You are on page 1of 11

ATTOCK CEMENT PAKISTAN LIMITED

REPORT ON:
WASTE HEAT RECOVERY SYSTEM
PREPARED BY:
MUHAMMAD FAIZAN UDDIN AHMED
SMT-1 (PRODUCTION)
9!"1
SUBMITTED TO:
M#$ ZAHID NAZIR
(MANA%EMENT REPRESENTATIVE)
BASIC FUNCTION:
To recover energy (heat) that is being wasted to atmosphere by hot gases through
steam production and generates electricity.
PATH OF THE HOT %ASES %ENERATED:
The exhaust gases from Rotary kiln and Pre-alciner are used to heat the incoming
feed material and gases are cooled. !ome amount of these gases is used in raw mills "
coal mills for drying purpose then exhausted to the atmosphere.
The clinker coming out of the Rotary kiln is at around #$%&' and is cooled to $%&-
(&&' temperature using ambient air. This generates hot air of about (%&-)&& '.
*nitially in +P, a part of these hot gases generated was used as combustion air in kiln
furnaces " remaining was simply wasted which was polluting the atmosphere and also
spreading a lot of dusts from these gases in nearby villages causing harm and nuisance
" earning displeasure of villagers.
*n order to minimi-e emission and utili-e the heat wasted in the gas. /+!T0 10+T
R0230R4 !4!T056 is installed which is shortly written as /1R!.
*n /1R! department the heat of the hot gases are utili-e in boiler to convert the feed
water in to superheated steam . this superheated steam is used in turbine. in which the
heat energy of the super heated steam is converted into the mechanical energy by
doing work on the turbine blades. This mechanical energy is further converted into
electrical energy by generator.
LINE DIA%RAM OF WHRS PROCESS:


C&&'()* +&,-#
S&.+ ,/+-# +/)0
D-/#/+&# B&('-#1
R2O P'/)+
S+-/3 4&)5-)1-#
T6#7()-
C'-/) ,/+-# +/)0
C'/#(.(-# P638 H&61- I)561+#(/' ,/+-# +/)01
L()--1 7&('-#1:
"1) +*R 78091*9: 22,0R ;2*,0R (A9C-1) 4/8/4(+: 9$;+&)1
"!) !8!P09<0< PR0-10+T0R ;2*,0R (SP-1) 4/8/4(+: 1<$;+&)1
L()--! 7&('-#1:
"1) +*R 78091*9: 22,0R ;2*,0R (A9C-!) 4/8/4(+: 1"$!+&)1
"!) !8!P09<0< PR0-10+T0R ;2*,0R (SP-!) 4/8/4(+: 1=$;+&)1
LINE-1 > ! BOILERS SPECIFICATIONS:
H/33-#()* M&+&# /+ SP-!(?P@/1- I)564+(&))
&.(=kw (#>$hp). $$&>(?&3.delta>star.$.&#>#.#=+
# strike per minute per hammer
Total no. of hammers @ &A
DESCRIPTION SP-1 A9C-1 SP-! A9C-!
I)'-+ T-38-#/+6#- (
"
C) (=& (?&
($% (?&
O6+'-+ T-38-#/+6#- (
"
C) $#% B) $#) B%
%/1-1 F'&, (N3
?
2 @#) #%=.AA$ #$(.?B% #B?.A$? #(#.=?)
E)-#*: /A/('/7'- (K4/' 2 @#) ?.B$A.B%$ ##.$%?.B#A =.B?#.&&( ##.B((.B)&
E)-#*: /A/('/7'- (MW) #& #( B #(
S+-/3 %-)-#/+(&) (T&)2@#) #$ #% ## #A
BLOCK DIA%RAM OF A9C BOILER LINE-1 > !:
M(B()* C@/37-#
HP S+-/3
D#63
S8 H8 S+-/3
LP
S+-/3
D#63
F--5 W/+-# .&#3 LP
Pump
F--5 W/+-# .&#3 HP
Pump
HIGH PRESSURE HIGH
TEMPERATURE SUPER
HEATER
HIGH PRESSURE LOW
TEMPERATURE SUPER
HEATER
HIGH PRESSURE
EVAPORATOR -2
HIGH PRESSURE
EVAPORATOR -1
LOW PRESSURE SUPER
HEATER
LOW PRESSURE
EVAPORATOR
HIGH PRESSURE
ECONOMIZER
LOW PRESSURE
ECONOMIZER
SHARED ECONOMIZER
T& S8
E4&)&3(C-#
LP
S+-/3
+&
T6#7()-
HP
S+-/3
+&
T6#7()-
%/1 I)
%/1 O6+
BLOCK DIA%RAM OF SP BOILER LINE-1 > !:
(
S+-/3 D#63
SUPER HEATER
EVAPORATOR -1
EVAPORATOR -2
EVAPORATOR -3
EVAPORATOR -4
ECONOMIZER
EVAPORATOR -5
T& A9C 3(B()* 4@/37-#
F#&3 A9C 1@/#-5 E4&)&3(C-#
%/1 &6+
%/1 I)
The above block diagram describes the flow of water " steam in the !uspension Pre-
heater boiler " +ir Cuenching ooler boiler. The function of each component is
explained below.
1) CLARIFIER:
*n clarifier. Poly aluminum chloride (P+) is added to remove suspended solids
supplied from the industrial water tank.
!) CLEAN WATER RESERVOIR :
*t is a reservoir next to clarifier tank. where the clean water is stored.
?) R2O PLANT :
1ere rich water is passed first through sand filter to remove sand " other suspended
solids and then through activated charcoal filter to remove organic solids. +fter that. in
Reverse osmosis. total dissolved solids (T<!) are removed by passing the rich water
from a no of semi permeable membrane which allows water to go through from lower
concentration to high concentration of water by applying osmotic pressure.
=) SOFT WATER TANKS :
The pure water coming from the R>2 plant is stored into soft water tanks having
capacity of #)& m
(
.
<) DEARATOR TANK :
*t is a device whose function is to remove the un-dissolve gases such as oxygen from
the soft water. *t advantage is that oxygen present in the water will cause corrosion of
tubes. thus increases the life of the boiler.
) BOILER :
+ boiler is usually. a closed vessel made up of steel. its function is to transfer heat
produced by +@- 4&3761+(&) &. .6-' to the water and ultimately to generate steam.
The heated or vapori-ed fluid exits the boiler is use in various processes i.e. electricity
generation. pumps driving. compressor driving etc.
CLASSIFICATION OF BOILER:
+ccording to the contents in the tubes the boilers are classified into two types
a) /+T0R T8;0 ;2*,0R (used +P,)
b) D*R0 T8;0 ;2*,0R
WATER TUBE BOILER:
+ ,/+-# +67- 7&('-#D is the one in which water circulates inside tubes heated externally
by the fire. *t is used where large amount of steam is reCuired.
FIRE TUBE BOILER:
+ .(#- +67- 7&('-#D is the one in which fire circulates inside tubes whereas water present
outside tubes in a drum. *t is used where large pressure of steam is reCuired.
WASTE HEAT RECOVERY BOILER:
+ WASTE HEAT RECOVERY BOILER is a special type of boiler that generates
steam by recovering heat from a process hot gas that would have otherwise been
wasted.
WASTE HEAT RECOVERY BOILER CONSISTS OFE
F--5 W/+-# P638
E4&)&3(C-#
S@/#-5 E4&)&3(C-#
EA/8&#/+&#
S68-# @-/+-#
S+-/3 D#63
S/.-+: V/'A-
W/+-# L-A-'
B'&, D&,) T/)0
These are briefly described belowE
/) F--5 W/+-# P638 :
The function of the feed water pump is to supply water to a boiler for the generation of
steam. There are six (&A) Deed water pumps installed. three (&() ,P water pump.
three (&() 1P water pump.
MOTOR POWER VOLT CURRENT T&#F6-
,P Deed
/ater Pump
=.% F/ (?& 3 #).= + $(.B 9m
1P Deed B& F/ (?& 3 #A&.A + $?A.% 9m
/ater Pump
7) E4&)&3(C-# > S@/#-5 E4&)&3(C-#:
The function of economi-er is to recover waste heat of gas and increase the
efficiency of boiler.
4) EA/8&#/+&# :
The function of evaporator. in waste heat recovery boiler is to convert saturated
water coming from steam drum into saturated steam by convey heat from hot gases.
5) S68-# @-/+-# :
The function of super-heater is to raise the boiler steam temperature above the
saturated temperature level. +s steam enters the super heater in an essentially dry
condition. further absorption of heat sensibly increase the steam temperature.
!uperheated steam is steam that is at a temperature higher than the saturation
temperature for the steam pressure. !uperheated steam contains more energy than
saturated steam.
-) S+-/3 D#63 :
*t is eCuipment whose function is to separate water " steam coming from the water
tubes and maintain its pressure.
.) S/.-+: A/'A-:
+ safety valve is a non-return valve which is used to reduce pressure of steam by
releasing steam when its pressure increases more then the bearing temperature of
steam drum.

