mr. rajesh singla, m/s isgec heavy engg. ltd. best solution to

Engineering for Excellence

ISGEC HEAVY ENGINEERING LIMITED

Welcome

All Delegates


Presentation Road Map

Overview : Company

Isgec Slop Fired Boilers

Insights of Isgec


Isgec Heavy Engineering Limited

Overview


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


ISGEC SLOP FIRED BOILERS

Next Generation Slop (Spent Wash) Incineration Technology


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


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


Solutions for Firing Slop

Travelling Grate Furnace with Slop Atomization


Solutions for Firing Slop

Travelling Grate Furnace with Slop Atomization

General Arrangement of Slop Fired Boiler



Spent Wash Boilers Executed


32 TPH, 35 Kg/cm2, 380 Deg C at Dharani Sugars, Villupuram Slop with Bagasse / Coal as supporting fuel

Spent Wash Fired Boilers Executed


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


22 TPH, 45 Kg/cm2, 400 Deg C at Mumias Sugar, Kenya Slop with Bagasse / Coal as supporting fuel

Commissioned in September- 2012



MUMIAS SUGARS & CHEMICALS LTD.

Site : KENYA Commissioned – Sep’





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



Brief Report


What Competitors Said

Total 8 Slides



40 TPH, 45 Kg/cm2, 400 Deg C at Balrampur Chini Mills, U.P. Slop with Bagasse as supporting fuel


BALRAMPUR CHINI MILLS LIMITED

Site : BALRAMPUR, UTTAR PRADESH Commissioned – Nove ber’





Feed water temp. at economiser Inlet °C 140

Main Fuel/s

− Slop + Bagasse

− Bagasse

MCR 100%



Brief Report


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


Brief Report



18 TPH, 45 Kg/cm2, 400 Deg C at Dalmia Sugars, Kolhapur Slop with Coal as supporting fuel


DALMIA SUGARS LIMITED

Site : KOLHAPUR, MAHARASHTRA Commissioned – Nove ber’





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%



Brief Report



24 TPH, 45 Kg/cm2(a), 390 °C at Madhucon Sugar & Power, Telangana Slop with Coal as supporting fuel


MADHUCON SUGAR & POWER LIMITED

Site : TELANGANA Commissioned – Ja uary’



Steam pressure at MSSV Outlet kg/cm2(a) 45


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%



Brief Report


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



Advantages of Isgec Design

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.


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.


Easy removal of gun for Cleaning

Reliable & Efficient On-Load Cleaning


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.


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.



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.




Improvement in Design


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


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



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.



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


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.


Engineering for Excellence With Above Design & Features,

minimum 60 days Continuous Operation of this boiler


1 x 220 TPH Travelling Grate Boiler for Ingenio Magdalena, SA, Guatemala

Delighted Customers : Cogeneration Boilers


190 TPH Travelling Grate boiler for 40 MW Bagasse / Coal based Power Plant for Kesar Enterprises, Baheri, U.P.



3 x 150 TPH Travelling Grate Boilers for Kamphaengphet Bioenergy Company, Thailand



130 TPH Travelling Grate Boiler at Coregreen Sugars Limited, Karnataka, India



36 MW Bagasse / Coal based Power Plant with 1 x 180 TPH Travelling Grate Boiler for Shree Dutta SSK, Kolhapur, India



Delighted Customers


28 TPH Biomass Fired Boiler for 8 MW Power Plant for Aldebran, Spain

Delighted Customers : Biomass Fired Boilers


Isgec Heavy Engineering Limited MORE ABOUT ISGEC


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


Global Experience


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


Isgec Yamunanagar


• 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


Isgec Dahej


Isgec Muzaffarnagar


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


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


• 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


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

http://www.isgecgroup.com/

mr. rajesh singla, m/s isgec heavy engg. ltd. best solution to

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