5.

CAPTIVE POWER PLANT

WASTE HEAT RECOVERY BOILER The WHRB shall be sized and designed to extract maximum sensible heat energy contained in the waste gases emanating from the Direct Reduction kiln. The major technical parameters of WHRB are given below. TECHNICAL PARAMETERS OF WHRB Type : Single drum, vertical, multipass, Semi-outdoor,natural circulation Steam output, maximum continuo- : us rating (MCR), tph Steam output, nominal continuous : Rating (NCR), t/hr Steam pressure at super- heater Outlet, ksca : 36 28 65 485 140 02 80,000 950-1000 35 160

Steam temperature at superheater : Outlet, C Feed water temp. Economiser, C : No. of Boilers Waste gas inlet conditions Gas flow, Nm3/hr Gas temperature, C Dust content, mg/Nm3 : : : :

Exit temperature of waste gases,C :

The boiler pressure part internals will be designed among other 50

considerations to withstand mechanical wear from the abrasive dust particles carried by the waste gases. The boiler consists of economiser, evaporator, super heater, integral piping, waste gas ducting with expansion joints, supporting structures, platforms and walkways, soot blowers etc. The proposed WHRB shall be unfired, single drum, top supported, three pass, natural circulation type. The high temperature dust laden waste gases from DR plant kiln will enter the first pass of the boiler. The water wall is the first heat transfer section arranged in the direction of gas flow. The entire section is made of water-cooled enclosure formed by tube fusion welded panel or fin welded panel tube. The water wall section is partitioned and a screen is provided at the inlet of second pass to safeguard the superheater from any fouling. Front-end rear wall is continuous and connected to top/bottom header. The sidewalls are provided with headers, which in turn are connected to steam drum by supply/riser tubes. Super heater-1 & 2 are the second heat transfer section in the direction of gas flow. It consists of plain tube assembly, inlet & outlet headers and connected links. Superheater section will be arranged in two stages with a spray type desuperheater in between to control the steam temperature. Depending upon the design, the superheater will be followed by evaporator section. Evaporator is located in the second pass after Superheater-1 in the direction of gas flow. It consists of inclined coils assembly made of plain tubes, inlet & outlet headers and connected link. Evaporator-2 & 3 (optional) are located in the third pass in the 51

direction of gas flow, having the coils similar to the evaporator coils. As per design, three or four blocks of economiser will be provided in the third pass to cool the gases up to around 160 C. Adequate number of soot blowers will be provided for on-line cleaning of heating surfaces. Soot blowing may be of steam type or acoustic depending upon the design. The drum and superheater outlet will be provided with springloaded safety valves of adequate relieving capacity. The Boiler will be provided with a suitable control system to ensure maximum steam generation for different waste gas inlet conditions. An attemperator will be provided to ensure constant superheater outlet temperatures over a wide operating range. The control system will be designed to ensure steady steam flow and temperature conditions. A three-element drum level control system consisting of drum level transmitter, feed water flow transmitter, steam flow transmitter and flow controller etc. will be provided. Instruments will be provided for measuring pressure and temperature of steam, feed water, waste gases at different sections. Direct level gauges and levels switches for steam drum will also be provided. Flow measuring device at the inlet of WHRB for measurement of waste gases will also be provided. Waste gas supply system : After burning chamber (ABC) and Dust settling chamber (DSC) will be located at the exits of DR plant kiln. Part of the dust carried by the waste gases will settle down at DSC. The after burning chamber 52

shall form an integral part of DSC. The DSC/ABC assembly will be connected to the DR plant kiln through refractory lined duct. The combustibles in the waste gases are burnt in the After burning chamber which will raise the waste gas temperature and will make the waste gases free from carbon mono-oxide. Provision will be made for water spraying to control the waste gas temperature in desired limits. From ABC outlet, the WHRB will be connected through a refractory lined duct. An Emergency stack cap on the top of ABC will be provided for diverting the waste gases from ABC to atmosphere when the WHRB is under shutdown or breakdown. Flue Gas Cleaning System : The gases passing out of WHRB also consists of large amount of dust particles and therefore needs to be cleaned before escaping the waste gases into the atmosphere. These gases, therefore, will be passed through one multi-field Electro-Static Precipitator (ESP). The ESP is installed in between the WHRB and Stack. The dust content in gas downstream of ESP shall be limited to 100 mg/Nm3. The ESP unit will be provided with transformers, rectifier and controls. The dust particles collected in the hoppers (below ESP) will be conveyed by means of conveyors or pneumatically and will be stored in Silos. This will be further disposed in dry form by trucks. Induced Draft Fan: One induced draft (ID) fan shall be provided to develop necessary draft to evacuate the waste gases from ABC through the boiler and conveyed up to inlet to the Chimney. Direct drive through flexible coupling with pneumatically operated suction damper is 53

