This document provides an overview of Sesa Sterlite Ltd's 4x600 MW independent power plant (IPP) located in Jharsuguda, India. The key points are:
1) The IPP has 4 units totaling 4x600 MW capacity supplied by SEPCO-III China. It uses boiler and turbine technology from Harbin and DFPS of China respectively.
2) Modifications were made to the boiler of one unit to improve efficiency and reliability. This involved reducing the surface area of low temperature superheater and reheater zones as well as increasing the economizer surface area.
3) Testing after the modifications showed improved parameters including a reduction in station heat rate of 14
Plant shutdowns can happen for a variety of reasons from
planned and unplanned to strategic and unexpected. No matter
the reason, it’s critical to have a sound plant shutdown
management plan in place.
Catalyst Catastrophes in Syngas Production - I
The Hazards
Review incidents by reactor
Purification….
Through the various unit operations to
Ammonia synthesis
Nickel Carbonyl
Pre-reduced catalysts
Discharging catalysts
Conclusion
Plant shutdowns can happen for a variety of reasons from
planned and unplanned to strategic and unexpected. No matter
the reason, it’s critical to have a sound plant shutdown
management plan in place.
Catalyst Catastrophes in Syngas Production - I
The Hazards
Review incidents by reactor
Purification….
Through the various unit operations to
Ammonia synthesis
Nickel Carbonyl
Pre-reduced catalysts
Discharging catalysts
Conclusion
16 big losses for manufacturing and servicesVishy Chandra
This presentation will provide information on what the 16 Big Losses are. The module will also introduce to a first-time connect of the 16 Big Losses to a service context.
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDSGerard B. Hawkins
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDS
Case Study: #0953616GB/H
HT SHIFT REACTOR CATALYST SPECIFICATION
Process Specification
This process duty specification refers to a Syngas Conditioning Unit which utilizes HT Shift reaction technology on a slip stream of raw gas to produce a recombined gas stream with a H2:CO ratio of 1.57:1. This is an important consideration as the Shift reactor is not required to minimize CO at outlet, and this specification refers to the expected performance that can be achieved in a single stage reactor scheme.
The Syngas Conditioning Unit is part of a proposed coal-to-liquids complex in which synthesis gas is produced by gasification of coal for downstream processing in a Fischer Tropsch reactor and Hydrocracker unit.
ERP, PDM, CRM, and EDM system critical success factors (CSF) have significant impacts on the success or failure of the project.
What are these CSF’s and how can a project asses their compliance against them?
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
- Process effects of pre-reforming
- Process benefits of pre-reforming
- Effect of Pre-reformer Inlet Temp on Primary Reformer Efficiency
- Services for Pre-reforming
Pre-Reforming Problems
- Features: Impact of Sulfur
- High Temperature Operation
- Catalyst Deactivation
- Which is Better - High or Low Inlet Temperatures ?
- Pre Reformer Loading
- Pre-Reformer Installation
- Pre-reformer Startup
- Catalyst Drying
- Catalyst Heating
- Reduction
In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the
ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such
as argon and methane to a limited extent. The source of H2 is demineralized water and the
hydrocarbons in the natural gas. The source of N2 is the atmospheric air. The source of CO2 is
the hydrocarbons in the natural gas feed. Product ammonia and CO2 is sent to urea plant. The
present article intended the description of ammonia plant for natural gas based plants and the
possible material balance of some section
Webinar: 'Applying carbon capture and storage to a Chinese steel plant.' Feas...Global CCS Institute
The Global CCS Institute has recently published a feasibility study report on applying carbon capture and storage (CCS) to a steel plant in China. Toshiba was commissioned to conduct the study in collaboration with Chinese corporations.
The feasibility suggests that carbon capture in Chinese steel plants is a cost effective means of reducing carbon emissions compared with similar plants around the world. In this webinar, Toshiba presented on the major findings of this feasibility study.
16 big losses for manufacturing and servicesVishy Chandra
This presentation will provide information on what the 16 Big Losses are. The module will also introduce to a first-time connect of the 16 Big Losses to a service context.
