a journey towards excellence of sap

CO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANTCO&CCDCO&CCD BHILAI STEEL PLANTBHILAI STEEL PLANT 1

A JOURNEY TOWARDSEXCELLENCE OF

SULPHURIC ACID PLANT

S.K. GHOSH, DGM(CCD)

ATUL GOSWAMI,SM(CCD)

BHILAI STEEL PLANT


SULPHURIC ACID PLANT, BSP


CAPACITY : 140 TPD COMMISSIONED IN THE YEAR 1993 DOUBLE CONTACT DOUBLE ABSORPTION

SYSTEM. DE-MINERALIZATION WATER TREATMENT

PLANT FOR BOILERS . STACK HEIGHT : 40 METER . SULPHUR CONSUMPTION 330 KG /TON

SALIENT FEATURES


ENVIRONMENT FRIENDLY FEATURES

• START UP SCRUBBER SYSTEM.

• SO2 IN FLUE GAS < 2.5 KG/TON

• SO3 / ACID MIST IN FLUE GAS < 90 MG/NM3.


PROBLEMS EMERGED

• SULPHUR STREAM -- DELAY IN WAGON UNLOADING -- QUALITY OF SULPHUR -- HEALTH OF MELTERS -- SULPHUR GUN

• AIR STREAM -- AIR BLOWER -- RESTRICTED AIR FLOW

• GAS STREAM -- HOT GAS FILTER -- CONVERTER


PROBLEMS EMERGED

• ACID STREAM -- CIRCULATION TANK -- PHE -- LIMITED STORAGE CAPACITY

• BOILER STREAM -- PROBLEMS IN DM PLANT -- WHB 1& 2 -- ECONOMISER -- SUPERHEATER


PROBLEMS EMERGED

• PROBLEMS DURING START UP -- INEFFICIENT SCRUBBER -- CHOCKING OF GAS LINES -- LIMITED SODA FACILITIES

• EROSION OF CONCRETE STRUCTURES & FLOORS

• INADEQUATE INSTRUMENTATION


PROBLEMS RESULTED IN

• DOWNFALL IN ACID PRODUCTION

• MISMATCH WITH REQUIREMENT

• COKE OVEN GAS BYPASSING.


PROBLEMS RESULTED IN

• PURCHASE OF ACID

• TIME LIMITATIONS FOR CAPITAL REPAIRS.

• ENVIRONMENTAL PROBLEMS DURING START UP


YEAR QUANTITY (MT)

2003-04

2004-05

2005-06

2006-07

2007-08

2008-09

192

1500* IPT (1000RSP;500BSL)

4718

NIL

1350

132

PURCHASE OF ACID


INNOVATIONS IN ACID PLANT

SULPHUR STREAM


EXTENDED SULPHUR GODOWN


NEW CLEAN COMPARTMENT


SLUDGE SETTLING CHAMBERS


SULPHUR GUN MODIFICATION



• AIR STREAM -- AIR BLOWER IN SERIES -- INCREASING DIA OF AIR

STREAM


INSTALLATION OF NEW BLOWER



GAS STREAM


REPAIR OF CONVERTER


INSTALLATION OF NEW HGF



BOILER STREAM


REPLACEMENT OF WHB & SUPERHEATER


REPLACEMENT OF ECONOMISER



ACID STREAM


COMMON ACID CIRCULATION TANK


REPLACEMENT OF PHE WITH S&T HE


REPLACEMENT OF STORAGE TANK


ADDITIONAL STORAGE TANK



SCRUBBING SYSTEM


ADDITIONAL CAUSTIC SODA TANKS


REPLACEMENT OF SCRUBBER GAS LINES


REPAIR OF FLOOR & DYKES


IMPROVEMENT IN INSTRUMENTATION


DESPATCHES OF ACID TO OTHER UNITS


PLANT 2009-10 2010-11

RSP

BSL

DSP

IISCO

502 932----361

4891350 500-----

DESPATCHES OF ACID

a journey towards excellence of sap

Technology

smccd bhilai steel plant

scrubber system

ton salient features

environment friendly

dgmccd atul goswami

tpd commissioned inthe

sulphur consumption

stack height