envisaged and the ID fan discharge will be connected to the stack through suitable ducting. The pneumatically operated suction dampers shall be of louver type design to accurately control the pressure settings inside the rotary kiln. Stack : A suitable height stack will be provided along with induced draft fan for DR Plant Kiln. Ducting from ID fan of the kiln shall be connected to the stack. The sizing and height of the stack will be determined to fulfill the pollution control board requirements during detailed engineering stage. Soot Blowers : Required numbers of soot blowers will be provided as considered necessary at suitable locations to remove the dust accumulated over the heat transfer surfaces. blowers with steam as the cleaning Electric driven soot is proposed. medium

Alternatively, installation of acoustic soot blowers shall be examined during engineering due to better techno-economics reported by these types of soot blowers. POWER GENERATION Steam availability from the proposed WHRB will be 28 TPH, although the boiler will be designed for 36 TPH. Steam Consumption norms Boilers with steam at 90 ata at 540C Boilers with steam at 65 ata at 485C : : 3.8 TPH/MW 4.2 TPH/MW 54

Boilers with steam at 40 ata at 410C

4.4 TPH/MW

It is advantageous to go for high-pressure design so as to optimise the power generation and safer boiler operation. Therefore, considering the Avg. Steam consumption norm for power generation as: 4.2 TPH steam / MW at 65 bar & 485C. Power generating potential from WHRB is 56T / 4.2 = 13.33 MW OR say 13 MW The Principle Thermal Scheme of Power Generation with WHRB is shown in Schematic sketch No. PE/13/005. TURBO-GENERATOR AND AUXILIARIES The estimated power generation from the waste heat recovery based power plant will be in tune of 13 MW. Considering any excess waste heat generation and other safety margin the proposed turbine generator will be 20% more than the estimated power generation. Therefore it is proposed to install 2 NOS. x 8 MW Turbo-generator set along with main condenser, air ejector system for main condenser, condensate pumps, lubricating & governing oil systems and auxiliary condenser. Deaerator: The Deaerator will be suitably located near the TG Building and shall be of Horizontal, Direct contact, Spray tray type. The Steam for the deaeration will be drawn from a suitable extraction of turbine. The make-up requirement of deaerator will be drawn from demineralising make-up water line. The deaerator shall be mounted on 55

a feed water storage tank of approximately 20-min. hold up capacity. Boiler Feed Pumps: It is proposed to install 4 Nos. 100% capacity, multi-stage, electric motor driven boiler feed pumps, one working and other stand by. The capacity of these pumps will be suitable to meet the boiler output including the spray water requirement of the attemperator. These pumps will generate necessary head to overcome the system resistance and will be able to supply feed water even under abnormal operating conditions. These pumps will be located in the TG Building. Power Distribution System : 13 MW power generated from the captive power plant will cater the loads of DR plant, captive power plant and other utilities. After self-consumption and DR plant consumption, almost 7.32 MW spare power will be available for other use like steel melting. The power single line diagram is shown in the schematic sketch no. PE/00/048 (Page 71). Auxiliary power distribution: The auxiliaries of the power plant will be fed at 415 V. The boiler feed pumps, induced draft fans and recirculating pumps and other auxiliaries will be supplied at 415 V. Motors : All AC motors will be squirrel cage induction type machines and will operate on 415 V, 3 phase, 50 Hz power supply. The rating and speed of various motors will be suitably selected based on duty requirements. All motors will be provided with class-F insulation. For motors above 30 kW, the stator winding will be connected to 24 V single phase AC supply during idle period for space heating. 56

Design of Motor control schemes will take into consideration the possibility of momentary voltage dips due to faults in the outside system causing dropping out of contractors and will devise appropriate strategies to prevent such mal-operation. Power and control cables : All 11 KV cables will be of aluminum conductor XLPE insulated type. LV power cables will be of 1.1 KV grade, aluminum conductor, PVC insulated type. Control cables will be of 1.1 KV grade multicore, stranded copper conductor. All cables buried directly in ground will be armoured type and cables laid in basements / trenches will be either armoured or unarmoured type. Cable tray system and supports will be of galvanised steel / aluminium channel type. Fire partitions will be provided to ensure fire safety and to localise the fire. Plant lighting system: Plant lighting will be planned using energy efficient luminaires. The lighting system will have centralised group-switching features, day light controls etc. 415 V LCSS will feed power in the power plant. A separate emergency lighting system will provide minimum level of illumination in the event of normal power supply failure. The emergency lighting loads will be fed by 220 V DC battery bank. DC Power Supply System: Control, protection and annunciation schemes of the electrical systems of plant will be designed to operate at 220 V DC. Separate DC systems will be provided for DR plant sections, TG house, boiler control and other loads. 57

