Boiler & Heater Group

Transcription

1 Boiler & Heater Group

2 Boiler & Heater Group New Trends in Tail Gas Fired Boiler Carbon Black Conference 2017 Chennai, India

3 About Thermax A leading engineering company providing equipment and solutions related to Energy and Environment

4 Our Core Business THERMAX Boilers & Heaters Cooling & Heating Power Generation Chemicals & Water Air Pollution Control Renewable Boiler & Heater Large capacity power boilers Thermal oil / water heaters Package boilers Energy recovery systems Cooling Exhaust & Multienergy fired chillers Steam fired chillers Hot water fired chillers Direct fired chillers Heating Steam/Hot water power plants Packaged solid/oil/gas fired boilers Fired thermic fluid heaters Exhaust waste heat recovery boilers Turnkey Power Plants Solid fuel based Gas based combined cycle Waste heat recovery based RE based incl. Biomass, Bagasse, solar, etc. O&M of power plants Chemicals Ion exchange resins Cooling water chemicals Fireside chemicals Polyelectrolyte Water and wastewater Wastewater & Effluent water treatment systems Water recycling Waste management Enviro ESP & Bag filters Scrubbers Air purification Retrofit & Revamp Solar Heating Cooling

5 Experience in Waste Heat Recovery Applications Cement Heat Recovery Carbon Black Sponge Iron Exhaust Blast Furnace Gas Coke Oven Gas Coke Dry Quenching DG Set Exhaust Gas Gas Turbine Exhaust Gas Fluid Catalytic Cracking Unit Sulphur Recovery Plant Coal Gasification Sulphuric Acid Plant Incinerators Iron Pyrites Roasters Zinc Pyrite Roasters Copper Smelters Copper Convertors Glass Furnace Electric Arc Furnace Coke Calcination Nitric Acid Caprolactum

6 Flow Diagram of Carbon Black Making Process - Key Points Cold Air Reactor Air Pre-heater Bag Filter Fuel Hot air Reactor Boiler Feed Heater Reactor Burner Tail Gas to Boiler Feed Input Tail Gas to Dryer

7 Key Tail Gas Points Utilization Tail gas is normally used for steam and power generation. In case of non-utilization for steam / power generation the tail gases are either incinerated or flared.

8 Key Tail Gas Points Characteristics Typical constituents: CO, H 2, CH 4, N 2, C 2 H 2, O 2, H 2 O, H 2 S, CO 2 Low Calorific value (LCV: kcal/nm³) lean gas. Combustion requires Temperature, Time and Turbulence.

9 Key Tail Gas Points Combustion Systems Water cooled furnace Refractory lined combustion chamber

10 Key Typical Points Tail Gas Fired Boiler Scheme Stack Steam Drum Convection Bank Combustor Economiser Burner Superheaters Air preheater

11 Key Salient Points Features of the Tail Gas Fired Boiler Thermal Efficiency of 85 % (Based on LCV) Externally fired combustion chamber for complete combustion of tail gases. Tangential entry of tail gas along with radial entry of combustion and dilution air into combustor ensures complete combustion. Combustor Orientation : Horizontal / Vertical Sufficient residence time for complete combustion of lean gases No auxiliary fuel is required during normal operation. Forced Draft / Balanced Draft System

12 Key Salient Points Features of the Tail Gas Fired Boiler Fully drainable Superheater. Superheater is placed in membrane panel construction, avoiding refractory lined casing. Screen tubes are provided before Secondary Superheater for protecting the same from direct radiation. Boiler Turndown Ratio 1:4

13 Key Salient Points Features of the Tail Gas Fired Boiler Rated superheat temperature is achieved for the given turn-down range because of Radiant Superheater. Convection section side walls consist of membrane panel construction. This ensures refractory less design. Boiler feed water pre-heater is provided to preheat feed water before entering Economiser. This ensures no corrosion of Economiser tubes. Bare tube Heat transfer surfaces to avoid gas side choking.

14 Key Emission Points Control Methods NOx Reduction SOx Reduction

15 Key Nox Reducing Points Methodology Low NOx Burners Air Staging Fuel Staging Flue Gas Recirculation DeNOx System - SNCR / SCR

16 Modularization Combustion Chamber

17 Modularization Boiler Block

18 Modularization Economiser Section

19 Modularization Refractory Lined Stack

20 Key Observations Points Captive power generation is a great success and makes these plants self sufficient. Continuous plant availability makes these plants highly reliable. If wheeling of power is allowed, Carbon black plants can be net exporters of power. Tail gas burning and conserving energy is also Environmentally friendly.

21 THANK YOU