLD ADPH

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POWER SAVING

INSTANTANEOUS POWER SAVING : 14KWH
POWER SAVING PER DAY : 336KWH
POWER SAVING PER ANNUM : 122640 KWH
SAVING OF POWER @Rs 3.20/- : Rs 3,92,448/- (PER

PUMP PER ANNUM)

SAVING OF POWER FOR ONE STREAM:Rs 11,77,344

/- (PER ANNUM)

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CALCULATION OF PAY BACK PERIOD

COST OF REPLACEMENT OF ONE PUMP : Rs 6,15,282/-
COST OF REPLACEMENT OF ONE STREAM : Rs 18,45,846/-
SAVING OF POWER FOR ONE STREAM:Rs 11,77,344 /- (PER

ANNUM)

PAY BACK PERIOD : 1.6 YEARS

THE PAY BACK PERIOD IS ABOUT ONE YEAR APART FROM IMPROVED LIFE OF COMPONENTS

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EFFICIENCY OF PUMP

WATER HORSE POWER SHAFT HORSE POWER

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REASON FOR INCREASE IN HYDRAULIC EFFICIENCY

FLOW PATTERN CHANGED FROM RADIAL

FLOW TO MIXED FLOW

TWISTED VANE IMPELLER
MODIFIED HYDRAULIC ASSEMBLY

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MIXED FLOW TWISTED VANE IMPELLER MODIFIED HYDRAULIC ASSEMBLY

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CONCLUSION

EFFICIENCY INCREASED BY 9%
POWER SAVING PER STREAM – 122.64 MW
NET SAVING IN TERMS OF MONEY – Rs. 11,77,344 /-

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