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Introduction:
Bauxite is the raw material from which alumina is extracted by alkali
process. Invented by Austrian Scientist Karl.Josheph Bayer, in nineteenth
century, it is the only process available for commercial extraction of
Alumina hydrate. The bauxite is mixed with hot sodium hydroxide solution
to dissolve alumina present in it. Using various techniques such as cyclonic
separation, settling, and filtration separates the non-reactive part consisting
mostly iron oxide. The soda solution having dissolved alumina in it is then
precipitated out at low temperature to get alumina hydrate as intermediate
product. This is calcined at about 1000OC to get alumina.
BAUXITE
The ore for alumina is present in different form and composition. The
tropical bauxite present in the hills of Panchapatmali of Damanjodi has
following components.
• Al2O3,3H2O GIBBSITE
• Al2O3, H2O BOHEMITE
• Fe2O3 HEMATITE
• Al2O3,2SiO2,(OH)4 KAOLINITE
• SiO2 QUARZITE
• H2O FREE MOISTURE
• V2O5 VANADIUM PENTOXIDE
• TiO2 TITANIUM DIOXIDE
• Ga2O3 GALIUM OXIDE
BALL MILL
Because the process of alumina processing involves solid bauxite and liquid
sodium hydroxide reaction, fine size of solid is necessary to have better
reaction and higher yield. The bauxite from silo is extracted at measured rate
and fed to ball mill, which grinds the material to about 63micron size. The
grinding process is accelerated by addition of dilute caustic soda solution at
150gm/lit soda concentration. Each of the four ball mills has grinding
capacity of 200tons/hr. Each ball mill is loaded with about 100tons of hyper-
steel spherical balls and rotates at 15RPM. Three streams of the plant
operate with four ball mills. The ground bauxite in caustic soda solution is
called as mill slurry is pumped to subsequent process called as pre-
desilication.
IMPORTANT TERMS
The slurry is then mixed with concentrated caustic soda solution and
pumped to cyclones for classification. The particles having bigger size than
63micron are recycled back to ball mill for further grinding. The fine
particle slurry proceeds to digestion process.
DIGESTION
Here the fine bauxite slurry in caustic soda solution is heated in tanks to
achieve 105OC. Sodium hydroxide reacts with alumina tri-hydrate to form
sodium meta-aluminate. The non reactive components such as iron oxide,
bohemite and silicon dioxide remain in suspended form in the slurry. Supply
steam for heating the slurry is at 9bar and 210 OC.
Al2O3, 3H2O+NaOH---------------------- NaAlO2+H2O
Digestion tanks are provided with agitators to prevent settling and increase
speed of reaction. The slurry remains for about 2hrs and 30minutes in
digestion tanks and then pumped to sand separating cyclones for removal of
coarse particles called as sand.
SAND SEPARATION
POST DESILICATION
Remaining amount of reactive silica, which could not react with soda in
Predesilication, reacts in digestion and forms sodium silicate. This sodium
silicate has to be converted to non-reactive sodalite in precipitation. For this
purpose, diluted slurry is heated in post desilication tanks up to 105 OC and
retained for about 8hrs.the slurry is slowly agitated in post desilication tanks
to just avoid settling and facilitate sodalite formation. Favorable condition is
high temperature and low concentration. Outlet of this process is pumped to
settler for solid waste separation.
SETTLER
These are big tanks having diameter of 40m and height 6m. Desilicated
slurry is fed at the centre and the mud settles down and clear liquor remains
at the top. Slow speed rake mechanism drives the settled mud from centre to
periphery. Synthetic flocculant is dosed to the settler feed to enhance rate of
settling. Settler overflow containing about 400mg/lit of solid and 165gm/lit
soda is collected in an overflow tank. The underflow of settler containing
500gm/lit of settled mud is washed in six stages with water to recover
maximum amount of soda. Part of that wash liquor is mixed with settler
overflow liquor to attain 148gm/lit of soda concentration i.e. favorable
condition for alumina precipitation. The liquor thus achieved is pumped to
security filter feed tanks for third and last stage of solid impurity removal.
SECURITY FILTRATION
Since 400mg/lit of solid impurity in the liquor will make the alumina impure
in precipitation up to unacceptable limit, further separation of solid is done
by means of filtration. For this purpose, settler overflow liquor is filtered in
security filter or Kelly filter to bring down the solid from 400mg/lit to below
30mg/lit. Kelly filters are pressure leaf filters being operated at 3ata
pressure. Quick lime solution is used as filter aid to help in filtration. The
liquor there after is called as aluminate liquor and is ready for of alumina
production by precipitation. The soda concentration here remains at 147gpl,
RP at 1.06.
PRECIPITATION
The seed hydrate is not only put in aluminate liquor for particle growth but
also for increasing the rate of precipitation as auto precipitation rate of
aluminate liquor is very low. Low concentration of soda in aluminate liquor,
low precipitation temperature, high surface area of seed hydrate, high
amount of seed hydrate are favoring factors for better precipitation.
Aluminate liquor mixed with seed is kept in precipitators for about 40hrs to
achieve substantial production. There are 16 precipitators of 4200m3
effective volume each in each stream. The precipitators are also cooled in
between to decrease the temperature to get more yields.
EVAPORATION
The spent liquor at 80OC is stored in spent liquor tanks. Part of the liquor is
pumped to ball mill to help in wet grinding and Predesilication. Major
portion of the liquor is concentrated in evaporators and used for digestion.
There are six evaporator batteries, each have six effects. Any one of the first
five effects can be bypassed for maintenance purpose. These are falling film,
backward feed evaporators. Steam is used for heating the spent liquor and
boil to get vapor, so that the liquor gets concentrated.
