DRI WASTE (CHAR) UTILIZATION IN POWER

DRI WASTE (CHAR) UTILIZATION IN
POWER PLANT TO REDUCE POWER
GENERATION COST
BY T.M. DANDAPAT
9/29/2014
1
TATA SPONGE
DRI PRODUCTION 390,000 MT PER ANNUM FROM 3
KILNS & 26 MW OF POWER PLANT
DRI UNIT
26 MW POWER PLANT
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Location
TATA SPONGE IRON LTD.
Corporate Office
Bhubaneswar Office
Coal Block in Angul
TATA SPONGE IRON LTD.
 In the Orissa province (Eastern part of India)
 275 KMs from the State Capital
 Remote mining cum agriculture area
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TATA SPONGE
An associate company of
Tata Steel Ltd., in the
business of manufacturing
of sponge iron. Based in
Joda, in the district of
Keonjhar, Odisha.
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INTRODUCTION
IN DRI (SPONGE IRON ) PRODUCTION
• RAW MATERIAL :
A) IRON ORE
B) NON COKING COAL
C) DOLOMITE
• PRODUCTS:
A) SPONGE IRON (DRI)
B) POWER FROM WASTE HEAT (WHRB)
• SOLID WASTE:
A) COAL CHAR ,
B) DE – DUST,
C) FLY ASH,
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FLOW CHART OF THE DRI PROCESS
BA
GIL
TE
RS
DE
DUST
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GENERATION OF SOLID WASTE
0.15 MT CHAR 30%
0.08MT DE DUST 16%
PER TON OF DRI SOLID
WASTE GENERATION IS
0.5 MT
0.225 MT FLY ASH 45%
0.045 MT OTHERS 9%
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KILN’S SOLID WASTE BREAKUP %
9
16
45
30
FLY ASH
CHAR
DE DUST
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OTHERS
8
COOLER DISCHARGE CHAR & DE DUST
• IN DRI MAKING THROGUH ROTARY KILNS
NON MAGNETIC CHAR CONTAINS ALONG
WITH FINISHED PRODUCT.
• THIS NON MAGNETC CHAR HAVING GOOD F.C
& GCV.
• CHAR IS 30% OF TOTAL SOLID WASTE
• DE DUST 16% OF TOTAL SOLID WASTE
HAVING GOOD F.C & GCV
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SIZE ANALYSIS in %
+6mm
-6 +3mm 0 – 3mm
12.3
22.2
65.5
CHAR
SIZE ANALYSIS in %
75 Mesh
25
-75 to 100 Mesh
75
DE DUST
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IN PUT COAL ANALYSIS
COAL SOURCE
V.M %
ASH %
F.C %
GCV Kilo
Calories/Kg.
IMPORTED
COAL S.A
25 - 27
14 - 16
57 - 60
6500 - 6700
INDIGENIOUS
COAL
25 - 26
26 - 30
45 - 48
5000 - 5500
SOLID WASTE CHAR & DE DUST ANALYSIS
V.M %
ASH %
F.C %
GCV Kilo
Calories/Kg.
CHAR
1–2
55 - 60
35 - 40
3200 - 3400
DE DUST
2–4
60 - 65
30 - 35
2800 - 3000
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COMPARISION OF THE F- GRADE COAL
WITH
CHAR & DE DUST
TYPEOF FUEL
V.M
ASH
F.C
GCV
K.Cal./Kg.
F – GRADE COAL
25 - 28
35 -40
30 - 35
3000 -3200
CHAR
1–2
55 - 60
35 - 40
3200 - 3400
DE -DUST
2–4
60 - 65
30 - 35
2800 - 3000
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• DEVELOPED A VALUE ADDED PRODUCT FROM SOLID
WASTE, CHAR IS BEING UTILISED AS FUEL IN CFBC /
AFBC BOILERS FOR POWER GENERATION
• DE – DUST GENERATES THROUGH BAG FILTERS FROM
FINISHED PRODUCT CIRCUITS AND IT CONTAINS
GOOD CARBON IN PULVERISED CONDITION (-75 to
100 MESH). IS ALSO BEING USED IN CFBC BOILERS
(10% MIXED WITH F – GRADE COAL 50 & 40% CHAR)
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FUEL REQUIREMENT FOR POWER GENERATION THROUGH
AFBC BOILERS (100% F –Grade coal @ Rs.3000/MT)
TYPE OF
BOILER
AFBC
15 MW
AFBC
25 MW
BOILER
CAPACITY
MAIN STEAM
PRESSURE
70 TPH
60Kgf/cm2
110 TPH
60Kgf/cm2
MAIN
STEAM
TEMP.
COAL
REQUIREQUI
REMENT
PER HOUR.
FUEL
REQUIREM
ENT PER
DAY
500 0C
17 MT
410 MT
12.3
732
500 0C
27 MT
648 MT
19.44
736
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FUEL COST
PER DAY
(Rs. Laks)
COST OF
STEAM PER
MT
(Rs.)
14
FUEL REQUIREMENT FOR POWER GENERATION THROUGH
CFBC BOILERS (100% F- GRADE COAL @ Rs.3000/MT )
TYPE OF
BOILER
BOILER
CAPACITY
MAIN
STEAM
PRESSURE
MAIN
STEAM
TEMP.
COAL
FUEL
REQUIRE REQUIRE
QUIREME MENT /
NT /Hr.