*) W/+-# L-A-' :
/ater level shows the operator the level of fluid in the boiler. also known as a sight
glass. water gauge.
*n our system at +P, we used five noGs water gauge.
#. ;i-olor :auge :lass
$. *ntelligent :auge :lass
(. 5agnetic :lass
). 0lectrode :auge :lass
%. Tube :auge :lass.
@) B'&, D&,) T/)0 :
1igh pressure blow down enters this vessel where the steam can GflashG safely and
be used in a low-pressure system or be vented to atmosphere while the
condensates blow down flows to drain.
;) STEAM TURBINE :
S+-/3 T6#7()- is a device that converts thermal energy of pressuri-e steam and
into mechanical energy.
*n general the steam turbine. essentially. consist of only two types. i.e.
a) *mpulse turbine
b) Reaction turbine
/) IMPULSE TURBINE :
+n (386'1- +6#7()- has fixed no--les that orient the steam flow into high speed
Hets. These Hets contain significant kinetic energy. which the rotor blades convert into
shaft rotation as the steam Het changes direction.
7) REACTION TURBINE :
*n the #-/4+(&) +6#7()-. the rotor blades themselves are arranged to form
convergent no--les. This type of turbine makes use of the reaction force produced
as the steam accelerates through the no--les formed by the rotor. !team is directed
onto the rotor by the fixed vanes of the stator. *t leaves the stator as a Het that fills the
entire circumference of the rotor. The steam then changes direction and increases
its speed relative to the speed of the blades.
The turbine installed in +P, waste heat recovery system department is impulse-
reaction condensing turbine. *ts specification are given below
SPECIFICATION OF TURBINEI
R/+-5 8&,-# 1!MW
R$P$M ?"""#23()
C#(+(4/' 18--5 &. 1+-/3 +6#7()- !1="#23()
R/+-5 18--5 &. 8&,-# *-)-#/+&# ?"""#23()
I)'-+ 8#-116#- 1$<MP/
I)'-+ +-38-#/+6#- ?<"
&
C(?!"G?9")
&
C
C&38-)1/+()* 8#-116#- "$?< MP/
C&38-)1/+()* +-38-#/+6#- 1H<
&
C
C&)5-)1()* 8#-116#- $""H MP/
R&+&# ,-(*@+ ;1""0*
W-(*@+ &. +@- 7&5: 1-4+(&) <?"""0*
H/)*()* ,-(*@+ &. 688-# 4&A-# 1="""0*
C&6)+-# 1(C- &. +@- +6#7()- 7&5: ('-)*+@ B ,(5+@ B
@-(*@+ )
<;""B??""B?<""

H) CONDENSER :
+ condenser is a device used to change the phase of matter i.e. from gas into liCuid
(steam into water) as well as maintain a pressure at the exhaust lower than
atmospheric pressure (#.&#( bars). This improves the efficiency of the plant. The
condensation of the steam occurs in the range of %&
o
to (?
o
" -B& Fpa.
T:8-1 &. 4&)5-)1-#1:
a) Jet condenser
b) !urface ondenser
/) SURFACE CONDENSERS :
*t is the type of condenser in which there is no direct contact between the exhaust
steam and cooling water (raw water) and the condensate can be re-used in the
boiler. 1ere. !team in the shell and water circulates in the tubes.
*n WHRS department of +P, surface condenser is installed for the condensation of
steam.
7) IET CONDENSER:
*t is the type of condenser in which there is direct contact between the exhaust
steam and cooling water and the condensate can be re-used in the boiler. The
cooling water must be pure in this type of condenser.
9) COOLIN% TOWER :
*t is one of the important components of the power plant. in which the temperature of
the hot water is decrease by direct contact with ambient air. The different types of
the cooling tower are natural draught cooling tower and forced or induced draught
cooling tower. These are briefly described belowE
a) 9atural draught cooling tower
b) Dorced draught cooling tower
c) *nduced draught cooling tower
/) NATURAL DRAU%HT COOLIN% TOWER :
*n this type of cooling tower the hot water is allowed to fall over louvers. The air flows
naturally (due to pressure difference between the ambient air and the air inside the
cooling tower) across the tower in the counter current direction cools the falling
water. These towers are use for the small capacity of power plants such as diesel
power plant.

7) FORCED DRAU%HT COOLIN% TOWER :
*n force draught cooling tower draught fan is installed at the side of the tower. The
hot water from the condenser enters the no--les. The water is sprayed over the
tower filling slats and the rising air cools the water.

4) INDUCED DRAU%HT COOLIN% TOWER:
*n draught cooling tower the fan is installed at the top of the tower. The hot water
is allowed to pass through cooling tower. The air moving in the upward direction
cools the water.
*n a cooling tower water cools mainly because of evaporation.

You might also like