The steam condensate from these multiple effect evaporators is sent back to
steam plant. Generated vapor is condensed in different effect and the
condensate is used in different area as sodic condensate. To enhance
capacity of evaporation battery, last effect is operated under vacuum and
spraying cooling water to the generated vapor generates the vacuum. The
product of evaporation battery is called as green liquor as it is capable of
giving production; the temperature is 105OC and concentration is 225gpl.
CALCINATION
QUALITY OF ALUMINA
• PHYSICAL QUALITY
• -45 12%max
• +125 15%max
• BET Area 60-80M2/GM
• Loss on ignition 1%MAX
• content 10%MAX
• CHEMIICAL PROPERTY
• Al2O3 (Purity) 98.5%MIN
Impurity
• Na2O 0.5%MAX
• CaO 0.05%MAX
• SiO2 0.02%MAX
• Fe2O3 0.015%MAX
Use of alumina:
1. Mainly for manufacture of aluminium
2. In ceramic industries for manufacture of refractory
3. For manufacture of tooth powder, tooth paste
There are various units, which are included under the steam and power
plant at NALCO Damanjodi. All these units are interconnected and affect
each other’s performance. The units are as listed below
DM Plant
Fuel Oil Handling plant
Coal Handling Plant
Boiler
Turbo generator
Ash Handling Plant
All the units were studied in the above order every section has an
intricate use of programmable logic control system (PLC) making the
whole plant an automated unit. Nalco is further focusing on converting
this whole PLC system to a Distributed Control System (DCS).
DM WATER PLANT
The purpose of the plant is to free water fro\m all kind of impurities,
including suspended particles, cations, anions, undesired gases like CO 2
hence demineralised water is free from all kinds of
impurities. Its importance arises when water is needed in the
boiler for the production of steam. Water in the boiler must
be demineralised because, mineralized water in the boiler
results formation of scales. Hence hindering the production
of steam in the boiler. Scaling has the following
disadvantages.
Results in the formation of holes in the water tubes of
the boiler.
Results in leakage of water in the core of the boiler
Coal burning is left incomplete
This steam is further utilized in the processes involving
the production of alumina. Hence serving the core purpose
of the plant.
Fuel oil is procured in oil tankers into the plant premises. This fuel oil
is fundamentally of two types light diesel oil and heavy fuel oil. There are
two separate oil tanks for storing the oil procured from the oil tankers. There
are specialized unloading oil pumps which help in unloading the oil from the
oil tankers to the oil tanks. The capacity of the HFO tank is 100 m 3 and that
of LDO tank is 25m3.All the three tanks have an earth grid resistance of
0.176 ohm.
There are specialized suction pups for drawing oil from HFO and LDO
tanks there are three LDO suction pumps and three separate HFO pumps.
These pumps are used depending on the requirement in the boilers. If the
requirement is less one of the pumps is used as a standby. These pumps
pump oil from the tank and direct it towards the strainer. These strainers are
two in number and they are aimed at filtration of the oil in order to remove
the oil sediments. The filtered oil from the strainer is sent to the oil heater.
These are also two in number, one standby and one inline. This oil heater is
used to reduce the viscosity of oil so as to make the oil suitable for boiler
operation. This oil is heated by interacting it with steam at a pressure of 11
ata and temperature of 220 degree Celsius
This oil is channelized into the oil guns where it is used for lighting up
the boiler.
Coal is used as a primary fuel in the boiler. This coal is used in the
production of steam by heating water inside the boiler. Thus coal forms a
major requirement in SPP. This steam is used for carrying out the various
unit processes. The coal is bought from Talcher coal mines, by wagons. This
coal used in the boiler is known as B- grade coal, i.e. bituminous variety of
coal. The coal is now made to undergo a series of processes before being fed
to the boiler. The processed coal is sent to the coal handling plant. And then
it is used up by the coal feeding plant.
Rota side wagon tippler: - tips the wagons so that coal is collected in
the coal hopper.
Coal mill: - the function of the coal mill is to reduce the size by
grinding the crushed pieces of coal to 200 mesh size. This reduction of size
due to grinding increases the surface area of coal to enhance combustion of
coal.
Seal air fan: - In the coal mill there is gap in the rotating and static
part of the mill. This may lead to loss of coal by flyaway, due to intense
pressure prevailing in the coal mill. To avoid this seal air fan is provided at
the outlet which sucks in cold air from the atmosphere and pumps it into the
coal mill where the gap is created. Hence the pressure of the air pumped in
is always more than pressure inside the coal mill. It avoids leakage of coal to
the atmosphere.
This function is carried out by the ash handling plant. Out of the total
ash produced 20 %is known as bottom ash which is collected in the water
impounded furnace (bottom hopper). The rest is conveyed out by flue gas
and is collected mainly in the ESP. the fly ash is collected in three parts, the
major amount is collected in EP hoppers, small amount of fly ash is
accumulated in the economizer and air pre heater hoppers. The scrapper
conveyor located below the bottom ash hopper carries the ash falling on it
and delivers it to the clinker grinder where clinkers are flushed away by low
pressure ash water into the trenches below the grinder. The ash water from
the trenches is collected in an ash pit, from where it is pumped to the ash
pond using slurry pumps.
This is a set up for collection of ash particles from flue gas produced in
the boiler core. These precipitators have very high efficiency of 99.9%. The
rest 0.1% is lost to the atmosphere. There are two passes for a boiler “ Pass
A” and “Pass B”. Each pass in a boiler has seven feeders; the fourth unit has
28 feeders.
