PROCESS LEVEL ENERGY MANAGEMENT TEAM ON ASH HANDLING PLANT - PowerPoint PPT Presentation

PROCESS LEVEL ENERGY MANAGEMENT TEAM ON ASH HANDLING PLANT MEMBERS: R K OJHA, LEADER ROMIT MOHAPATRA, MEMBER K V REDDI, MEMBER DILIP DAS, MEMBER

NALCO AT A GLANCE SOLAR POWER PLANT CORPORATE OFFICE WIND POWER PLANT BAUXITE MINES ALUMINIUM SMELTER ALUMINA REFINERY CAPTIVE POWER PLANT PORT FACILITIES ROLLED PRODUCT UNIT

SALIENT FEATURES BAUXITE MINES: ALUMINA REFINERY: ALUMINIUM SMELTER:  Area od deposit – 16Sq.KM  Capacity – 22.75 Lakh TPA  Capacity – 4.60 Lakh TPA  Resource – 310 MT  Atmospheric pressure digestion  180KW Cell technology  Capacity – 68.25 Lakh TPA  Pre-desilication & inter-stage  Micro-processor based pot  Transport – 14.6KM long cable cooling for higher productivity regulation system  Co-generation – 4X18.5MW power  Ingot, wire rod, billet, strip belt conveyor casting CAPTIVE POWER PLANT: ROLLED PRODUCT UNIT: PORT FACILITIES:  Capacity – 1200 MW  Capacity – 50000 MT/ annum  Location: Visakhapatnam  Micro-processor based burner  Products – Cold rolled sheets, coils  Export - Alumina  Import – Caustic Soda management system from continuous caster route  Automatic turbine run-up  Technology – FATA Hunter of Italy  Mechanised storage and ship system handling facilities  Specially designed barrel type high pressure turbine SOLAR POWER PLANT: WIND POWER PLANT:  Capacity – 260 KW  Capacity – 50.4 MW, A.P.,  Commissioned roof top solar commissioned in Dec’2012  Capacity – 47.6 MW, Rajastan, power plant at Corporate Office commissioned in Jan’2014

ALUMINA REFINERY ALUMINA MAKING PROCESS STEAM GENERATION PROCESS BOILERS: TURBOGENERATORS: Make – M/s BHEL Make – M/s BHEL Capacity – 4 Boilers of 200TPH Capacity – 4 TGs’ of 18.5MW – 1 Boiler of 250TPH Type - Extraction back Type - VU40, Bi-drum, natural pressure TG circulation, oil/ p.f. fired, fixed Higher cycle efficiency due to tangential corner fired co-generation

PROCESS FLOW DIAGRAM FUEL STEAM BOILER AIR FLUE GAS CHIMNEY ECONOMISER DM WATER AIR PRE-HEATER DRY ASH COLLECTION ESP WET ASH SYSTEM FLY ASH SILO ASH POND 6 PRAYASH QC

WET ASH DISPOSAL SYSTEM STREAM#6 ESP BLR #5 STREAM#5 BOTTOM ASH HOPPER STREAM#4 BLR #4 BOILER BLOW DOWN BLR #3 STREAM#3 BLR #2 ECONOMISER STREAM#2 AIR STAGE BLR #1 PREHEATER 3 STREAM#1 STAGE 2 STAGE LINE - 1 5 2 3 4 1 7 PRAYASH QC

ASH DISPOSAL PUMP HOUSE ASH SLURRY PUMP ASH SLURRY PIT ASH POND

UPGRADATION OF ASH SLURRY PUMPS

ASH DISPOSAL PUMP HOUSE ADPH-I ADPH-II • NO. OF STREAMS : 03 • NO. OF STREAMS : 03 • ASH SLURRY PUMPS: 09NOS • ASH SLURRY PUMPS: 09NOS • SERIES PUMPING • SERIES PUMPING • CAPACITY: 635M3/HR • CAPACITY: 350M3/HR • HEAD: 44MTRS • HEAD: 50MTRS • MOTOR: 150KW • MOTOR: 110KW

ADPH-I UPGRADATION OF ASH SLURRY PUMP IN STREAM-1 OF OLD ADPH • ORIGINAL PUMP • UPGRADED PUMP • EFFICIENCY : 67% • EFFICIENCY : 76% • POWER CONS : 120KW • POWER CONS : 106KW

POWER SAVING • INSTANTANEOUS POWER SAVING : 14KWH • POWER SAVING PER DAY : 336KWH • POWER SAVING PER ANNUM : 122640 KWH • SAVING OF POWER @Rs 3.20/- : Rs 3,92,448/- (PER PUMP PER ANNUM) • SAVING OF POWER FOR ONE STREAM:Rs 11,77,344 /- (PER ANNUM)

CALCULATION OF PAY BACK PERIOD • COST OF REPLACEMENT OF ONE PUMP : Rs 6,15,282/- • COST OF REPLACEMENT OF ONE STREAM : Rs 18,45,846/- • SAVING OF POWER FOR ONE STREAM:Rs 11,77,344 /- (PER ANNUM) • PAY BACK PERIOD : 1.6 YEARS THE PAY BACK PERIOD IS ABOUT ONE YEAR APART FROM IMPROVED LIFE OF COMPONENTS

WATER HORSE POWER EFFICIENCY OF PUMP = SHAFT HORSE POWER

REASON FOR INCREASE IN HYDRAULIC EFFICIENCY • FLOW PATTERN CHANGED FROM RADIAL FLOW TO MIXED FLOW • TWISTED VANE IMPELLER • MODIFIED HYDRAULIC ASSEMBLY

MIXED FLOW TWISTED VANE IMPELLER MODIFIED HYDRAULIC ASSEMBLY

CONCLUSION • EFFICIENCY INCREASED BY 9% • POWER SAVING PER STREAM – 122.64 MW • NET SAVING IN TERMS OF MONEY – Rs. 11,77,344 /-