Captive Thermal + DG Power Plant for 0.9 mio tons per annum Cement
Plant at Ariyalur, Tamil Nadu, India
Key Project Data
Thermal Plant |
Fuel |
|
Neyveli Lignite |
GCV-2800
Moisture – 52% |
Imported Coal |
GCV-6000
Moisture - 13.2% |
Coal handling system |
125
TPH with pre & post screens |
Boiler |
|
Capacity |
55000
kg/hr |
Pressure |
66
kg/cm2 |
Temperature |
485
deg. C |
Boiler feed |
Over
& Under bed feeding |
Type |
Fluidised
Bed |
Turbine |
Two-bleed cum condensing
steam turbine with water cooled condenser
|
12.5
MW |
Generator output voltage
|
6.6
KV |
Emission
|
less
than 80 mg/Nm3 |
Instt. & Control
|
Complete
operation from plant DCS |
Water Treatment |
RO plant for cycle water, cooling water and other plant requirement.
|
Operation of plant |
Operation hours
|
Min.
8000 hours/annum |
Expected life span
|
More
than 25 years |
Synchronization
|
With
DG sets and public utility |
DG Plant |
Fuel |
HFO/LSHS/FO |
Capacity |
3
x 6 MW |
Engine Type |
18
V 32 (Wartsila) |
Generator |
7500
KVA (ABB) |
|
The uncertain power scenario of the public utility
due to wide gap in supply & demand, poor quality of power and hiked power tariff
result into additional problems for cement plants in terms of loss in production and
increased maintenance/ operation costs. HOLTEC helps in working out cost effective and
reliable total power and energy solution for a plant. The most attractive option is
arrived at based on the project cost, fuel option analysis, process energy demand pattern
analyses, operating flexibility and host of other fundamental issues.
Grasim Industries Limited
(GIL) based on the option evaluation study conceived that for effective operation of
cement plant, a captive power plant is the need of the hour. A 30 MW Power Plant
consisting of 12.5 MW of Thermal Power and 18 MW of DG Power was found to be most
suitable.
GIL with a total installed
capacity of nearly 10 mio tons per annum is one of the major players in Indian Cement
Industry. It is part of Birla Group, a leading business group of India having diverse
business interests.
Owner
Grasim Industries Ltd. (GIL), India
Consultant
Holtec Consulting
Private Limited, India
Scope of
Consulting Services
Power scenario and option evaluation study.
Preparation of plant technical concept, fuel
option analysis, heat and mass balance diagram, plant layout, philosophy for C&I using
DCS system, energy efficient electrical system.
Preparation of the detailed tender document
for power plant, techno-commercial evaluation report and recommending suppliers as per
merit.
Review/approval of contract documents,
design documents and drawings.
Inspection of machinery and equipment at
manufacturer’s works.
Preparation of project schedule, periodic
updating, monitoring and progress reporting.
System design for recording/certification of
quantities and for monitoring and control of construction and erection activities.
Supervision of commissioning and preparation
of provisional acceptance certificates.
Preparation of Final Project Report
containing a comprehensive record of the implementation of the whole project.
Salient Features
For installation of the captive power
plant, detailed option evaluation study was carried wherein type of power plant Thermal,
DG or Gas based and mode of installation viz. Own, BOOT, BOO & BLOT was carried out.
Based on above study considering various pros & cons Own Power Plant was recommended.
The DG Plant of 18 MW was commissioned in record time of 5 months. Thermal Plant is under
implementation, which would result into net savings of about 4.8 mio US $ per annum.
|