Download - Gas producer plant
THE NEW GENERATION, COAL THE NEW GENERATION, COAL FIRED, COST EFFICIENT, FULLY FIRED, COST EFFICIENT, FULLY
SAFE AND AUTOMATED, EXTENDED SAFE AND AUTOMATED, EXTENDED SHAFTSHAFT
producer gas producer gas plantplant
INDIA INDUSTRIAL ENTERPRISES
SUPPLIER :-
producer gas is generated by blowing air producer gas is generated by blowing air and steam through a bed of incandescent and steam through a bed of incandescent
solid fuel under such condition that the solid fuel under such condition that the combustible matter of the solid fuel is combustible matter of the solid fuel is
converted into combustible gases. converted into combustible gases.
gas produced from coal based producer gas produced from coal based producer contains some gaseous hydro-carbons and contains some gaseous hydro-carbons and
tar vapour along with carbon monoxide, tar vapour along with carbon monoxide, hydrogen, carbon dioxide and balance hydrogen, carbon dioxide and balance
nitrogen.nitrogen.
process viewprocess view
reactor zone temperaturesreactor zone temperatures
1200
1100
1000
800
600
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300
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100
LTC 1 GAS
LTC 2 GASOUTLET GAS
MIXINGCHAMBER
JACKETBOILER
ASH
HYDRAULICCYLINDER
REACTOR
COAL BUNKER
SECTOR GATE
BELL CONE VALVE 1
BELL CONE VALVE 2
SOFT WATEROVERHEAD
TANK
VAPOURDRUM
LEVEL CONTROLVALVE
TEMP. CONTROL VALVE
FLOW CONTROL VALVENORMAL SPEED
CONTROLCONTROL & INSTRUMENTATION & INSTRUMENTATION
AUTO SAFETY FEATURES DURING POWER / FLAME AUTO SAFETY FEATURES DURING POWER / FLAME FAILUREFAILURE
BLAST AIR FLOW CONTROL AREABLAST AIR FLOW CONTROL AREA
DRUM LEVEL CONTROL AREADRUM LEVEL CONTROL AREA
B.S.T. CONTROL AREAB.S.T. CONTROL AREA
GAS OUTLET AREAGAS OUTLET AREA
PRODUCER GAS COMPOSITIONPRODUCER GAS COMPOSITION
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O2 0.4%
CmHn 4%
CO2 5%
H2 12%
CO 27%
N2 52.8%
Existing cost of fuel for Rotary Kiln
Pulp Production : 179 TPD
White Liquor consumption : 470 kgs/TP
White Liquor production : 84.13 TPD
Lime Consumption : 0.77 MT/MT WL
Lime Production : 64.8 TPD
Fuel Oil Consumption : 0.186 T/MT of Lime
Fuel oil consumption : 12.05 TPD
Cost of Fuel oil : Rs.20048/MT
Cost of fuel oil : Rs.2.42 lacs/day
Proposed cost of fuel for Rotary Kiln withProducer Gas
ITEMITEM UNITUNIT Con/DayCon/Day RateRate Cost/DayCost/Day
CoalCoal MTMT 2525 3432.53432.5 8581285812
Fuel OilFuel Oil MTMT 3.013.01 2004820048 6034460344
PowerPower KWHKWH 12001200 2.292.29 27482748
Process Process WaterWater
cumcum 6060 1.71.7 102102
Soft WaterSoft Water CumCum 2424 1212 288288
ManpowerManpower NosNos 1818
PerPer 66 477477 28622862
CasCas 1212 132132 15841584
TOTAL CostTOTAL Cost 1.54 lacs1.54 lacs
Savings in Fuel oil cost after Producer gas
Cost of fuel before Producer gas : 2.42 lacs/day
Cost of fuel after producer gas : 1.54 lacs/day
Savings in fuel cost after installation of Producer Gas :
Savings per day : 0.88 lacs
Annual Savings : 321.2 lacs
Investment (Offer ) : 223 lacsTaxes : 8 lacs(appx)Civil works : 30 lacsTotal cost : 261 lacs
Simple Payback : 297 days: 10 months
Safety Interlocks
1.Control of Producer Gas output as per heat demand:-A pressure transmitter will be fitted at the outlet gas header before gas booster, which will generate signal to monitor and control the gas pressure.This will be done by increasing or decreasing the air flow from Air Bowers.
2.Control of B.S.T. and addition of steam and air:-Addition of steam is also important for regulated gasification with optimum steam carbon reactions,temp.control and prevention of clinker formation.For optimum Co and H2 formation,a blast saturation temp.of 60deg.c.will be ideal.
3.Interlocks in the Gas booster and the associated Gas train:- a) At pressure below 15mmwc in the gas header,the gas booster can not be started. b) Gas booster can not be started without starting of Air Blower. c) If the gas booster is not in operation,the gas isolation valve on the gas train can not be opened.
Safety Interlocks
4. Interlocks in Air Line:- In case of Power failure the individual pneumatic damper PVC in air line to gasifier will shut immediately.
5. Interlocks in steam circuit:- Full opening of steam valve to B.S.T. controller in case of power failure.In this case when the air flow stops, steam will continue to flow to gasifier to stop back flow of gas to the air line
6.Interlock of Gas sealing after washing chamber :- a) In the event of Power failure,the liquor outlet valve from the washing chamber sump,which normally remains open will shut immediately as a necessary step to fill up the sump with water for sealing the gas out let line from sump. b) Simultaneously with above operation,a valve in make up water line from Overhead emergency water tank will open to allow water to sump for filling it and sealing the gas line.
Safety Interlocks
7. Interlocks with Kiln/Burner:-
a) In case of flame failure which is scanned by flame scanner,it will send signal to the solenoid circuit of the gas isolation valve and the valve will be automatically close.
b) As long as the gas booster is not in operation,the gas isolation valve can not be opened.
c) If ID fan of the kiln fails,gas isolation valve will close immediately.
d) If gas pressure at burner inlet is above 150 mmwc or below 30mmwc the gas isolation valve will close after 10 seconds.
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