The essential loads within the power plant, which will be maintained during an emergency situation, are listed below. v Emergency oil pump. v Emergency lighting v Control power supply to various switchboards, electrical control panels etc. v Annunciation system. v Fire alarm system. v Plant communication system. v All emergency drives. To meet the above requirement, 220 V DC lead acid battery bank of adequate capacity along with double charger unit will be provided. The battery capacity will be designed based on 30-min. supply to the essential auxiliaries and 1-hour duration for emergency lighting system. The 220 V DC distribution board will cater to the needs of above essential auxiliaries. Each DC system will be provided with its own trickle and boost charger and distribution cabinet. Redundancy will be provided by additional battery / system interconnections so that failure of either one battery bank or charger does not cause outage of the DC system. Uninterrupted power supply for essential loads : An uninterrupted power supply system with adequate capacity and complete with battery bank rated for 30 minutes back up will be planned for ensuring uninterrupted power to critical AC loads such as unit control desk, PLC, instrumentation loads including the DCS. 58

Earthing: The electrical equipment of power plant complex including non current carrying frames and structures will be earthed as per provisions of the standard IS: 3043. Galvanised steel flats / MS rode will be used for forming the main earth grid and an appropriate number of ground electrodes will be provided to achieve specified earth resistance values. Separate and independent earthing connection will be made for electronic equipment in order to make its functioning free from system disturbances. Lightning protection system / aviation obstruction lighting: The entire plant building and structures including the chimney will be protected against lighting strokes as per guidelines stipulated in IS: 2309. Aviation obstruction light fixtures for chimney will be provided as per the guidelines of International Civil Aviation Authority / Airport Authority of India. INSTRUMENTATION AND CONTROL SYSTEM : Control room instrumentation: In line with the modern trends in power station design, a comprehensive instrumentation and control system is planned for the power plant. The system envisaged will be distributed control system (DCS) comprising of state-of-the art and highly reliable microprocessor based digital controls. A group of subsystem modules, functionally distributed will be envisaged for WHRB units, 59

and TG house. These subsystem modules will be interconnected through the redundant data highway for high-speed data transmission. The subsystems modules will be provided with standard features like processor level redundancy, high speed processing and efficient functional blocks to perform dedicated functions like open loop monitoring, closed loop functions, sequential logics etc. Two numbers of operator work stations with colour graphic terminals, key-boards, storage devices and printers will be provided as man machine interface to operate the units from the control room. The WHRB data will be in multiple forms having its signals in DR control room as well as in TG house. All these operator workstations will also be interconnected through data highway. The functions performed by the various subsystem modules will be broadly divided into the following: - open loop monitoring system - Automatic closed loop control system - Sequence, protection and interlocking system - Operator interface - Data logging, storage, retrieval, and reporting The details of functions are as follows: Open loop monitoring system: The sub-system responsible for this function will acquire data from the field sensors and condition the signal as per required signal configuration and float the data on the highway for other sub-systems to utilise the data. The open loop monitoring will include measurement of various process variables viz pressure, temperature, 60

flow level, analysis etc. of the steam generation units and the Turbogenerator units.

Automatic Closed loop control system: The sub-system modules for this function will perform the closed loop control of the WHRBs and Turbo-Generator units. The Signal from the field sensors will be acquired and the final control elements will be modulated to keep the process variable at the set value. Some of the important automatic control loops of the steam generation units and Turbo-generator sets are as follows - drum level control - superheated steam temperature control - deaerator level and pressure control - condenser hot well level control Sequence protection & interlocking system : The sub-systems for this function will perform the sequential start-up and shutdowns and interlocking logics will ensure safe operating conditions for the safety of the operating personnel as well as protection to the equipment. Field Instrumentation : Field instrumentation for monitoring process parameters will have the following features- smart transmitters to measure pressure, flow. - thermocouples & RTDs for temperature measurement, will be connected to temperature transmitters with 461

20mA output signal. - Gauges and switches for local indications and interlocks.