An ESP consists of a negatively charged discharge electrode, which is
Boiler
The boilers set up in Nalco Damanjodi at its steam and power generation
plant (spp) have the following specifications:
VU type, natural circulation
Capacity: uses 200tonnes/hours
Fuel injection type, tangential fixed corner type fuel firing,
Bidrum,
Steam pressure: 67 Kg/cm2
Steam temperature: 485 ºc
Inputs: -
There are three basic needs which a boiler requires:
water to generate steam
fuel to heat the water
air to support combustion
Outputs: -
initially the steam generated by the boiler was used to meet the
requirements of the plant i.e. The process of alumina refining but gradually
it was seen that steam produced could be further utilized to generate power
as a by product. Thus the outputs of the boiler now are
steam for the process of alumina refining
power as a by product
residual products (waste products)
Construction: -
Dimensions:-
Cuboidal in shape
Height – 150 ft
The inner walls of the boiler entirely comprises of vertical water tubes with
a bore diameter of 75 mm each. These vertical tubes are called as steam
generating tubes. The water tubes a re separated by thin vertical tubes of
metal called fins. To ensure safety of maintenance workers the boiler is
insulated from the outside. Further description is done taking into account
the various paths of the inputs
Water:
The water from the dm plant output is stored in the DM tank. From the
dm tank the water is taken to the make up water tank (MUWT). Water from
the MUWT is pumped to the deaerator chamber; wherein the dissolved
oxygen is removed from the dm water by using steam. This oxygen free
water is stored in the deaerator tank, which is below the deaerator chamber.
The water is now pumped to the steam drum through the boiler feed pump
arrangement.
Before being sent to the feed pump it is first set to the feed station (level
control) and then to the economizer (preheating) and then to the steam drum.
Now the water from the steam drum is fed to the mud drum by means of
bank tubes. Now from the mud drum water moves to the ring header via
down comers.
The steam generating tubes inside the boiler are connected to the ring
header. And as the water in the boiler heats up it passes in to the ring header,
resulting in natural circulation.
This saturated steam is now fed into the super heater placed inside at
the top of the boiler
Finally the super heated steam at 485 ºc is fed into the main streamline.
This is the main steam header. This header is now the input to the turbines
hence aiding in power generation.
Air path: -
Now any fuel in any form is bring injected in to the boiler chamber it
catches fire or undergoes combustion instantaneously.
Thus in order to control this combustion there are some very elaborate
arrangements
Boiler is always kept at a negative pressure, so that pressure does not
increase to an explosive value.
Producing a forced air draft does this.
Fuel path: -
The fuel used in the boiler is of two types. One is the fuel oil and the
other is the pulverized coal. Coal is used as a fuel as it is less costly
compared to fuel oil. But the fuel oil has its own significance. Since the coal
cannot be used for combustion as it will result in improper combustion. So
HFO is first used to attain a necessary temperature in the boiler of about 600
ºc and then coal dust of 200 mesh size is injected into the boiler after this
temperature is attained. Initially LDO was used to attain ignition
temperature in the boiler for firing HFO and then coal.
Steam drum: contains both steam and water pumped in there by the
boiler feed pump.
Bank tubes: connect the steam drum and the mud drum
Wind box: contains heated air from the air pre heater. It provides air in
the proper proportion for complete combustion in the boiler.
Scanner air fans: in order to keep the scanners cool and clean the
glass surface is blown by blasts of cold air continuously. Thus for cooling
and purging scanner air fans are used
Turbine
The working steam flows axially through the single casing extraction
back pressure. The emergency stop valves are arranged on the casing at the
inlet, their purpose being to shut off the total steam flow, the boiler to the
turbine in the shortest possible time. The live steam flows trough the
emergency stop valve housings, which are welded on to the side of the
turbine casing, to the hp control valve chest. The control valves regulate the
steam flow through the turbine according to the load demand.
The blading both in the high pressure and low pressure parts of the
turbine is of the impulse type with high reaction. These parts serve as
regulating stages.
After expansion through the hp part some of the steam is let off
through the two extraction steam mains. For isolating the turbine from the
mains an extraction stop valve is provided which operates in the same way
as the live steam emergency stop valves. It’s purpose is to isolate the turbine
from the extraction steam mains in the case of shutdown and thereby avoid
steam flowing back into the turbine
The pressure at the point of extraction is governed by the LP control
valves. The steam flow through the LP part is related to the extraction steam
quantity in such a way that the pressure at the extraction point is kept
constant within the design range. The hp and LP control valves are each
positioned by a hydraulically operated relay cylinder via linkage system.
The steam passes via the diffusers and the hp inner casing nozzle
bowls to the regulating stage. The inner casing is not horizontally split
thereby allowing optimum dimensions with approximately constant wall
thickness. Besides the nozzle ring and its locking ring for the mounting of
the diaphragms is built into the hp inner casing. These diaphragms are split
horizontally and are fixed to the locking ring by radial bolts. Thereby free
thermal expansion with exact centering is allowed. The axial steam forces on
the diaphragms are carried by the inner casing via the locking ring and its
bayonet lock. The centering of this locking ring in the inner casing is
achieved by axial keys arranged around the circumference
The use of the hp inner casing severely reduces the internal pressure
acting on the outer casing therefore the outer casing flanges and bolts can be
reasonably dimensioned
The lp inner casing is arranged downstream of the hp inner casing, the
lower steam conditions allowing it to be horizontally split.
The diffuser for the low-pressure valves which are necessary for
maintaining the extraction pressure and for controlling the lp steam flow are
screwed into and locked in the inner casing. The nozzles which are attached
to two half rings are inserted direct in the inner casing halves. The
diaphragms are located I the inner casing by radial centering bolts and
vertical bolts t horizontal joint thereby guaranteeing free thermal expansion.
In order to eliminate steam leakage between the rotor and inner casing
with closed lp control valves a labyrinth seal is provided which operates as a
shaft gland.
The exhaust and bearing pedestal is fixed to the sole plates since the
lower casing and the bearing pedestal do not allow for axial movements
between casings and bearing pedestals, thermal expansion of the casing
pushes the front bearing pedestal forward, sideways movement of the
bearing pedestal is prevented by axial guide keys. The bearing pedestals
cannot twist tip or lift.
