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
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