Operator Interface: The operator workstations envisaged for WHRB unit and TG Sets will provide a window to the process, and the operator can monitor the performance of various process equipment and take corrective actions in case of any abnormality, through the monitor keyboard provided as a part of the operator workstation. The various mimic pages, trend displays and alarms displays provided, as part of the workstation will enhance the operators monitoring of the process from the central control room. Data Logging, Storage, Retrieval and Reporting: The sub-system responsible for this function will acquire all process data and store them for retrieval in future for historical trend and analysis. The data stored in this sub-system will be utilised to generate performance reports as part of the management information system. DESCRIPTION OF MAJOR SYSTEM ELECTRICAL Basic Design Concept For designing the various electrical systems and equipment the following basic concepts shall be applicable: a. Ambient temperature : The design ambient temperature shall be 50C. b. Voltage levels : Voltage levels in the proposed plant shall be 11 KV for evacuation, 11KV for generation, and 415 volts for 62

LT load & auxiliaries and 110 volts DC. Single-phase AC motors shall not be used except in very special cases of low power for which panel mounted 415/240-volt transformers shall be used. For 110-volt AC control supply, if used, separate panel mounted 415/110 volt transformers shall also be used. c. Variations : Voltage variation shall be 10%, frequency variation shall be 5% and combined voltage and frequency variation shall be 10%. d. Fault levels : Fault levels for the various voltage systems for design of breakers shall be as under : a. b. c. d. e. 11 KV 6.6 KV 415 volt 110 volts DC 40 KA 40 KA 50 KA 20 KA

Basic insulation level: The basic insulation levels shall be 75 KV for 11 KV system, 38 KV for 11 KV neutral and 60 KV for 6.6 KV system. Control and Protection : Controls shall be micro-processor based and centralized in a central control room.

f.

Power Evaluation Power will be generated at 11 KV and evacuated at 11 KV in the Induction furnaces and DR plant. Electric Drives Electric drives shall be 3 phases, 50 cycle, squirrel cage induction motors operating at nominal voltage of 415 volts. Motors shall be of high power factor, Class F insulation, IP-55 enclosure designed for direct on line starting with as low starting current as possible. 63

Motor rating shall be at least 1.15 times the consumption at the duty point of the driven equipment. Motor torque characteristic shall be such as to ensure smooth and rapid starting and acceleration f the driven equipment. Motors shall be provided with suitable heating arrangement while at standstill. Motors up to 30 KW shall be suitable for 24V winding heating. Motors above 30 KW and HT motors shall be provided with separate 240V heating coils. Electrical protection proposed for the various equipment shall be generally as indicated below: Generator : Differential (87G) Inter turn fault(95) Stator earth fault (64G) Loss of excitation (40) Negative sequence current(46) Reverse power (32) Low forward power (37) Rotor earth fault (64R) Voltage balance (60) Generator pole slipping (98) Overload (50) Backup impedance(21G)

64

Station Transformers

Service :

Backup over current (51) Restricted earth fault (64 REF) Earth fault (64) Buchholz (63)

11KV switchgear

Inverse / definite time over current (51) Instantaneous short circuit (50) Under voltage (27)

415 Volt switchgear

Instaneous over current (50) Time graded S/C protection for Incomers feeders. Under voltage (27)

Breaker

controlled :

Short circuit 9510 Thermal overload (49) Unbalance (46) Locked rotor (50 L/R) Earth fault (51N)

415 volts Motors

Contactor controlled 415 volts motors DC System

: :

Thermal overload with SPPR for motors with rating above 30 KW Insulation monitoring Under voltage (27) or no volt relay

Static relays shall be provided as far as possible. All tripping relays shall be suitable for operation from 65% to 130% of control supply voltage. Grounding & Lightning Protection The system grounding envisages generator neutral Earthing through secondary, resistance loaded distribution transformer and 65

415V system neutral grounded through high resistance to facilitate ground fault and transient over voltage reduction. Separate station ground grid for power station shall be provided for grounding of equipment and structures maintaining step and touch potentials within the safe limits. Separate grounding bus, independent of station grounding bus, shall be provided for DDC Systems. Lightning protection for building / structures/ equipment shall be provided. Steam Generator ( SG) Controls The main controls for the steam generator shall essentially comprise of the following: 1. 1.1 1.2 2. 3. 4. 5. Combustion Control Fuel/flow control Air flow control Furnace draft control Primary Air header pressure control Drum level control and associated BFP loop controls Superheated steam temperature control

Steam Turbine Generator (STG) & Auxiliaries The major controls associated with the STG are: a. b. c. Turbine Governor control Lub.oil temperature control Seal steam pressure control 66

d. e. f. g. h. i.

