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A SEMINAR PRESENTATION ON SUMMER TRAINING FROM HINDUSTAN ZINC LIMITED MADE BY: KALYAN GORAI 4 TH YR.,MECHANICAL
51
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A SEMINAR PRESENTATION

ON SUMMER TRAINING

FROM

HINDUSTAN ZINC LIMITED

MADE BY:KALYAN GORAI4TH YR.,MECHANICAL

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HINDUSTAN ZINC LIMITED

CHANDERIYA LEAD ZINC SMELTER(CAPTIVE POWER PLANT)

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• A power plant is an industrial facility for the generation of electric power. The power produced in Hindustan Zinc Limited is for its own production purposes, and is known as a Captive Power Plant (CPP).

• While supplying uninterrupted and reliable power to Chanderiya Lead Zinc Smelter, the CPP has been additionally wheeling power to its Agucha, Debari and Dariba units of Hindustan Zinc Limited.

• Recently sale of power has also been initiated with both RSEB and power exchange.

• Captive Power Plant in Chanderiya consists of 3 units (2X77 MW + 1X80 MW)=Total of 234 MW.

INTRODUCTION

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• Disturbances in taking power from grid.

• Grid power distribution is unreliable both in quality and quantity.

• Taking power from grid is much more expensive as compared in generating its own power i.e. SELF GENERATION –CPP.

• Cost of grid power Rs./kWh 4.50 to 5.50

• Cost of Captive Generation Rs./kWh 2.00 to 2.50

NEED OF CPP

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BOILER CLASSIFICATION & CPP SPECIFICATIOS :

MAKE & YEAR: : BHEL,2004

Acc to application : Utility boiler

Acc to operating pressure : Sub-Critical (Re-circulation type)

Acc to fuel : Solid fuel (pulverised fuel firing)

Acc to draft : Balanced draft

Acc to circulation : Natural circulation

Acc to pass : Two pass (outdoor type)

Acc to firing : Tangential firing

Acc to pressure : High pressure

Acc to position : Vertical

Acc to support : Top supported with buck stay

TECHNICAL SPECIFICATIONS

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• Type of Turbine : High press, high Temp Impulse-Reaction• Rotation Speed : 3000rpm• Rated Power : 77MW• Main steam inlet pressure : 90 kg/cm²• Rated steam flow inlet : 286.4 T/hr• Stage of heaters : 2LP, 1 De-aerator & 2HP• Heat Rate : 2640 kcal/ kwhr

Turbine Specifications

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Thermal power stations produce electricity by burning fuel in a boiler to heat water to produce steam. This steam at high pressure rotates the blades of a turbine which spins a generator to produce electricity. The steam is further cooled in a condenser to form water and sent again to boiler.

Thermal Power Station

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BOILER

BOTTOM ASH HOPPER

ASHSILO

ASH PUMP

ESP

IDFAN

ASHDYKE

AIR PRE -HEATER

FD FAN

DISPOSAL -- ACC

CHIMN

EY

BUNKER

HOT PA FANFEEDER

PULVERISER

TURBO ---GENERATOR

CONDENSER

BFP

HP HEATER

DEAERATOR

CT

CW PUMP

LP HEATER

CEP

COAL YARD

RESERVOIRDM PLANT

FILTERDM TANK

POWER

COAL TO ELECTRICITY

CRUSHER

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1) BOILER AND AUXILIARIES.

2) TURBINE,GENERATOR AND AUXILIARIES.

3) ESP (ELECTROSTATIC PRECIPITATOR)

4) COOLING TOWER

5) DE-MINERALISING PLANT

MAJOR COMPONENTS

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Furnace Water wall tubes Pressure Parts

Drum Super heaters Reheaters Economizers

Air pre heaters Soot Blowers Coal Bunkers and feeders Pulverizes Coal Piping Burners Igniters & warm-up Burners Duct work Insulation and Legging

BOILER OVERVIEW

1) Boiler Terminology

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• Furnace is the primary part of boiler where the chemical energy of fuel is converted to thermal energy.