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDSGerard B. Hawkins
SYNGAS CONDITIONING UNIT FEASIBILITY CASE STUDY: COAL-TO-LIQUIDS
Case Study: #0953616GB/H
HT SHIFT REACTOR CATALYST SPECIFICATION
Process Specification
This process duty specification refers to a Syngas Conditioning Unit which utilizes HT Shift reaction technology on a slip stream of raw gas to produce a recombined gas stream with a H2:CO ratio of 1.57:1. This is an important consideration as the Shift reactor is not required to minimize CO at outlet, and this specification refers to the expected performance that can be achieved in a single stage reactor scheme.
The Syngas Conditioning Unit is part of a proposed coal-to-liquids complex in which synthesis gas is produced by gasification of coal for downstream processing in a Fischer Tropsch reactor and Hydrocracker unit.
ERP, PDM, CRM, and EDM system critical success factors (CSF) have significant impacts on the success or failure of the project.
What are these CSF’s and how can a project asses their compliance against them?
1. Introduction reasons for purification, types of poisons, and typical systems
2. Hydrogenation
3. Dechlorination
4. Sulfur Removal
5. Purification system start-up and shut-down
- Process effects of pre-reforming
- Process benefits of pre-reforming
- Effect of Pre-reformer Inlet Temp on Primary Reformer Efficiency
- Services for Pre-reforming
Pre-Reforming Problems
- Features: Impact of Sulfur
- High Temperature Operation
- Catalyst Deactivation
- Which is Better - High or Low Inlet Temperatures ?
- Pre Reformer Loading
- Pre-Reformer Installation
- Pre-reformer Startup
- Catalyst Drying
- Catalyst Heating
- Reduction
In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the
ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such
as argon and methane to a limited extent. The source of H2 is demineralized water and the
hydrocarbons in the natural gas. The source of N2 is the atmospheric air. The source of CO2 is
the hydrocarbons in the natural gas feed. Product ammonia and CO2 is sent to urea plant. The
present article intended the description of ammonia plant for natural gas based plants and the
possible material balance of some section
Webinar: 'Applying carbon capture and storage to a Chinese steel plant.' Feas...Global CCS Institute
The Global CCS Institute has recently published a feasibility study report on applying carbon capture and storage (CCS) to a steel plant in China. Toshiba was commissioned to conduct the study in collaboration with Chinese corporations.
The feasibility suggests that carbon capture in Chinese steel plants is a cost effective means of reducing carbon emissions compared with similar plants around the world. In this webinar, Toshiba presented on the major findings of this feasibility study.
'Applying carbon capture and storage to a Chinese steel plant.' Feasibility s...Global CCS Institute
The Global CCS Institute has recently published a feasibility study report on applying carbon capture and storage (CCS) to a steel plant in China. Toshiba was commissioned to conduct the study in collaboration with Chinese corporations.
The feasibility suggests that carbon capture in Chinese steel plants is a cost effective means of reducing carbon emissions compared with similar plants around the world. In this webinar, Toshiba presented on the major findings of this feasibility study.
Methanol Casale Advanced Reactor Concept (ARC) Converter Retrofit CASE STUDY #10231406
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FINAL YEAR INDUSTRIAL TRAINING REPORT-ALBARIO ENGINEERING NANDIPUR 435 Combin...Umer Azeem
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This presentation by Morris Kleiner (University of Minnesota), was made during the discussion “Competition and Regulation in Professions and Occupations” held at the Working Party No. 2 on Competition and Regulation on 10 June 2024. More papers and presentations on the topic can be found out at oe.cd/crps.
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This presentation, created by Syed Faiz ul Hassan, explores the profound influence of media on public perception and behavior. It delves into the evolution of media from oral traditions to modern digital and social media platforms. Key topics include the role of media in information propagation, socialization, crisis awareness, globalization, and education. The presentation also examines media influence through agenda setting, propaganda, and manipulative techniques used by advertisers and marketers. Furthermore, it highlights the impact of surveillance enabled by media technologies on personal behavior and preferences. Through this comprehensive overview, the presentation aims to shed light on how media shapes collective consciousness and public opinion.
0x01 - Newton's Third Law: Static vs. Dynamic AbusersOWASP Beja
f you offer a service on the web, odds are that someone will abuse it. Be it an API, a SaaS, a PaaS, or even a static website, someone somewhere will try to figure out a way to use it to their own needs. In this talk we'll compare measures that are effective against static attackers and how to battle a dynamic attacker who adapts to your counter-measures.