The balance piston partially compensates the axial thrust as the axial
thrust also depends on the turbine load the remaining thrust is taken by the
thrust bearing at the same time the balance piston labyrinth seals the
pressure in the wheel chamber against the gland steam pressure.
Pressure measuring points on the various steam spaces are provide for
supervision, thermometers on the bearing oil return lines allow for regular
bearing checks.
TURBOGENERATOR
INTRODUCTION
In the recent years many basic industries could not meet their
production targets because of lack of availability of power in adequate
quantity. Non-availability of power has affected production as well as safety
of some of the core industries. Looking from this angle and based upon the
steam requirement of alumina extraction process, detailed study was
conducted for suitable selection of TURBO GENERATORS.
For creating a flux by the rotor circuit a voltage has be applied to this
rotating winding through slip rings and carbon brushes. Hence when the
turbine is running at almost constant speed the generated voltage output is
dependant on the field/rotor input supply.
The Active power output generated is dependant on the steam input supplied
to turbine, by varying steam input the MW output generated by the generator
can be varied.
SYSTEM DESCRIPTION:
There are three 18.5 MW extraction and back pressure turbines in
NALCO Alumina Refinery at Damanjodi. A tuning PRDS system along with
Dump Condenser and Vent system makes the generating facility capable of
island operation isolating the plant from power cuts.
Steam flow through the turbines is in axial direction. To shut off the total
steam supply from Boiler to Turbine in the shortest possible time Emergency
Stop Valve (ESV) is arranged at the turbine inlet. The live steam flows
through ESV to the valve chest of HP Control valves which regulate the
steam flow through the turbine according to the load demand.
They are bladed both in the high pressure and low pressure parts of the
turbine is of the impulse type with high reaction. The HP and LP parts serve
as regulating stages. For EG type of turbine, part of the steam is bled from
the turbine at the extraction branch behind the HP drum bladed and fed to
extraction steam. Extraction stop valve is provided in the same way as live
steam emergency stop valve to isolate the turbine from extraction mains,
thereby avoiding steam flowing back to the turbines causing over speeding
of the turbine due to reverse flow.
Speed governor generates the secondary oil pressure for control valve
actuators (servomotors) in such a way that the change in amount of steam
flow through HP and LP parts of the turbine is the same The SRV IV
governor controls the turbine speed and maintains it at a constant value in
accordance with the functional relationship represented by its characteristic
line. The pressure of the secondary oil discharged at the governor output side
forms the input signal that acts on the control piston of the servomotor.
The following mechanical protections are inbuilt into the governing system.
1. Over speed protection. – Set between 8 to 10% above the rated
speed.
2. Low lube oil pressure protection. Set at 0.7kg/cm2g.
3. High back pressure protection. – Set at 7.2 kg/cm2 g.
4. High extraction pressure protection. – Set at 12.2 kg/cm2 g.
5. Emergency hand trip device. To trip the set locally in emergency.
LUBRICATION SYSTEM
The lubrication system delivers clean, filtered Oil at the specified
pressure to the bearings of the generator, turbine, coupling and gearboxes. It
furnishes governor and control oil requirements also.
The main oil tank has a capacity of 11000 ltr. The tank is provided
with a level sight gauge glass, a low-level alarm switch. It has the facility of
a centrifuge equipped with a heater, filling, draining and venting.
During normal operation of the turbine total oil requirement is met by
Main Oil Pump(MOP) which is turbine driven. During start up Auxiliary Oil
Pump(AOP) meets the oil requirement which is powered from AC source .
In addition an Emergency Oil Pump(EOP) powered from DC source caters
to the bearing lubrication and subsequent cooling down of the set during
power failure.
Two oil coolers are provided, each serving as a standby to the other to
cool the total oil flow used for the set.
The oil after leaving the cooler goes to the filter. Paper
cartridges(disposable) are used in this(in filter unit, each serving as a
standby to the other. High differential pressure across the filter calls for a
change of cartridges.
THE CENTRIFUGE
The centrifuge is a machine, which applies centrifuge force to a liquid.
The rotor, called a bowl has an opening in the bottom to allow the fluid to
enter, and opening in the top of the bowl to allow the liquid or fluids to
discharge. The fluid entering the rotating bowl is caused to rotate with the
bowl. Centrifugal force is generated by the rapid rotation. The liquid, as it
passes from the bottom to the top of the bowl, is acted upon by the
centrifugal force generated the separation of liquids is thus effected and the
removal of solids also accomplished separating it into its various parts
according to their relative weight. The heavier parts (Such as solids and
sludges), are forced through the liquid and form a layer on the inside wall of
the bowl. The heavier liquid forms a cylindrical layer upon which floats a
cylindrical layer of the lighter liquid. The light liquid is assumed to be oil,
and the heavy liquid water.
Clarification:
Separation:
The term “separation” is used to describe the result of gravity or
centrifugal force acting on two liquids, such as oil and water. A centrifugal
separator is one that is adjusted to continuously separate and discharge these
liquids. Since this force is also acting on any solids present, clarification
takes place at the same time through the deposit of these solids present
clarification takes place at the same time through the deposit of these solids
against the wall of the bowl. Water is fed first when the machine (bowl)
reaches its full speed to the gravity through or to the centrifuge bowl. The
bowl will be filled up with water and the excess water will overflow through
the water drain passage. This is followed by oil entering the bowl. If,
however, oil is first fed, the trough or the bowl will fill up until water drain
port height is reached and the oil will then overflow, discharging through the
water drain. This means that the oil is delivered at the outlet normally
intended for water, because there is not water in the bowl to seal off this
outlet and thus cause the oil to overflow. In any oil and water separation,
water must first be fed to the bowl in order to create this seal. This operation
is known as “priming”.
