4 MW Waste Heat Recovery Power Plant

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4 MW Wa ste He at Recovery Powe r P lant

UltraTech Cement Limited
A.P. Cement Works, Tadipatri
13 t h &14t h May 2010

Presentation
to A PPCB
Presenter:
V. Devi Prasad
Date : 25-07-2006
Asst. Vice President

APCW Po wer
Total Plant Po wer Demand : 104 MVA ( Ph-1+II : 39+6 5 MVA )

4.0 Waste H eat Recovery Po wer Plant
Organic Rankine Cycle Turbin e:


Tech nical Ben efits

Power Sour ces:





2 x 25
50
4
2 x 12

MW
MVA
MW
MW



The rmal Po wer plant (CF BC Boiler s)
EB Po we r
Wast e Heat Recov ery P owe r plan t
DG Powe r plan t (stand by)

Other Options:



The rmal,
Gas,



Wind,




Solar,
Wast e Heat recov ery.

Phase I - Kiln:
Design

: FLS

Capacity
Dimension s

: 8000 TPD
: 75 x 4. 75 Dia,

Pre- hea ter





No Wate r Consu mptio n
Non IBR
No Extra Manp ower

( N o WT P )



Attract s CDM Ben efit s

(Environment)

( No Steam)
( 1 per shift)

Suppliers:
- Steam t urbin e

Energy Converter
WHOH

: ORMAT Systems Limited, Israel.
: Transparent Energy Systems, Pune

- Organic Rankine Cycle

Cement Plant - Overvie w

( Met )

High vapor turbine efficiency at low speed

Condensing near atmospheric pressure

Smaller size air cooled condensers

Moisture free turbine ex pansion.

: 6 Stage

Phase I - Cooler
Design
: FLS, COOLAX,
Cooler Fan s
: 16,
Cooler are a
: 141 Sq. M et,
Cooler Vent fa n: 58 5 kW.

Typical Heat Bala nce in Ce ment Mfg

Ov erall View
WHRU - In put Para meters

Basis of Design :
Gas Design Mass Flow rat e

: 485 To ns / Hr
(Vo lu met r ic Fl ow 3 75, 500 N m3/ Hr )

Design Gas (In / out )Te mp.

: 320 / 150 °C

Max. Dust loading

: 90 mg / Nm3

Ave. Dust pa rticle size
Air pressur e aft er ESP

: 45 Micron s
: -30 mm WC

Design Conditio ns
Ambient Temp.

C y c le

D ia g r a m o f P o w er G en e r a t io n

C l i n k er C o o l er
H ea t S ou r c e

: 35 Deg C. (Ave. Temp :

W as t e

H e at B o i l e r W a s t e
H e at R e c o v er y

F r om

Cl in k er C o o le r W a s t e

O R C -E q u ip m e n t
P o w e r G en e r a t i o n

G as

A i r C o n d e n se r
Co o l i n g
- P r oc e ss

ga s

32 Deg C)

Altitude

: 350 Me t AMSL
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 ir c u it

WHRU – O utput Pa rameters

- C i r cu i t

C o o lin g

- C i r cu i t

WHOH – Outp ut Param eters

A IR FRO M CLINK ER

Design Po wer O ut put P aram ete rs:
Gross Out put

P e n ta n e

485 M

485 M

150 T

320 T

Waste Heat Oil Heater
Out put parameters

: 4000 kW
280 M
270 T

Net out put (OEC)

: 3335 kW

Aux. Power Con s.

: 665 kW

THERMAL O IL

Flow rate

: 247 TPH

Temperature, inlet : 120°C

WASTE H EAT

ACC Fans : 12 X18.5 = 222 kW
Seal oil Lube system : 2X3.7 = 7.4 kW
WHOH Pumps : 2X37 =74 kW

Temperature, outlet : 270°C

270 M
1 20 T

Pentane Pumps : 2X180 =360 kW
RECO VERY U NI T
( 21,800 Q )

C IRCU LATIO N PUMP
5 0 KW

M - [ t /h ]
P - [ kPa ]
Q - [ kW ]
T -o [ C ]

Quantity

:125 Tons

Design Pressure

: 7.5 Bar

Dry Weight

: 500 Tons

Aux. Power Cons.