About the Speaker
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Diogo Sousa, Engineering Manager @ Canonical
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Eureka, I found it! - Special Libraries Association 2021 Presentation
Boiler Modification for SHR & Reliability Improvement SSL (IPP)
1. An Energy & Environment
Conscious, Sustainable &
Prosperous Organization
SESA STERLITE LTD
4X600 MW IPP
1
2. Power Business Overview
Location Capacity
Jharsuguda IPP 4X600 MW
Jharsuguda CPP 9X135 MW
TSPL 3X650 MW
4X600 MW IPP Jharsuguda (Supplied by SEPCO -III)
Boiler Make HBC China
TG DFPS China
2
Sesa Sterlite – Power Overview
Contributing to India’s Energy
Security
An Energy & Environment Conscious Sustainable Organization
3. PROJECT - BOILER MODIFICATION FOR RELIABILITY AND
STATION HEAT RATE IMPROVEMENT
3
4. 4X600 MW INDEPENDENT POWER PLANT
First 600 MW Power Plant of Odisha
ESP – FF Hybrid precipitator maintaining SPM < 50 mg/Nm3
Plant supplied by SEPCO-III China (Boiler- Harbin , Turbine- DFPS)
Plant equipped with modern online performance and combustion
Optimisation softwares.
IPP has got accreditation with EnMS 50001:2011 , EMS 14001:2004 ,
QMS 9001:2008 and OHSAS 18001:2007 to ensure sustainability .
Opportunities identified and executed for efficiency and reliability
4
5. 5
Milestone
Particulars U#1 U#2 U#3 U#4
1st Light up 20-Dec-10 12-Jun-10 20-May-11 19-Feb-12
Date of
Synchronization
27-Dec-10 10-Aug-10 9-Jul-11 29-Mar-12
Date of Achieving
Full Load
28-Dec-10 14-Oct-10 16-Aug-11 25-April-12
Date of COD 30-Mar-11 9-Nov-10 19-Aug-11 26-Apr-12
MILESTONES OF SSL , JHARSUGUDA
6. Guaranteed Station Heat Rate achieved in all the Units
Saving Potential in SHR identified in three parameters
High Superheat Spray 150 TPH w.r.t 65 TPH (rated)
High Reheat Spray 33 TPH w.r.t 0 TPH (rated)
Less RH Steam Temperature 525 w.r.t 538 DegC
High metal temperature excursion causing tube failures
Difficult to Control Operating Parameter With Top Mill
Operation.
6
OPPORTUNITIES IN BOILER
7. BOILER DETAILS
Boiler Make The China Harbin Boilers co. Ltd
Boiler Type
Subcritical , Reheat, Single Furnace ,
Single Reheat , Forced Circulation ,
Balanced Draft , Dry bottom ,
Tangential corner fired pulverised Fuel
Fired
SH Outlet Steam pressure (MPa) 17.5
Design Temp (DegC) 541
Boiler Capacity (TPH) 2060
RH Steam Outlet Pressure (MPa) 3.8
RH Steam Temperature (DegC) 541
Fuel consumption (TPH) 433
7
8. Losses identified at early stage
Initiatives started to counter the problem
Combustion Experts Dr. V T Satyanathan (Ex-BHEL) conducted study
Combustion Experts of Squam Power Plant Technical Consultancy
engaged for optimisation
STEAG Germany combustion optimisation software installed
Online trials conducted and detailed study carried out
8
CORRECTIVE MEASURES
9. Trials conducted since 2011 to Dec 2012 mainly focused on
(i) SADC tuning
(ii) Burner Tilts
(iii) OFA damper regulations
(iv) Soot Blowing Optimisation
Trials Conducted but desired result could not be achieved with
above Trials.
Conclusion: SSL insisted Sepco-III to study and provide solution.
9
10. ENGAGEMENT OF HBC- OEM
Sepco-III depuetd Combustion expert from Harbin Boiler
Trial Conducted by Harbin Experts from 4-18th December 2012
Operation and combustion expert exercised all the possible
combinations
CONCLUSION :
Improvement in performance parameter not achieved
Harbin suspected the variation in fuel was leading to deviations
Harbin referred the problem to design institute for review and solution.
10
11. Review and Proposal
Design institute recommended modification
Harbin proposed modification in three zones of boiler
Reduction of Surface area of LTSH from 12944 to 7696 m2
Reduction of radiation side wall Re-Heater width from 8191 to6268
mm
Increase of Economiser surface from 215000ft2 to 277000 ft2
Boiler efficiency and SHR will remain unaffected.
