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

SULPHURIC ACID PLANT, BSP

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

ENVIRONMENT FRIENDLY FEATURES

• START UP SCRUBBER SYSTEM.

• SO2 IN FLUE GAS < 2.5 KG/TON

• SO3 / ACID MIST IN FLUE GAS < 90 MG/NM3.

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

PROBLEMS EMERGED

• ACID STREAM -- CIRCULATION TANK -- PHE -- LIMITED STORAGE CAPACITY

• BOILER STREAM -- PROBLEMS IN DM PLANT -- WHB 1& 2 -- ECONOMISER -- SUPERHEATER

PROBLEMS EMERGED

• PROBLEMS DURING START UP -- INEFFICIENT SCRUBBER -- CHOCKING OF GAS LINES -- LIMITED SODA FACILITIES

• EROSION OF CONCRETE STRUCTURES & FLOORS

• INADEQUATE INSTRUMENTATION

PROBLEMS RESULTED IN

• DOWNFALL IN ACID PRODUCTION

• MISMATCH WITH REQUIREMENT

• COKE OVEN GAS BYPASSING.

PROBLEMS RESULTED IN

• PURCHASE OF ACID

• TIME LIMITATIONS FOR CAPITAL REPAIRS.

• ENVIRONMENTAL PROBLEMS DURING START UP

YEAR QUANTITY (MT)

2003-04

2004-05

2005-06

2006-07

2007-08

2008-09

1500* IPT (1000RSP;500BSL)

PURCHASE OF ACID

INNOVATIONS IN ACID PLANT

SULPHUR STREAM

EXTENDED SULPHUR GODOWN

NEW CLEAN COMPARTMENT

SLUDGE SETTLING CHAMBERS

SULPHUR GUN MODIFICATION

• AIR STREAM -- AIR BLOWER IN SERIES -- INCREASING DIA OF AIR

STREAM

INSTALLATION OF NEW BLOWER

GAS STREAM

REPAIR OF CONVERTER

INSTALLATION OF NEW HGF

BOILER STREAM

REPLACEMENT OF WHB & SUPERHEATER

REPLACEMENT OF ECONOMISER

ACID STREAM

COMMON ACID CIRCULATION TANK

REPLACEMENT OF PHE WITH S&T HE

REPLACEMENT OF STORAGE TANK

ADDITIONAL STORAGE TANK

SCRUBBING SYSTEM

ADDITIONAL CAUSTIC SODA TANKS

REPLACEMENT OF SCRUBBER GAS LINES

REPAIR OF FLOOR & DYKES

IMPROVEMENT IN INSTRUMENTATION

DESPATCHES OF ACID TO OTHER UNITS

PLANT 2009-10 2010-11

502 932----361

4891350 500-----

DESPATCHES OF ACID

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