EXCITATION SYSTEM:
The Pulse generator, intermediate pulse amplifiers are duplicated one each
for AUTO & MANUAL channel
The pulse final stage and its power supply, thruster and its cooling
circuitry, pulse transformers etc are in 3 different and independent sections
Follow up control:
It functions only when AVR is in AUTO mode
It is employed everywhere one must influence a controlled variable with
discontinuous final control elements. Here it is utilized to give signals to
raise /lower the MANUAL reference to follow the AUTO POT reference.
And thereby ensuring surge free operation in case of change over from
Auto To manual channel
It has an electrical interlocking so that both raise & lower signals are not
available at the outputs simultaneously.
Output raise /lower is available at test point 25 /24 of RU 05.
Manual limiter
It is used in both MANUAL and AUTO mode
Limits rotor current in (N-2) operation in both AUTO/MANUAL
Takes an input from load angle limiter to control the field current
__sed on the existing load angle to prevent out of step operation of
generator, in case of changeover from AUTO to MANUAL.
It is an open loop operation.
Limits the rotor current to a set value in (N-2) operation in AUTO.
Rotor angle limiter overrides the manual reference.
Priority of N-2 over rotor current limitation.
Field current regulator
It is used in MANUAL mode
To limit the rotor current / regulate the field current.
This is used to regulate current to set value especially when the
excitation system has a series compounding transformer.
Limiters
All the limiters namely - Stator current limiter, rotor current limiter,
integrator, Rotor angle limiter operates in parallel with the reference
value of the AVR at input.
Power supply
The power supply for the electronics is obtained from the excitation
transformer through a regulation supply transformer after rectification/
regulation / stabilisation in the power supply Modules
For Auto channel TWO power packs UN 2007 and UN2004 are
provided. UN 2001 and UN 2004 are functional upto minimum of 30
% 0f the rated supply voltage
Each Pulse output Stage has its own power pack UN 2001
Synchronous Voltage for pulse generation is obtained from a
Synchronous transformer/of ratio 140/380 V AC whose primary is
connected to the excitation transformer secondary a filter. A Voltage
relay supervises the synchronous voltage
The supply for cooling fans of the thyristor cubicle is obtained from
the excitation transformer through a fan supply transformer of ratio
140/380V AC
TECH DATA:
AOP:
Frame -KPD OR026 MOTOR -
KW-7.5
Total head -89.56 mm. RPM -2870
RPM -2970 Voltage -415 V
Rating -75 KW Current -28 Amp
EOP:
TG-1 & 2 (Motor) KW –7.5 TG-3KW -
7.5
RPM -3000 RPM -2800
Current -103 Amp. Current -103Amp
Voltage -110, Voltage -110V
Motor brg. -SKF-6312 Brg. -
SKF63062
CTP:
MOTOR: Induction motor Pump: Tyoe-OPK-6-32-
250
KW-7.5, Voltage – 415 V. Capacity-4.5 m3/hr.
RPM-2850, Current-14.0 Amp Year – 1989, RPM-2900
JOP:
DC AC: Induction Motor
KW-3.7,RPM-1440, Voltage-415 V, Current-
7.6 Amp.
Voltage-110 V, Current –41 Amp. KW – 3.7, RPM – 1440
Brg. Ce: skf 6306Z, Connection Delta
Gland Steam Condenser
Qty. of gland steam at inlet 1448 kg/hr(max),
Pr and temp of gland steam at inlet 0.98ata / 3100c
Quantity of cooling water 150 m3/hr.
CW temp. At inlet / outlet 35/420c
Surface area 40 m2
Size of tubes (Odx Thk…….) 15x1x2500mm
No of tubes 352
Metallurgy of GSC
Tubes Ad. Brass, SB III C
44300
Shell, Channel, covers & tube plates CS, SA 516 Gr 60
Flanges Carbon steel
Support plates CS, IS 2062
Water I/L, O/L & steam I/L pipes CS, SA 106 Gr B
Impingement plate SS, SA 240 TP 304
Oil Cooler
Qty. of oil 68.12 m3/hr.
Oil I/L and O/L temp 59.9/450c
Pr. Drop in oil side 1.3 kg/cm2
Qty. of cooling water 100 m3/hr.
CW I/L and O/L temp 36/40.10c
Cooling surface 100 m2
Tube size (Odx Thk.xl.gth.) 15x1x2610 mm
No. Of water passes 4
Metallurgy of tubes Adm. Brass, SB III C-
44300
SYSTEM DESCRIPTION:
With three TGs and dump condenser the requirement of cooling water
increased and hence Cooling Tower – III was established. It caters to the
requirement of huge amount of cooling water for dump condenser, generator
coolers, turbine lubrication oil coolers and gland steam condensers. There
are three cooling water pumps (CWP), three auxiliary cooling water pumps
(ACWP) and four induced draft cooling tower fans (CTF) in Cooling Tower
– III. Suction pipes of CWPs and ACWPs are connected to common water
sump. The sump level is made up with addition of filtered water. Discharges
of ACWPs are connected to a common to a common header and the water is
supplied to TG auxiliaries cooling system i.e., generator coolers, lubrication
oil coolers and gland steam condensers. Discharges of CWPs are connected
to a common header and the water is circulated through the dump condenser.
The CW outlet lines from TG auxiliaries and dump condenser are connected
to a common header and re-circulated back to Cooling Tower. The hot water
is sprayed in the hot basins in the form of fine spray through nozzles. Water
gets cooled by coming in contact with the air circulated due to induced draft
created by cooling tower fans. The cold water is collected in the cold-water
basin from where it flows to the cooling water sump through strainers. To
control internal corrosion and scale formation on the inner surface of the
circulating pipes, corrosion inhibitors like Zinc Sulphate and Sodium Hexa
Meta Phosphate are dosed, in the cooling water sump. Chlorine is also
added to control the growth of algae, fungi and other bacteria. Cycle of
concentration (ratio between the TDS of circulating water and the fresh
make up water) is maintained normally within 3. When it increases the
water from the cold-water basin is drained and the loss in made up with
fresh floodwater to reduce the cycle of concentration.
