W.H.R.B (Waste Heat Boiler)

A waste heat which is being generated from W.H.R.B 100 TPD Klin of 24,000 NM^3/hr. this depends on Metalisation of sponge Iron and klin operation. presently Coal quality has deteriorated tremendously and accordingly gas volume decreases. for which many of the enterpruners telephonic contacted about Quality of Steam generation at 64 ata, 485 Deg C, for 10 TPH of Steam.

So, for above low Steam generation, let me explain the following reasons, which are as follows: -

(1) Low gas generation from Klin.
(2) Low capacity of Celler Fan.
(3) Coal Composition.
(4) WHRB Boiler design parameter i.e. economizer storage capacity.

So, the above problems can be solved following ways: -

(a) Increase the volume of air (Oxygen) to klin keeping full coal burning.
(b) Injection Coal fines in ABC Chamber or WHRB Boiler.
(c) Regulation economizer water volume with respect to design of WHRB 11 Ton steam
generation then holding capacity of economizer is more for 10 ton WHRB.
(d) Check Flue gas temperature at ESP Inlet.

As in the year 1993 waste heat boiler was made available in India only by BHEL at Prakash industries, Champa (C.G.) 32 Kg/Cm^2, at 400 Deg C.

Now technology has developed & we are getting from 100 TPD Klin of steam of 10 TPH, at 66 ata, at 485 Deg C from many Boiler manufacturer.

Today development have been made in 300 TPD klin & 500 TPD Klin in which Boiler manufacturer can produce steam at 105 Kg/Cm^2, at 490 Deg C. which is High pressure steam from WHRB coupled with CFBC for 30 MW to 50 MW will be more economical for Power Generation and sponge Iron Klin can generate power to boost the economy of the system.

New Concept of Waste Heat Steam Generation

Raipur Power Gen has developed a New concept of WHRB( Waste Heat Recovery Boiler) from sponge Iron Kiln.

In General Sponge Iron Kiln we have for example 100tpd( tones per day ) that generates 24,000 cum/hr hot gases at 950degC to be used for WHRB to produce steam of 10 tph (tones per hour ) , 64ata, 485degC with each boiler attached with 100 tpd Sponge Iron Kiln .
We know in this we would need 3 WHRB’s would be needed under 3 separate kiln.
In the new concept that RPG has developed we have combined 3X100 tpd sponge from Hot Gas duct in one WHRB (waste heat recovery boiler) having isolation slide gate (water cooled ) at inlet of hot duct on riser side.
This slide valve can withstand temperature upto 1600degC and by valve controlling we can control the pressure inside the kiln if necessary.

After combining all the three duct’s in one WHRB we can get waste gas of 3X24000cum/hr & corresponding steam generation 30 tph (tonne per hour) for running steam turbine generator. And now if one kiln is under shutdown we are providing pulverized coal nozzle to generate more gas vice versa we would get more steam from waste heat boiler. The coal nozzles and slide gates valves are imported.

The Operation of this kind of a project under my guidance will begin from JUNE 09.
For which boilers are under erecting stage.

The total design and concept has been verified by boiler design experts.
We sincerely and firmly believe and wish that we will achieve success in our developmental project and in future times this can be used with coal dust in plant for recycle.

D.Mukherjee
9827172172

Projects Handled

Indo-Lahari Power Ltd. Raipur (C.G.) - 6 MW BIOMASS (Rice Husk Based) , loan from IREDA, IDBI.
Vandana Vidyut Ltd, Bilaspur (C.G.)- 8 MW BIOMASS (Rice Husk Based) , loan IREDA.
Indsil Power Company Ltd.(C.G.) - 12 MW Coal Based
Drollia Electrosteels (P) Ltd (C.G.)- 12 MW Air Cooled Condenser Waste Heat Based
SKS Ispat Power (C.G.) - 25 MW Waste Heat Based
CHIND Power and Steel Pvt. Ltd. (C.G.)- 8 MW BIOMASS (Rice Husk Based) - Ongoing
G.R. Sponge and Power (P) Ltd.(C.G.) - 8 MW Air Cooled Condenser Waste Heat Based
Sunil Sponge (P) Ltd. Raipur (C.G.) - 8 MW Air Cooled Condenser Waste Heat Based - Equipment order placed - Ongoing
Aarti Sponge & Power (P) Ltd.(C.G.) - 10 MW Air Cooled Condenser Waste Heat Based - Equipment order placed - Ongoing
Devi Steel and Power Pvt. Ltd (C.G.) - 8 MW Air Cooled Condenser Waste Heat Based - Ongoing
Shyam Sponge and Power Pvt. Ltd (C.G.)- 20 MW Air Cooled Condenser Waste Heat Based - Ongoing
Mahaveer Energy and Coal Benefication Pvt. Ltd (C.G.) - 12 MW BIOMASS (Rice Husk Based) - Ongoing, on verge of completion
Kasturi Cements and Power Pvt. Ltd.(C.G.) - 30 MW Coal Based - Project initialized
Saikrupa Biotech Pvt. Ltd. (Andhra Pradesh) - 15 MW BIOMASS (Rice Husk Based) - Project initialized
N.R. Sponge Pvt. Ltd. (C.G.) - 12 MW Air Cooled Condenser Waste Heat Based - Ongoing
Bilasraika Sponge Iron India Pvt. Ltd. - 12 MW Air Cooled Condenser Waste Heat Based - Ongoing

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