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.

1. THE NEW GENERATION, COAL
FIRED, COST EFFICIENT, FULLY
SAFE AND AUTOMATED, EXTENDED
SHAFT
producer gas plant
SUPPLIER :-
INDIA INDUSTRIAL ENTERPRISES

2. producer gas is generated 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.

3. process view

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

5. CONTROL & INSTRUMENTATION

6. AUTO SAFETY FEATURES DURING POWER / FLAME
FAILURE

7. BLAST AIR FLOW CONTROL AREA

8. DRUM LEVEL CONTROL AREA

9. B.S.T. CONTROL AREA

10. GAS OUTLET AREA

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 of fuel 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 of fuel 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 Fuel oil 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 of Producer 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. Interlocks in 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. Interlocks with 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.

18. THANKS