• Furnace is incorporated with water wall tubes where water is evaporated to steam.

• TYPES OF WATER WALL TUBES :

1. Tangent tube wall : Tubes are closely attached

from the panels.

2. Membrane wall : Tubes are welded together

by means of metal strips.

Furnace & Water Wall Tubes

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• Superheaters are provided in the boiler to raise the steam temperature above the saturation temperature by absorbing heat from flue gas.

ADVANTAGE:

1. By increasing the temperature of steam useful energy can be recovered thereby increasing efficiency of cycle.

2. It eliminates condensation of steam in pipelines, thus avoiding erosion of blades.

TYPES OF SUPERHEATERS :• Radiant Superheaters :The superheaters placed above

the furnace which can view the flame.• Convective Superheaters : The other surfaces are called

convective type.

SUPERHEATER

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• REHEATER is used to raise the temperature of steam from which part of the energy has been extracted in high pressure turbine.

• By reheating efficiency can be increased which increases with number of stages.

• Single reheating is usually applied for capacity above 100MW & 2 reheat above 500MW.

DESUPERHEATER :• This is located between two superheater header and

the steam flows through it. Water of high quality is introduced into the superheated steam through a spray nozzle at the throat of a venturi section which mixes and cools the superheated steam. By regulating the water spray steam temperature can be easily controlled.

• The spray water will normally obtained from feed water line after the HP heaters and before feed regulation station.

REHEATERS & DE-SUPERHEATERS

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• An Economiser absorbs heat from the flue gases and add this as sensible heat to the feed water before water enters the evaporative circuit of boiler.

• Feed water is supplied to economiser inlet header via feed stop and check valves.

• Flow of feed water is upward through the economiser that is counter flow to flue gases & from outlet header feed water is led to steam drum.

• By recovering heat from flue gases and supplying it to feed water it increases efficiency in steam generation or in other words saves fuel.

ECONOMISERS

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• APH is a heat exchanger in which air temperature is raised by transferring heat from other fluid such as flue gases.

• Stability of combustion is improved by use of hot air.

• Less unburnt flue particles in flue gas.• In case of pulverised coal combustion ,hot air can be

used for drying the coal as well as for transporting the pulverised coal to burners.

TYPES : 1. Recuperative Type : Heating medium is on one side

& air is on the other side of tube /plate & heat transfer is by conduction

through the material which separates the media. 2. Regenerative Type : Heating medium flows

through a closely packed rotating matrix to raise its temperature and then air is

passed through the matrix to take up the heat.

AIR PRE HEATER(APH)

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REGENERATIVE TYPE(APH)

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• PA (Primary air fan) : These are the high pressure fans which supply the air needed to dry & transport coal either directly from the coal mills to the furnace or to the intermediate bunker.

These fans are usually of the radial aerofoil type.

• FD (Forced draft fan) : These fans supply the air necessary for fuel combustion and must be seized to handle the stoichiometric air plus the excess air excess air needed for proper burning of the fuel.

These fans are usually of the radial aerofoil or variable pitch axial type.

• ID (Induced draft fan) : These fans evacuate combustion products from the boiler furnace in atmosphere through stack by creating sufficient negative pressure .

FANS

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• Rated Power : 77 MW• Rated Voltage : 11.5 kV• Rated Current : 4800 A• Rated Speed : 3000 rpm• Power Factor : 0.8 lag• Rated Frequency : 50 Hz• Efficiency : 98.5%

Generator Specifications

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2) TURBINE

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• Turbine is a Prime Mover Which Converts “Thermal Energy Of Fuel Into Mechanical Energy”.

• Steam is allow to expand through narrow orifice, it assumes kinetic energy at the expenses of enthalpy, this kinetic energy is converted into mechanical energy through the impluse or rection of steam against the blade.

• Steam moves continuously through blades as a result Centrifugal pressure exerted on the blade.

• TOTAL MOTIVE FORCE =

CENTRIFUGAL FORCE + CHANGE OF MOMENTUM (ROTATIONAL ENERGY)

Principle Of Turbine

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NAME• CONDENSER

• MAIN AIR EJECTOR

• CW PUMPS

FUNCTION Condense the steam & maintain the

vacuum at the exhaust of LP Turbine.

