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Gas producer plant
The document describes a new generation of coal-fired, cost-efficient, fully automated and extended shaft producer gas plant. It provides details on the producer gas composition and process, and estimates cost savings of using producer gas compared to fuel oil. Safety interlocks are also described to ensure safe operation including controls for gas output, steam addition, pressure monitoring and automatic valve closing in failure scenarios.
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Gas producer plant
- 1. THE NEW GENERATION,COAL FIRED, COST EFFICIENT, FULLY SAFE AND AUTOMATED, EXTENDED SHAFT producer gas plant SUPPLIER :- INDIA INDUSTRIAL ENTERPRISES
- 2. producer gas isgenerated by blowing air and steam through a bed of incandescent solid fuel under such condition that the combustible matter of the solid fuel is converted into combustible gases. gas produced from coal based producer contains some gaseous hydro-carbons and tar vapour along with carbon monoxide, hydrogen, carbon dioxide and balance nitrogen.
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- 4. reactor zone temperatures COAL BUNKER SOFT WATER OVERHEAD TANK SECTOR GATE BELL CONE VALVE 1 LTC 1 GAS BELL CONE VALVE 2 OUTLET GAS LTC 2 GAS LEVEL CONTROL VALVE REACTOR 100 VAPOUR 200 DRUM 300 MIXING CHAMBER 400 600 800 JACKET 1000 BOILER 1100 1200 ASH TEMP. CONTROL VALVE HYDRAULIC CYLINDER NORMAL SPEED FLOW CONTROL VALVE
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- 6. AUTO SAFETY FEATURESDURING POWER / FLAME FAILURE
- 7. BLAST AIR FLOWCONTROL AREA
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- 11. PRODUCER GAS COMPOSITION 100 90 80 70 O2 0.4% 60 CmHn 4% CO2 5% 50 H2 12% 40 CO 27% N2 52.8% 30 20 10 0
- 12. Existing cost offuel for Rotary Kiln Pulp Production : 179 TPD White Liquor consumption : 470 kgs/TP White Liquor production : 84.13 TPD Lime Consumption : 0.77 MT/MT WL Lime Production : 64.8 TPD Fuel Oil Consumption : 0.186 T/MT of Lime Fuel oil consumption : 12.05 TPD Cost of Fuel oil : Rs.20048/MT Cost of fuel oil : Rs.2.42 lacs/day
- 13. Proposed cost offuel for Rotary Kiln with Producer Gas ITEM UNIT Con/Day Rate Cost/Day Coal MT 25 3432.5 85812 Fuel Oil MT 3.01 20048 60344 Power KWH 1200 2.29 2748 Process cum 60 1.7 102 Water Soft Water Cum 24 12 288 Manpower Nos 18 Per 6 477 2862 Cas 12 132 1584 TOTAL Cost 1.54 lacs
- 14. Savings in Fueloil cost after Producer gas Cost of fuel before Producer gas : 2.42 lacs/day Cost of fuel after producer gas : 1.54 lacs/day Savings in fuel cost after installation of Producer Gas : Savings per day : 0.88 lacs Annual Savings : 321.2 lacs Investment (Offer ) : 223 lacs Taxes : 8 lacs(appx) Civil works : 30 lacs Total cost : 261 lacs Simple Payback : 297 days : 10 months
- 15. Safety Interlocks 1.Control ofProducer Gas output as per heat demand:-A pressure transmitter will be fitted at the outlet gas header before gas booster, which will generate signal to monitor and control the gas pressure.This will be done by increasing or decreasing the air flow from Air Bowers. 2.Control of B.S.T. and addition of steam and air:-Addition of steam is also important for regulated gasification with optimum steam carbon reactions,temp.control and prevention of clinker formation.For optimum Co and H2 formation,a blast saturation temp.of 60deg.c.will be ideal. 3.Interlocks in the Gas booster and the associated Gas train:- a) At pressure below 15mmwc in the gas header,the gas booster can not be started. b) Gas booster can not be started without starting of Air Blower. c) If the gas booster is not in operation,the gas isolation valve on the gas train can not be opened.
- 16. Safety Interlocks 4. Interlocksin Air Line:- In case of Power failure the individual pneumatic damper PVC in air line to gasifier will shut immediately. 5. Interlocks in steam circuit:- Full opening of steam valve to B.S.T. controller in case of power failure.In this case when the air flow stops, steam will continue to flow to gasifier to stop back flow of gas to the air line 6.Interlock of Gas sealing after washing chamber :- a) In the event of Power failure,the liquor outlet valve from the washing chamber sump,which normally remains open will shut immediately as a necessary step to fill up the sump with water for sealing the gas out let line from sump. b) Simultaneously with above operation,a valve in make up water line from Overhead emergency water tank will open to allow water to sump for filling it and sealing the gas line.
- 17. Safety Interlocks 7. Interlockswith Kiln/Burner:- a) In case of flame failure which is scanned by flame scanner,it will send signal to the solenoid circuit of the gas isolation valve and the valve will be automatically close. b) As long as the gas booster is not in operation,the gas isolation valve can not be opened. c) If ID fan of the kiln fails,gas isolation valve will close immediately. d) If gas pressure at burner inlet is above 150 mmwc or below 30mmwc the gas isolation valve will close after 10 seconds.
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