Coordinated master control for boiler and turbine Hot well level control Deaerator level control Boiler feed pump(s) recirculation Condensate Extraction Pump(s) recirculation Circulating water pumps

The other major controls for the plant would cover: i. ii. iii. iv. Auxiliary cooling water pumps flow Generator and other electrical systems indications and protections Interlocking of coal handling plat and ash handling plant with boiler Other important equipment control in the plant.

AUXILLIARY SYSTEMS Water Systems: Water is used as a cooling medium in the heat exchanger equipment of boiler auxiliaries such as sample coolers, boiler feed water pump cooling etc. In addition, it is used as make-up water for boilers after de-mineralisation and also used for dust conditioning in the dust handling system. The break-up of make-up water for captive power plant is given in following tableSystem Cooling water circulating system Make-up Water Requirement (m3/Hr.) 112

67

De-mineralised make-up water for boiler make-up Total Recirculating Cooling Water System:

6 118

The recirculating cooling water system will consist of the following major items - two electrically driven pumps (1 working & 1 stand-by) with associated drive motors - induced draft cooling tower of total capacity 225 m3/hr of RCC construction with single cell with a capacity to cool 225 m3/hr over a cooling range of 10C. Cold water from the cooling tower basin will be pumped by the recirculating cooling water pumps to the various consumers in the plant. The hot water return from the consumers will return to the cooling tower for cooling and recirculation. About 3 m3/hr of make-up water will be added in the cooling tower basin to compensate the evaporation, drift and once through loss for dust separation system. De-Mineralisation plant: To meet the requirement of de-mineralise water as a make-up water for boiler, a de-mineralisation plant of one stream 4 m3/hr is provided. Water quality shall meet the turbine and boiler manufacturers recommendation. The demineralisation plant will consist of the following equipment - Clarified water storage tank, pumps and associated pipe work. - Multi-grade pressure sand filters. - Activated carbon filters 68

Strong cation exchanger Degasser, degasser storage tank, set of pumps Weak base anion exchanger Strong base anion exchanger Mixed bed exchanger Dosing equipment/ regeneration equipment along with pumps and pipe work. - Demineralisation water storage tank with pumps - Neutralisation system for treatment of the effluents from demineralisation plant. - Interconnecting pipe work Clarified water from the raw water treatment plant will be stored in a storage tank and then pumped to the pressure sand filters. The filtered water will be passed through activated carbon filters to remove the residual chlorine and organic and then passed through the cation exchanger. Decation water will be degassed in degasser tower to remove dissolved gasses. Degassed water will be collected in degassed water storage tank and then pumped through weak base anion exchanger, strong base anion exchanger and mixed bed exchanger. Demineralised water will be stored in the DM water storage tank and will be pumped to the boiler. Hydro-choric acid and caustic soda will be used for regeneration of exhausted ion exchange resins. Bulk aid and alkali storage tanks with unloading pumps, measuring/ preparation tanks, ejectors etc will be provided for transfer, dilution and conveying acid / alkali for regeneration purpose. Waste effluents collected from demoineralisation plant will be laid through channels lined with acid resistant bricks into the neutralisation pit. For complete neutralisation of the effluents, lime from lime tank will be added by gravity and mix thoroughly by means of air agitation grid provided in the pit. Two pumps will be provided 69

for disposal of treated effluent. The storage tanks will be located outside the building and all other equipment will be located inside the building. Dust Handling System: For handling, conveying and storing the dust, from the various dust collection hoppers of DSC, ABC, Boiler, ESP a comprehensive dust handling system will be provided. The system will consist of following items of equipment and facilities. a. Rotary Feeders b. Dust Conditioners c. Storage Bins d. Belt conveyors e. Dust Storage Silo of adequate capacity f. Supporting Steel structures for the above. However, Pneumatic conveying and wet scrapping of the dust at various locations can also be installed in place of above dust handling system. The dust collected at the various hoppers will pass through rotary feeders for uniform feeding to dust conditioner where from the dust is collected in the storage bin. The dust handling system is shown in the schematic drawing no. PE / 00 / 033 (Page 71).

70

WASTE GASES FROM KILN

ESP

WASTE HEAT RECOVERY BOILER

STEAM

ASH

TURBINE

Alternator

DRI

CAPTIVE Consumption

OTHER LOADS

71