Main the vacuum by extracting the non condensable gases from the condensate.

To circulate cooling water through condenser tubes for cooling the system.

Turbine Auxiliaries

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NAME• CEP

• LPH

• DEAERATOR

FUNCTION Extract condensate from condenser

hot well & passes it to deaerator.

To raise the temperature of condensate by transferring heat taken from turbine extraction.

To remove dissolved gases from feed water by increasing there temperature with pegging steam taken from APRDS.

Turbine Auxiliaries

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NAME• BFP

• HPH

• OIL PUMPS1. MAIN OIL

PUMP(MOP)

FUNCTION To pump the feed water from

deaerator to Boiler (Economiser) at a very high pressure.

Before going to boiler it is again heated by turbine extractions.

To supply lube oil & control oil during “Normal operation of Turbine”.

Turbine Auxiliaries

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NAME

2. AUXILIARY OIL PUMP (AOP)

3. EMERGENCY OIL PUMP (EOP)_

4. JACKING OIL PUMP (JOP)

FUNCTION

To supply lube & control oil during “ Start up & Shut down of Turbine ”.

To supply lube oil to bearings during “ AC failure ”.

For lifting turbine shaft during startup & shut down.

Turbine Auxiliaries

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TURBO GENERATOR

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A Generator is an electromechanical device that converts mechanical energy to alternating current electrical energy by using a rotating magnetic field. Any AC generator can be called as an Alternator.

POWER OUTPUT OF TURBO GENERATOR :P D2 . L . B . A . n

P : Power in MVAD : Bore Diameter of Core in metersL : Length of Active Rotor Body in metersB : Air Gap Flux Density in TeslaA : Stator Ampere-Turn Loading in Amp./metern : Speed in rpm

• ,

DEFINITION

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Stator

Stator Core

Rotor

Bearing

Shaft Seal

Terminal Bushing

Oil Catcher

Cooler

InsertCover

MAIN PARTS OF TURBO GENERATOR

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Stator End Winding Assembly

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Rotor Body

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Rotor Fan Blades

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•Magnetizes the rotor poles and creates the required magnetic intensity for stator conductors thereby developing the stator voltage .

•Regulates terminal voltage of the machine.

•Meet excitation power requirements under all normal operating conditions.

•Enables maximum utilization of machine capability.

•Guard the machine against inadvertent tripping during transients.

•Improve dynamic & transient stability thereby increasing availability.

Excitation System

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3) ESP

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An electrostatic precipitator is a Device which removes dust or other finely divided particles from flue gases by charging the particles inductively with an electric field, then attracting them to highly charged collected plates.

ESP

FUNDAMENTAL PARTS OF ESP:

•Casing•Hopper•Gas Distributor Screen•Collecting System•Emitting System•Rapping Mechanism of collecting system•Rapping Mechanism of Emitting System•Insulator Housing

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• Removal of dirt from flue gases in steam plants.• Cleaning of air to remove fungi and bacteria in

establishments producing antibiotics and other drugs.

• Cleaning of air in ventilation and air conditioning systems.

• Removal of oil mists in machine shops and acid mists in chemical process plants.

• Cleaning of blast furnace gases. • Recovery of valuable materials such as oxides of

copper, lead, and tin. • separation of rutile from zirconium sand.

Application of ESP

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4) COOLING TOWER

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• Cooling tower is an application where the plant heat exchangers are cooled with water.

• The pump keeps the water re-circulation through the heat exchangers where it picks up heat and distributes on to the cooling tower. The heat is released from the water through evaporation.

• The cold water enters the heat exchangers for cooling. The resulting hot water from heat exchangers is sent to cooling tower.

• The cold water exits the cooling tower and is sent back to the exchangers for cooling.

• Make up water source is used to replenish around 2 % of water lost due to evaporation and drift.