Conclusion
SAFETY
Industrialization has brought within its wake several problems. One such
is industrial accident. With rapid advances in industrial processes, newer
types of dangers to life, limb and health are being increasingly
introduced. Mechanical, Electrical, Chemical and Radiation hazards be
set us on all sides. Yearly, several lakhs of employees are injured in
factories due to accidents. Annexure 1 gives the details of accidents in
India during 1978 to 1981.
MINING MODEL
For drawing up annual production programme, indicating the qualities
and quantities and for studying in advance the various overburden and
bauxite faces, a numerical mining model is made by transformation of
information obtained from the deposit model in the Geostatistical studies. It
consists in a breakdown of the deposit to a 100mX100m krigged grid. Each
of such panel is further divided to a block of over burden a block of bauxite
to be mined in first phase and thick block of bauxite to be mined in second
phase. After allowing for unminable areas locked up in mining infrastructure
and peripheral barriers and Appling the loss and dilution factors for each
such panel the following parameters are determined.
Tonnage of overburden to be removed.
Tonnage of minable ore in each phase with Al2O3 and SiO2 content
showing of minable bauxite between the two phases is done keeping in
view mass mining in firs phase (with nominal dilution) and selective
mining in the second phase.
MINING TECHNIQUE:
The morphology of the bauxite deposit, the irregular roof and floor makes it
impossible to adopt conventional ‘Benching Method’ of open pit mining at
Panchapatmali, Instead , a modified ‘Trench Method’, consisting of
development of roughly parallel trenches with staggered faces, form initial
main track has been adopted. This technique facility mining of different
zones of a deposit, featuring different thickness, independent of one another,
thereby simplifying mechanized mining within individual trenches with
minimum loss and dilution.
Normally the width of the trenches are kept more than 40 mts for efficient
use of heavy machineries and the level differences between adjacent
trenches, is kept less than 4mts. The faces of the trenches are systematically
advanced to maintain a ‘Saw Tooth Configuration’ of work sites, which
ensure adequate flexibility in mining operations and safety to the equipment
deployed.
ALUMINA
World Capacity - 38 MT / Year
India’s Capacity - 1.47 MT / Year
Rank of India - 7th
ALUMINIUM
World Capacity - 18 MT / Year
India’s Capacity - 0.58 MT / Year
Rank of India - 7th
APPLICATIONS OF ALUMINIUM.
Transport – Land, Sea, air, Space
Building
Defence
Power transmission
Food processing
Pharmaceuticals-tables, Ointments
Milk Products-yoghurt, curd, cheese, butter, sterilized milk.
Sweets – Chocolates bars, boxes of chocolates, ice creams, chewing
gum.
Household aluminium foil.
Coffee, Tea- vacuum packaging.
Dried food : Soups, Cereals, Potato puree, baby food.
Instant foods.
Drinks – Refreshments, Beer, Fruit juice.
Tobacco
Pet Food.
Cosmetics
Glues, Paints, Inkcatridges.
AREAS OF USAGE OF ALUMINIUM PACKAGING
Packaging/Food Processing is an important application sector of
aluminium directly involving the human society.
Withstands both heat and cold.
Easy to sterilize for food and medical applications.
Excellent barrier against liquids, vapours and light.
Light weight, hygienic and non-contamination-longer shelf life of end
products.
Lacquer able and printable.
In soft temper has full dead fold properties and ease of shaping.
Nontoxic, Odorless, tasteless, colourless and hygienic.
Good heat reflectivity (light & UV Rays) and conductivity.
Non-permeable
Laminatable.
Lightweight
Corrosion Resistant.
Recyclable & Biodegradable.
CONCLUSION
Even through aluminium has a high environmental cost in the primary
stage, it is very well compensated for by its environmental and
resource friendly characteristics, during its use and reuse phases.
Aluminium fits perfectly in to the future scenario where the parameters
will the technology, economy and ecology.
Aluminium has the advantage of being available abundantly in our
country as opposed to tin, which is imported.
Aluminium is tottaly recyclable with no loss in quality, hence highly
eco-friendly and safe as opposed to plastic, which is not biodegradable.
Aluminium is safe, the most environment friendly and a highly useful
material.
All accusation/criticisms against aluminium with respect to health are
hearsay, lacking any scientific and clinical evidence.
ENVIRONMENT MANAGENT
Since inception NALCO has taken adequate steps for pollution control
and environment management by selecting eco-technology process and
equipment on the advise of M/S Aluminum Pechiney (AP) the
consultants, who have good experience in marinating stringent pollution
control standards of Europe.
Further, the company has adopted a detailed environment
management plan (EMP), which was prepared after extensive studies on
environment impact assessment .This EMP has the approval of orissa
state pollution control Board (OSPCB) and ministry of environment and
forests (MOEF) government of India.
Measures taken:
Measures taken by the company in all its units for environment
management are as follows.
Mines
Periphery barrier of 15m width having green cover around mines.
Garland drains & drainage control within mines.
Dust suppression at source and sprinkling of water
Total overburden excavated with topsoil is used for reclamation and
rehabilitation of mines our areas with vegetation cover.
Alumina Refinery:
Highly efficient ESP s at calciners and steam generation plant.
Multi- stage washing of red mud & lining of red mud pond to
impound highly alkaline waste.
Use of dust collectors in alumina transport and handing areas & stack
emission control at steain generation plant.
Recycling of waste water.
Smelter
Hooding of pots and absorption of gas by dry scrubbing with alumina
in fume treatment plant.
Delluoridation to reduce fluonne level of contaminated surface water
& recycling it to achieve zero discharge.