DAY
CFBC
15 MW
75 TPH
66Kgf/cm2
480 0C
20 MT
CFBC
25 MW
110 TPH
66Kgf/cm2
480 0C
28 MT
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FUEL
COST
PER DAY
Rs. Laks
COST OF
STEEM
PER TON
(Rs)
480 MT
14.40
800
672 MT
20.16
763
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FUEL REQUIREMENT FOR POWER GENERATION THROUGH
AFBE BOILERS (15 MW PLANT)
(IN COMBINATION OF F- GRADE COAL AND CHAR)
• CONSIDERING THE STEEM GENERATION FROM 15MW AFBC BOILER
IS 1680 MT
• FUEL COMBINATION IS 60% F- GRADE COAL & 40% CHAR
• REQUIREMENT OF F – GRADE COAL = 24*10.9 =261 MT/DAY
REUIREMENT OF CHAR = 24*8 = 192 MT/DAY
• COST OF THE F-GRADE COAL = 3000*261= Rs.7.83 LAKH
COST OF THE CHAR
= 1300*192= Rs.2.496 LAKH
• TOTAL FUEL COST IS 10.326 LAKHS
• SO THE COST SAVINGS BY USING THE CHAR COMBINATION FUEL
IS = 12.3 – 10.326 = 1.974 LAKH /DAY
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FUEL REQUIREMENT FOR POWER GENERATION THROUGH
AFBC BOILERS (60% F –Grade coal @ Rs.3000/MT & 40% char
@Rs.1300/MT)
TYPE OF
BOILER
AFBC
15 MW
AFBC
25 MW
STEAM
GENERATION
/DAY MT
FUEL COST
FOR F-GRADE
COAL 100% IN
(Rs. LAKH)
(A)
FUEL
COST SAVINGS IN
COMBINATION
STEEM /TON
COAL AND CHAR
(Rs.) (C) =A-B
60:40 IN
(Rs.LAKH)
(B)
1680
12.3
10.326
117.50
2640
16.44
16.147
124.74
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FUEL REQUIREMENT FOR POWER GENERATION THROUGH
AFBE BOILERS (25 MW PLANT)
(IN COMBINATION OF F- GRADE COAL AND CHAR)
• CONSIDERING THE STEEM GENERATION FROM 25MW AFBC BOILER
IS 2640 MT/DA
• FUEL COMBINATION IS 60% F- GRADE COAL & 40% CHAR
• REQUIREMENT OF F – GRADE COAL = 24*17.4 =417.6 MT/DAY
REUIREMENT OF CHAR = 24*11.6 = 278.4 MT/DAY
• COST OF THE F-GRADE COAL = 3000*417.6= Rs.12.528 LAKH
COST OF THE CHAR
= 1300*278.4= Rs. 3.619 LAKH
• TOTAL FUEL COST IS 16.147 LAKHS
• SO THE COST SAVINGS BY USING THE CHAR COMBINATION FUEL
IS = 19.44 – 16.147 = 3.293 LAKH /DAY
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FUEL REQUIREMENT FOR POWER GENERATION THROUGH
AFBC BOILERS (60% F –Grade coal @ Rs.3000/MT & 40% char
@Rs.1300/MT)
TYPE OF
BOILER
CFBC
15 MW
CFBC
25 MW
STEAM
GENERATION
/DAY MT
FUEL COST
FOR F-GRADE
COAL 100% IN
(Rs. LAKH)
(A)
FUEL
COST SAVINGS IN
COMBINATION
STEEM /TON
COAL AND CHAR
(Rs.) (C) =A-B
60:40 IN
(Rs.LAKH)
(B)
1800
14.40
11.136
181.33
2640
20.16
15.590
173.10
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YEARLY SAVINGS
•
•
•
•
AFBC 15 MW: 06.31 Cr.
AFBC 25 MW: 10.54 Cr.
CFBC 15 MW: 10.44 Cr.
CFBC 25 MW: 14.62 Cr.
LIST OF THE PARTIES USING CHAR
•
•
•
•
•
•
•
•
M/S ADHUNIC METALIKS Ltd.,
M/S MSP STEEL & POWER LTD.
M/S VISA STEEL LTD.
M/S SHREE GANESH METALIKS LTD
M/S SHYAM METALIKS AND ENERGY LTD
M/S K P TRADING
M/S VIKASH COAL COMPANY
M/S SHREE JAGANNATH METALLIC INDUSTRIES
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AN APEAL TO THE GOVT. OF INDIA INORDER TO
DECLARE CHAR IS NOT A WASTE
• IT IS TO BE MANDATED TO UTILISE THE CHAR
GENERATED FROM DRI PLANTS IN AFBC /CFBC
BASED PLANTS.
• ADVISE RAILWAYS TO GIVE SUBSIDY IN
FRAIGHT FOR TRANSPORTING.
• GIVING TAX EXEMPTIONS ON UTILISING THE
CHAR IN POWER PLANTS.
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• CONSERVE NATURAL RESOURCES BY USING
CHAR GENERATED FROM COAL BASED DRI
PLANTS IN AFBC / CFBC BOILER BASED POWER
PLANT WHICH OTHERWISE CALLED AS WASTE.
• GENERATE WEALTH FROM CHAR (ENERGY
SOURCE) WHICH OTHERWISE DECLARED AS
WASTE
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CORPORATE OFFICE : 202,2nd Floor HMP HOUSE ,4 FAIRLEY PLACE
, KOLKATA-711101
REGISTERED OFFICE : 206, 2nd Floor SHREENIKETAN
APARTMENT,BARBIL,KEONJHAR ,ODISHA
CONTACT NO : +91 9007819992 ; +91 9830870011 ; +91 9937754992 ;
+91 9668423900
CONTACT PERSON - SHAKEEL ANSARI (DIRECTOR)
EMAIL ID : aryavarta.mn @gmail.com
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