: 65 kW

Air Compressor : 1X12 kW : 12 kW

Waste Heat Oi l Heater

OEC Details
ORMAT Energy Converter
GENER A TOR GR OSS POWE R = 40 00 K W
OEC NE T P OW ER =3 40 0 K W

Turbine :

GEN ERATO R
G

TURB IN E

Three s tage-Impuls e ty pe
Speed: 1500rpm
RECU PERA TOR
2, 880 Q

FAN S
M
200 KW

Generator:
6.6MVA, 50Hz , 1500rpm

VAP ORIZER
11, 850 Q

AIR COO LED
CON DEN SER
18, 640

Motive Fluid:
Pentane – 23 Tons
Flow : 172 T/h
Before Turbine:


Good thermal stability



High heat transfer coefficient



Low viscosity



Non-tox ic, safe & easy to handle



Non-corrosive

Temp: 204 Deg C
Pressure: 23.8 Bar
Condenser: Air Cooled

AIR 35 T

PREH EATE R
9, 950 Q

F EED PUM P
32 0K W

Operation Performa nce

OR MA T Ener g y C onv erter

Unit

07 - 08

GrossGeneration

Lac kW h

224

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

Descri ptio n

08 - 09

Maximum Power recor ded

Maintenance

09 - 10

228

165

: 4.35 MW

Pr oject

OEC (supply) : ORMAT

WHOH (Supply & Erection) :
Tran sp are nt
Othe rs: Duc ting, Pipin g, Civil,
The rmic Electrical s, OEC Er ection
and Plan t Commissioning.
-

Turbine Clocked 21,000 Hrs

-

Turbine seal failed.

-

Major Overhaul done in Mar.’10.

-

All internals found OK.

Project No – 0872
Registration date 19 th oct`07
Expected reduction in emission by 20,851 Tons of CO2

Ø In house Engine ering
Ø WHOH - Vendor id entifica tion in India

CO 2 Reduction

Ø Pressu re d rop ac ross WHOH wi th in th e fan ca pacity.

(T on s o f CO 2)

2007-08 (VERs)

7,477

2007-08 (CERs)

7,636

2008-09 (CERs)

Start: Sept. 2005
Commissioned : March 2007

Project Chall enges….

CDM Project

Year

Executio n Pe riod: 1 8 Mon th s

15,079

Ø Executio n by in ho use co nt ract s
Ø Interfaci ng be twe en OEC & WHOH

(Und er iss ua nce)

2009-10 (CERs)

10,823

Ø Clarity on inpu t dat a.

(Und er v erific atio n)

2010-16 (CERs)

1,05,000
(Expect ed )

Ø Hook up d uring Plant shu tdo wn

O&M Teeth ing pro blems. …
Ø Longer synch roniza tion time
(Breaker closing angle increased from 5° to 10°)

Our verdict….

Ø First of it s kind in In dia & 2nd in world f or thi s ap plication.
Ø One pe rso n /shif t op era tion.

Ø Turbi ne injec tion Valve (Flow serve to Fisher)

Ø Commission ed in Ma rch`0 7. Comple ted 2 1,000 H rs.

Ø Vaporizer Lev el cont roller (Location)

Ø Meet s 4 % of Pha se 1 P ower r equir emen t
Ø Zero wate r con sum ption

Ø WHOH – HMI to Scada (Improvement)
Ø Empha sis on minimizing th e th ermal p ollution .
Ø ACC Fan Motors (Frequent bearing failures for ACC fan motors)
Ø Thermic flui d circulatio n pum ps (Upgraded from 30 to 37 kW)

Happy to ans wer your questio ns…
ns…..

Ø High Availability
Ø No fuel req uirem ent – N egative P ower Ge nera tion co st

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