Specially designed preservation system for spent pot lines.
Captive power plant
Electrostatic precipitators with advanced intelligent controllers and
effective stack emission control.
Efficient burner management to reduce emission of carbon monoxide.
Ash pond with zero discharge and recycling of wastewater.
ISO 14000
In its quest for excellence in environmental care the company crossed
a milestone when M&R complex was certified under ISO 14001. Alumina
refinery of the company is the first chemical plant in the country to be
certified under ISO 14001.
Today all the four units of the company have achieved ISO 14001
certification as detailed below.
Unit Date of certification certifying agency
Mines June 24, 1996 M/s Aspects moody
certification, Uk
Relinery February 10, 1997 -do-
Cpp December 19, 1997 M/s RWIUV, Germany
Smelter May 25, 1998 -do-
From February 2000 onwards re-certification of mines & refinery by M/s
RWTUV, Germany.
The ISO 14000 certification has not only helped to improve the
image as an eco-friendly company but has also given significant financial
benefits. These benefits have come mostly due to better house keeping
reduction in waste generation and systematic collection for disposal of
wastes and improvement in performance particularly with respect to
consumption norms.
Environment management must be an integral part of every level of
business enterprise successful management will have to expand its sphere of
influence to embrace a considerably wider concept have environment. The
growing compulsions on account of the environment awareness have forced
the industries to a provocative retrospection of their processes to ensure
compliance of specific emission standards and assure the public that their
product/process are more eco-friendly.
The Environment management system (EMS) is an emerging
environmental imperative. It is a comprehensive management tool to bring
in substantial improvements in any industry in overall environment
management. The EMS certification enables companies to acquire the label
of environmentally sound enterprise and also accrue the benefits of benefits
of improved economic performance.
Considering the importance and requirement mines & refinery
units has been certified with ISO 14000 since 1996 & 1997 respectively &
recently we have switched over to RWTUV as our certifying agency since
11.07.2000 for compatibility with ISO- 9000 system also.
COMMITMENT
We dedicate ourselves to total environmental management system for
prevention of pollution and continual improvement for achieving our
objectives.
The policy and the information on environment protection efforts shall be
shared with public and all interested parties through periodical publications,
booklets, pamphlets posters etc.
CLAUSES OF BS 7750, 1994
1. ENVIRONMENTAL MANAGEMENT SYSTEM
2. ENVIRONMENTAL POLICY
3. ORGANISATION & PERSONNEL
4. ENVIRONMENTAL EFFECTS
5. ENVIRONMENTAL OBJECTIVES & TARGETS
6. ENVIRONMENTAL MANAGEMT PROGRAMME
7. ENVIRONMENTAL MANAGEMINT MANUAL &
DOCUMENTATION
8. OPERATIO CONTROL
9. ENVIRONMENTAL MANAGEMENT RECORD
10. ENVIRONMENTAL MANAGEMENT AUDITS
11. ENVIRONMENTAL MANAGEMENT REVIEWA
ENVIRONMENTAL POLICY
While committing to the corporate environmental policy of NALCO
Alumina refinery, Damanjodi, resolves to protect and maintain a green
and clean environment while contributing to sustainable socio-economic
development of the region through its activities.
Clause 1: Scope
The scope of the standard has been expanded to include new application in
the 2004 version of the standard. They include options to demonstrate
conformity by :
Making a self-determination or self-declaration
Seeking confirmation from parties who have an interest in the
organization, for instance, customers
Seeking certification or registration of the EMS by an external
organization
Implication
An organization is now required to define the scope of its EMS. This
scope directly links the management system with the organization’s
activities products and services. The word and determine how it fulfils these
requirements related to requirements in ISO 14001 have been added to the
clause 4.1. Two things need to be done in this regard. Firstly, define the
scope of the organization’s EMS including what activities, operations,
services and products are included with it. The scope needs to be
documented one possibility could be in the environmental policy. Secondly,
there is a need to evaluate and document how an organization’s EMS fulfils
the requirements of ISO 14001. This could be done as part of the internal
audit or as part of management review, as long as it is traceable.
Clause 3: Terms and Definitions
ISO 14001:2001 includes some definitions not included in the 1996 version.
Some of the definitions in ISO 14001:1996 have also been revise to ensure
they are more consistent with terminology in ISO 9001:2000.
The following are the new terms and definitions introduced in ISO
14001:2004:
3.1 Auditor - person with the competence to conduct an audit
3.3 Corrective Action- Action to eliminate the cause of a detected
nonconformity
3.4 Document- Information and its supporting medium
3.14 Internal Audit-Systematic independent and documented process for
obtaining audit evidence and evaluating it objectively to determine the
extent to which the environmental management system audit criteria set
by the organization are fulfilled.
3.15 Nonconformity- Non-Fulfillment of a requirement
3.17 Preventive Action-Action to eliminate the cause of a potential
nonconformity
3.19 Procedure - Specified way to carry out an activity or a process
3.20 Record - Document stating results achieved or providing evidence
of activities performed
The following are terms and definitions that have been modified in the
new version of ISO 14001:2004:
3.2 Continual improvement - Recurring process of enhancing the
environmental management system in order to achieve improvements
in overall environmental performance consistent (“consistent” in place
of “in line”) with the organization’s environmental policy.
3.7 Environmental impact- Any change to the environment whether
adverse or beneficial wholly or partially resulting from an organization’s
environmental aspects (“environmental aspects”in place of an
organization’s activities products or services”)
3.8 Environmental management system (EMS) - Part of an
organization’s management system used to develop and implement its
environmental policy and manage its environmental aspects. (In place of
“The part of an organization’s management system that includes
organizational structure planning activities responsibilities practices
procedures processes and resources for developing implementing
achieving reviewing and maintaining the environmental policy”)
3.9 Environmental objective - overall environmental goal consistent
with the environmental policy that an organization sets itself to achieve.
