4 mw waste heat recovery power plant
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Presentation to APPCBDate : 25-07-2006
UltraTech Cement LimitedA.P. Cement Works, Tadipatri
13 th & 14th May 2010
4 MW Waste He at Recovery Powe r P lant
Presenter:V. Devi Prasad
Asst. Vice President
APCW Po wer
Power Sour ces:
2 x 25 MW Thermal Power plant (CFBC Boilers) 50 MVA EB Power 4 MW Waste Heat Recov ery Power plant 2 x 12 MW DG Power plant (stand by)
Other Options: Thermal, Gas,
Wind,
Solar, Waste Heat recov ery.
- Steam turbine
- Organic Rankine Cycle
Total Plant Power Demand : 104 MVA ( Ph-1+II : 39+65 MVA )
4.0 Waste H eat Recovery Power Plant
Suppliers:
Energy Converter : ORMAT Systems Limited, Israel.WHOH : Transparent Energy Systems, Pune
Organic Rankine Cycle Turbine:
Technical Benefits High vapor turbine efficiency at low speed
Condensing near atmospheric pressure Smaller size air cooled condensers
Moisture free turbine expansion.
No Water Consumption ( No WT P ) Non IBR ( No Steam) No Extra Manpower ( 1 per shift) Attracts CDM Benefits (Environment)
Cement Plant - Overview
Phase I - Kiln: Design : FLS
Capacity : 8000 TPD Dimensions (Met) : 75 x 4.75 Dia,
Pre-hea ter : 6 Stage
Phase I - CoolerDesign : FLS, COOLAX,Cooler Fans : 16, Cooler area : 141 Sq. Met,Cooler Vent fan: 585 kW.
Typical Heat Bala nce in Cement Mfg
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WHRU - Input Para meters
Basis of Design:
Gas Design Mass Flow rate : 485 Tons / Hr (Vo lu metr ic Fl ow 3 75,500 N m3/ Hr)
Design Gas (In / out)Temp. : 320 / 150 CMax. Dust loading : 90 mg / Nm3
Ave. Dust pa rticle size : 45 MicronsAir pressure after ESP : -30 mm WC
Design ConditionsAmbient Temp. : 35 Deg C. (Ave. Temp : 32 Deg C)
Altitude : 350 Met AMSL
Ov erall View
W ast e ga s
Cl i n k er C o o l er H ea t S ou r c e
C l i n k er C o o l er W a st e G a s
T h e rm al O i l C i r c u i t
H e at B o i l e r W a s t e H e at R e c o v er y
O R C - E q u i p m e n t P o w e r G en e r a t i o n
A i r C o n d e n se r Co o l i n g - P r oc e ss
P e n ta n e - C i r cu i t C o o l i n g - C i r cu i t
C y c le D ia gr a m o f Po w er G ene r a t ion F r om Cl ink er C o o le r W as t e G as
Design Power O utput Param eters:
Gross Out put : 4000 kW
Net out put (OEC) : 3335 kW
Aux. Power Cons. : 665 kW
Pentane Pumps : 2X180 =360 kW
ACC Fans : 12 X18.5 = 222 kW
Seal oil Lube system : 2X3.7 = 7.4 kW
WHOH Pumps : 2X37 =74 kW
Air Compressor : 1X12 kW : 12 kW
WHRU O utput Pa rameters
P - [ kPa ]
M - [ t /h ]
Q - [ kW ]
T - [ C ]o
( 21,800 Q )
WASTE H EAT
RECOVERY U NI T
485 M
320 T
270 T
280 M
1 20 T270 M
5 0 KWC IRCU LATION PUMP
A IR FROM CLINK ER
THERMAL OIL
150 T
485 MWaste Heat Oil Heater
Out put parameters
Flow rate : 247 TPH
Temperature, inlet : 120C
Temperature, outlet : 270C
Quantity :125 Tons
Design Pressure : 7.5 Bar
Dry Weight : 500 Tons
Aux. Power Cons. : 65 kW
WHOH Output Parameters
Waste Heat Oi l Heater
Good thermal stability
High heat transfer coefficient
Low viscosity
Non-toxic, safe & easy to handle Non-corrosive
GENERATOR GROSS POWE R = 4000 KW
M
AIR 35 T
G
GEN ERATO R
32 0 K WF EED PUM P
CON DEN SERAIR COO LED
200 KW
TURB IN E
RECU PERA TOR
OEC NE T P OW ER = 3400 KW
FAN S
18,640
VAP ORIZER
PREH EATE R
11,850 Q
2,880 Q
9,950 Q
ORMAT Energy Converter
Turbine :Three stage-Impulse typeSpeed: 1500rpm
Generator:6.6MVA, 50Hz, 1500rpm
Motive Fluid:Pentane 23 TonsFlow : 172 T/hBefore Turbine:
Temp: 204 Deg CPressure: 23.8 Bar
Condenser: Air Cooled
OEC Details
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ORMAT Ener gy Conv erter Operation Performa nce
Maximum Power recor ded : 4.35 MW
Description Unit 07 - 08 08 - 09 09 - 10
Gross Generation Lac kW h 224 228 165
Net Export Power Lac kW h 191 195 140
Aux. Consumption % 15.1 14.6 15.0
Ave. Gross Output MW 3.0 3.2 3.0
Availability factor % 90.7 99.9 93.3
Run Hours Hrs 7,482 7,037 5,556
Maintenance
- Turbine Clocked 21,000 Hrs
- Turbine seal failed.
- Major Overhaul done in Mar.10.
- All internals found OK.
Project
OEC (supply) : ORMAT
WHOH (Supply & Erection): Transparent
Others: Duc ting, Piping, Civil, Thermic Electrical s, OEC Erection and Plant Commissioning.
Execution Period: 18 MonthsStart: Sept. 2005
Commissioned : March 2007
CDM ProjectCDM Project
Year CO2 Reduction (Tons o f CO 2)
2007-08 (VERs) 7,477
2007-08 (CERs) 7,636
2008-09 (CERs) 15,079(Und er iss ua nce)
2009-10 (CERs) 10,823(Und er v erific atio n)
2010-16 (CERs) 1,05,000(Expect ed )
Project No Project No 0872 0872 Registration date 19Registration date 19thth oct`07 oct`07 Expected reduction in emission by 20,851 Tons of COExpected reduction in emission by 20,851 Tons of CO22
Project Challenges.
In house Engineering
WHOH - Vendor identifica tion in India
Pressure drop ac ross WHOH wi th in the fan capacity.
Execution by in house contracts
Interfaci ng between OEC & WHOH
Clarity on input data.
Hook up during Plant shutdown
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O&M Teething problems.
Longer synchroniza tion time
(Breaker closing angle increased from 5 to 10)
Turbi ne injec tion Valve (Flow serve to Fisher)
Vaporizer Lev el controller (Location)
WHOH HMI to Scada (Improvement)
ACC Fan Motors (Frequent bearing failures for ACC fan motors)
Thermic flui d circulation pum ps (Upgraded from 30 to 37 kW)
Our verdict.
First of its kind in India & 2nd in world for thi s application.
One person /shif t opera tion.
Commissioned in Ma rch`07. Completed 21,000 H rs.
Meets 4 % of Pha se 1 Power requirement
Zero water consum ption
Emphasis on minimizing the thermal pollution.
High Availability
No fuel requirem ent N egative Power Genera tion cost
Happy to answer your questionsHappy to answer your questions....
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