Definition

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ATMOSPHERIC NATURAL

DRAFT

MECHANICAL DRAFT

AIR COOLED

CONDENSER

AIR COOLED HEAT

EXCHANGER

Classification Of Cooling Tower

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Natural draft cooling towers :• Distinct shape much like a tall cylinder,it operates on a chimney principle that

allows air movement on density differential.• Such towers have the advantage of not requiring any fans, motors,gear boxes

etc.• Due to the tremendous size, these type of towers are used only for very high

flow rates.Mechanical Draft cooling towers.• These are more widely used. These towers utilize large fans to force air

through circulating water.• The water falls downward over fill surfaces which help increase the contact

time between the water and the air.This helps maximize heat transfer between the two.

Types of cooling tower

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De- Mineralization System consisting of:-

• PSF (PRESSURIZED SAND FILTER)• ACF (ACTIVATED CARBON FILTER)• SAC (STRONG ACID CATION EXCHANGER) • DEGASSER• WBA (WEAK BASE ANION EXCHANGER . • SBA (STRONG BASE ANION EXCHANGER). • MB (MIX BED).• UF FILTER

De-Mineralization (DM) is the process of Removing mineral salts from water by using the Ion Exchange process which produces water with high quality & purity that used in “Boiler as a Feed Water”.

6) DE-MINERALISING PLANT

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Raw waterpond

Clarifier CWST

DEGASSER.

Goshunda Dam

Alum Dosing For coagulation

Poly Dosing For Flocculation

Chlorine Dosing For Killing Bacteria & Algae

For Storage

Remove Dead Suspended Particles

Remove Odour & Organic Matters

Remove Cations e.g.

Ca+,Mg+,Na+.

REMOVAL OF CO2

Remove Carbonates & Bi-carbonates

Remove Anions e.g.

Cl-,SO4-.

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HOTWELL

DMST

A

B

TO CST

Hot well make up pumps

Remove Remaining Silica:PH: 6.8-7.0Cond.:<1.00ųS/cmSilica:0.02ppb

Membrane Filter to Remove Colloidal Silica

From SBA

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7)COAL HANDLING PLANT

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Overview Of CHPCOAL Transportation by RAIL

Through wagon Tippler

Apron feeder

Vibrating type

non vibrating type

Primary crusher house

Reduced size from 600mm to 100mm

SECONDARY CRUSHER

HOUSE

Reduced size from 100mm to 20mm

MAGNETIC SEPRATOR

Separate magnetic particles i.e. iron

Vibrating screen

Allow only 20mm sized coal

RECLAIM HOPPER

Through belt

conveyor

COAL DRIER

Through Tippler

COAL BUNKER

PULVERISER TO BURNERS

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Wagon Tippler Bottom Discharge Wagon

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Coal System

• Through Wagon Tippler the Raw coal is fed to primary crusher house via belt conveyor where the size of coal is reduced from 600mm to 100mm. Magnetic separator, separates the iron particles & then to secondary crusher house for further reduction of coal (20mm sized).

• Vibrating screen allows only 20mm sized coal to drier & through tippler or trolley ,it passes over to coal bunker & then pulverizers for further crushing through volumetric feeder .

• The Pulverized Coal is then mixed with primary air which carries the coal air mixture each four corners of the furnace burners.

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8) ASH HANDLING PLANT

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ESP

FLY ASH SILO

BULKER

Unloading

Plate valve

COM

PRESSOR

Compressed air

Fly ash

ASH HANDLING PLANT

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ASH HANDLING PLANT

Fly ash is captured and removed from the flue gas by electrostatic precipitators located at the outlet of the furnace and before the induced draft fan. The fly ash is periodically removed from the collection hoppers below the precipitators. Generally, the fly ash is pneumatically transported to storage silos for subsequent transport by trucks.BOTTOM ASH SYSTEM

At the bottom of every boiler, a hopper has been provided for collection of the bottom ash from the bottom of the furnace. This hopper is always filled with water to quench the ash and clinkers falling down from the furnace. Some arrangement is included to crush the clinkers and for conveying the crushed clinkers and bottom ash to a storage site.