In place of “overall environmental goal arising from the environmental
policy consistent with the environmental policy that an organization sets
itself to achieve and which is quantified where practicable”.
3.10 Environmental performance - Measurable results of an
organization’s management of its environmental aspects. In place of
“Measurable results of the environmental management system related to
an organization’s control of its environmental aspects based on its
environmental policy objectives and targets”
3.11 Environmental policy - Overall intentions and direction of an
organization related to its environmental performance as formally
expressed by top management. In place of “statement by the organization
of its intentions and principles in relation to its overall environmental
performance which provides a framework for action and for the setting of
its environmental objectives and targets”
3.12 Environmental Target - Detailed performance requirement
applicable to the organization or parts there of that arises from the
environmental objectives and that needs to be set and met in order to
achieve those objectives (in place of detailed performance requirement
quantified where practicable , applicable to the organization or parts there
of that arises from the environmental objectives and that needs to be set
and met in order to achieve those objectives)
3.18 Prevention of pollution - Use of processes practices techniques
material products services or energy to avoid reduce or control (separately
or in combination) the creation emission or discharge of any type of
pollutant or use of processes parcties material products that avoid reduce
or control pollution which may include recycling treatment process
changes control mechanisms ,efficient use of resources and material
substation.
Implication
There are changes to several of the definitions which impact on an
organization’s system the implication of the key changes are highlight
below.
Auditor - This definition is new and is taken from ISO 9001:2000 and links
to demonstrate that its internal auditors are competent and auditor
competence must be defined in the organization’s EMS
Internal audit - Internal audit has replaced the term environmental
management system audit partly to avoid confusion by users of the standard
with external (certification) audits. The wording of the definition has been
amended to emphasize that internal audits must be independent. The focus
of the internal audit has changed from one of determining conformance of
the EMS to determination of conformance with the EMS audit criteria.
Continual improvement - The definition of continual improvement has
been amended with an additional emphasis that the continual improvement
process is recurring and is not a one-off event. The definition also is more
definitive by linking it to environmental performance rather than
improvement of the management system. Organizations will need to ensure
that they have clearly defined audit criteria.
Environmental performance - The definition environmental performance
has changed in focus from the management system to the organization’s
management of its environmental aspects. Organizations will need to ensure
that the evidence they use to demonstrate environmental performance
improvement is in accordance with the revised definition.
Prevention of pollution - The definition of prevention of pollution has been
clarified to reflect methods and options for the prevention of pollution. An
organization will need to examine how it defines prevention of pollution
(and its scope) to ensure that it covers new concepts of creation emission or
discharge of any type of pollutant or waste.
Environmental policy - Several changes now require an organization to
review its environmental policy. The organization needs to ensure that its
policy.
Is developed by top management
Covers the scope of your EMS and does not imply a wider scope than
that
Covers all activity products and services within the scope of than EMS
Notes change to terminology related to legislative and regulatory
requirements
Reflects other environmental requirements the organization may have
subscribed to
Is distributed to everyone working for or on behalf of the organization
such as sub-contractors, contractors, temporary staff, and remote
workers.
Implication:
If the organization decides to communicate about its environmental
aspects it needs to establish methods of communication in its EMS.
The decision regarding this matter must be documented by the
organization. Most organizations do communicate about their
environmental aspects: sometimes actively to all the public, e.g.
through an environmental report or by the use of an environmental
mark/logo on their product; sometimes selectively requirements, e.g.
monitoring returns to environmental regulators. In all these cases the
organization will need to establish its methods for communicating. It
is probable that only very few organizations do not communicate in
some way and hence do not need a method of communication.
4.4.4 Documentation
Revision:
This clause has not changed in intent but has been updated to align it more
with ISO 9001:2000.
The listed EMS documentation now includes the environmental policy,
objectives and targets, a description of the scope of the EMS, a description
of the main elements of the EMS and their interaction and reference to
related documents, documents and records required by the standard,
documents and planning, operation and control of processes that relate to the
significant environmental aspects.
Implication:
The organization will be required to demonstrate that the above documents
are in place to ensure the effective planning, operation and control of
processes, which relate to significant environmental aspects. The extended
requirements are in accordance with the requirement of ISO 9000:2000.
Organization must record the results (and maintain the records) of the
periodic evaluation of compliance and these will need to be considered at
the management review.
Implication:
Organizations will be required to retain records of the periodic
evaluation of legal compliance undertaken. Note should be made that
this clause requires organizations to undertaken an evaluation of
compliance against all legal and other requirements and that this will
be a pre-requisite of accredited certification. This means that
compliance against each and every piece of legislation/regulation
relating to an organization’s environmental aspects will need to be
evaluated before it can be considered to be in conformity with ISO
14001:2004. It will not be acceptable for organizations to claim that
the periodic evaluation will be covered by their internal EMS audit
programme at some future date.
Implication:
The organization will need to demonstrate that audits have been
planned and an audit programme is in place- this may be done through
the organization’s audit procedure.
Organizations must also retain records from audits and provision for
this must be included in the procedure.
Purpose:
TPM POLICY:
Autonomous Maintenance
Develop equipment competent operators to maintain basic
conditions of equipment & shop floor and eliminate forced deterioration.
Planned Maintenance
Improve Reliability & Maintainability of equipments.
Focused Improvement
Improve overall plant effectiveness by systematic elimination of
losses through Kaizens.
Quality Maintenance
Develop perfect equipments to ensure perfect quality of outputs.
Office TPM
Improve efficiency of office activities to provide excellent support
for manufacturing.
Development Management
Redesign and/or select equipments for “high equipment
effectiveness”.
16 MAJOR LOSSES
TPM aims for “Zero Loss”. Overall Plant effectiveness can be improved by
eliminating 16 major losses described below: