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

400

300

200

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

0

10

20

30

40

50

60

70

80

90

100

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.

THANKS