All the performance test will be carried out after modification.
11
12. Review and Approval of Project
SSL & Ex-BHEL design expert Mr. Sivaraman Krishnamurthy
reviewed the proposed modification
Proposal review meeting held at Harbin China in March 2013.
Challenge of pressure part alteration in limited access reviewed
Unit outage for longer time > 60 Days
Directorate of Factories & Boiler reviewed and approved the
project
SSL approved the project anticipating long term gain in
Conservation of natural resource and reduction in carbon
emission.
12
13. REMOVAL OF PRESSURE PART
Material received within 3 months of project approval from China
120 Nos. tube Reheat radiation wall removed from each side
Water wall LTRH headers replaced with new headers
Lower group of LTSH Removed
13
Cutting of LTRH
Tube and Header
Removal of LTRH
Header
Economiser Tube
cutting
14. ERECTION OF PRESSURE PART
Erection methodology was prepared by Harbin & Sepco-III
Job safety analysis carried out in detail
Each lifting tools to be used in project tested before
commencement of project
14
Steam Cleaning of
Tubes
Erection of
Economiser Coil
Lifting of water wall panel
through bottom ash
hopper
15. Erection of Pressure Part
Detailed Quality assurance plan to ensure quality work
Radiography conducted in 100% joint in RH and LTSH area
Radiography in 20% joint of Economiser.
15
Readiness for
position eco tube
Economiser coil in
position
16. PROJECT – Boiler Modification
First modification started in Boiler of Unit#3 w.e.f 12th July 2013
Modification carried out during scheduled annual overhaul of Unit-3
Sepco-III executed the modification project
Material was supplied from China in short duration of 3 months
16
Removal of LTRH
Header Fitment of new
LTRH Header
Erection of new
LTRH link pipe
17. PROJECT – Boiler Modification
Manpower engaged 250
No of Days for project completion - 60
Cost of Project Rs 500 millions INR
No of Welding Joints 3485
17
Lifting of Economiser Coil Addition of Economiser bank New Added Economiser bank
18. Re-Commissioning & Demonstration
Detailed programme prepared for Boiler flushing
Flushing continued for 3 Days to bring the parameters in limits
Post-modification demonstration carried out for
Boiler Efficiency test
Boiler efficiency test at design and worst coal
Demonstration for Zero Reheat spray and rated Super heater spray
Demonstration for top mill and bottom mill operation
Reliability test for design unit load ramp up and ramp down
14 Days reliability run by OEM
All the tests were successfully completed
18
19. Boiler Parameters After Modification
19
S.No Parameter Description UOM Design
Before
Modificatio
n
After
Modificatio
n
1 Power Generation MW 600 599 601
2 Coal flow TPH 420 411 383
3 Main Steam Pressure Mpa 16.7 16.37 16.66
4 Main steam Temperature DegC 538 539 539
5 RH steam Temperature DegC 538 536 538
6 RH Steam Pressure MPa 3.8 3.61 3.49
7 SH Spray TPH 65 150 66
8 RH Spray TPH 0 25 0
20. SH Spray Reduced from 150 TPH to 66 TPH
RH Spray Reduced from 33 TPH to Zero
Top Mills Service operation became normal operation
Improvement in SHR of 14Kcal/KWH achieved
SHR Improvement contributed to saving of 87000 MT of coal per
annum
Reduction in CO2 emission by 2.3 lacs MT emission due to
improvement in SHR.
20
Result Summary
21. CALCULATION OF GAIN AFTER MODIFICATION
S.No.
IMPROVEMENT
AREA
UOM
Before
Modification
After
Modification
Improve
ment
Gain in
Heat
Rate
(Kcal/K
wh)
Net Saving
in Millions
(INR)Per
annum
Net
Saving
of Fuel
Per
Annum
(MT)
1 Av . Power Generation MW 600 600 0 0 0 0
2 Reheat Temperature DegC 525 538 13 6.7 24 10534
3 Reheat Spray % 2.4 0 2.4 7 26 11088
4 SH Spray % 8.6 3.5 5.1 0.12 0.44 190
Total Savings Per unit per Annum (@90% PLF , 3000 Kcal/Kg GCV) 50 21812
Total Saving Per Annum for 4X600 MW 201 87247
21