A

SEMINAR PRESENTATION
ON
SUMMER TRAINING
FROM

HINDUSTAN ZINC
LIMITED
MADE BY:
KALYAN GORAI
4TH YR.,MECHANICAL
HINDUSTAN ZINC LIMITED

CHANDERIYA LEAD ZINC SMELTER

(CAPTIVE POWER PLANT)
 INTRODUCTION
• A power plant is an industrial facility for the generation of
electric power. The power produced in Hindustan Zinc
Limited is for its own production purposes, and is known as
a Captive Power Plant (CPP).
•
• While supplying uninterrupted and reliable power to
Chanderiya Lead Zinc Smelter, the CPP has been
additionally wheeling power to its Agucha, Debari and
Dariba units of Hindustan Zinc Limited.
•
• Recently sale of power has also been initiated with both RSEB
and power exchange.
• Captive Power Plant in Chanderiya consists of 3 units (2X77
MW + 1X80 MW)=Total of 234 MW.

 NEED OF CPP
• Disturbances in taking power from grid.
•
• Grid power distribution is unreliable both in quality and
quantity.
•
• Taking power from grid is much more expensive as compared
in generating its own power i.e. SELF GENERATION –
CPP.
• Cost of grid power Rs./kWh 4.50 to 5.50
• Cost of Captive Generation Rs./kWh 2.00 to 2.50

 TECHNICAL SPECIFICATIONS
 BOILER CLASSIFICATION & CPP SPECIFICATIOS :
 MAKE & YEAR:
 Acc to application
 Acc to operating pressure
 Acc to fuel
 Acc to draft
 Acc to circulation
 Acc to pass
 Acc to firing
 Acc to pressure
 Acc to position
 Acc to support


: BHEL,2004
: Utility boiler
: Sub-Critical (Re-circulation type)
: Solid fuel (pulverised fuel firing)
: Balanced draft
: Natural circulation
: Two pass (outdoor type)
: Tangential firing
: High pressure
: Vertical
: Top supported with buck stay
 Turbine Specifications
• Type of Turbine : High press, high Temp Impulse-Reaction
• Rotation Speed : 3000rpm
• Rated Power : 77MW
• Main steam inlet pressure : 90 kg/cm²
• Rated steam flow inlet : 286.4 T/hr
• Stage of heaters : 2LP, 1 De-aerator & 2HP
• Heat Rate : 2640 kcal/ kwhr
 Thermal Power Station

 Thermal power stations produce electricity by burning fuel in a boiler to heat water to
produce steam. This steam at high pressure rotates the blades of a turbine which spins a
generator to produce electricity. The steam is further cooled in a condenser to form water
and sent again to boiler.
 COAL TO ELECTRICITY
C
COAL YARD H
CRUSHER I
M
N
E
Y
ID
FAN

BUNKER FD FAN

ESP
AIR PRE
-HEATER

POWER FEEDER
HOT PA FAN
ASH PUMP

PULVERISER
ASH
BOILER SILO

BOTTOM ASH
HOPPER
HP HEATER DISPOSAL -
TURBO --- - ACC
GENERATOR
DEAERATOR
ASH
BFP DYKE
LP HEATER

CONDENSER
CT

CEP
FILTER RESERVOIR
DM TANK DM PLANT
CW PUMP
 MAJOR COMPONENTS
1) BOILER AND AUXILIARIES.
2) TURBINE,GENERATOR AND AUXILIARIES.

3) ESP (ELECTROSTATIC PRECIPITATOR)

4) COOLING TOWER

5) DE-MINERALISING PLANT

1) Boiler Terminology
lFurnace
BOILER OVERVIEW
lWater wall tubes
lPressure Parts
lDrum
lSuper heaters
lReheaters
lEconomizers
lAir pre heaters
lSoot Blowers
lCoal Bunkers and feeders
lPulverizes
lCoal Piping
lBurners
lIgniters & warm-up Burners
lDuct work
lInsulation and Legging
 Furnace & Water Wall Tubes


• Furnace is the primary part of boiler where the

chemical energy of fuel is converted to
thermal energy.
• Furnace is incorporated with water wall tubes
where water is evaporated to steam.
•
• TYPES OF WATER WALL TUBES :
1. Tangent tube wall : Tubes are closely attached

 from the panels.

2. Membrane wall : Tubes are welded together
 by means of metal strips.
 SUPERHEATER
• Superheaters are provided in the boiler to raise the steam
temperature above the saturation temperature by absorbing
heat from flue gas.
ADVANTAGE:

1. By increasing the temperature of steam useful energy can be

recovered thereby increasing efficiency of cycle.

2. It eliminates condensation of steam in pipelines, thus avoiding

erosion of blades.
TYPES OF SUPERHEATERS :

• Radiant Superheaters :The superheaters placed above

 the furnace which can view the
flame.
• Convective Superheaters : The other surfaces are called
 convective type.



 REHEATERS & DE-SUPERHEATERS
• REHEATER is used to raise the temperature of
steam from which part of the energy has been
extracted in high pressure turbine.
• By reheating efficiency can be increased which
increases with number of stages.
• Single reheating is usually applied for capacity
above 100MW & 2 reheat above 500MW.
 DESUPERHEATER :
• This is located between two superheater header and
the steam flows through it. Water of high
quality is introduced into the superheated steam
through a spray nozzle at the throat of a venturi
section which mixes and cools the superheated
steam. By regulating the water spray steam
temperature can be easily controlled.
• The spray water will normally obtained from feed
water line after the HP heaters and before feed
regulation station.
•

 ECONOMISERS
• An Economiser absorbs heat from the flue gases
and add this as sensible heat to the feed
water before water enters the evaporative
circuit of boiler.
• Feed water is supplied to economiser inlet
header via feed stop and check valves.
• Flow of feed water is upward through the
economiserthat is counter flow to flue gases
& from outlet header feed water is led to
steam drum.
• By recovering heat from flue gases and
supplying it to feed water it increases
efficiency in steam generation or in other
words saves fuel.
AIR PRE HEATER ( APH )
• APH is a heat exchanger in which air temperature is
raised by transferring heat from other fluid such
as flue gases.
• Stability of combustion is improved by use of hot
air.
• Less unburnt flue particles in flue gas.
• In case of pulverised coal combustion ,hot air can be
used for drying the coal as well as for
transporting the pulverised coal to burners.
 TYPES :
 1. Recuperative Type : Heating medium is on one
side & air is on the other
 side of tube /plate & heat transfer is by conduction
through the material
 which separates the media.
 2. Regenerative Type : Heating medium flows
through a closely packed
 rotating matrix to raise its temperature and then air
is passed through the
 matrix to take up the heat.
REGENERATIVE TYPE ( APH )
 FANS
•
• PA (Primary air fan) : These are the high
pressure fans which supply the air
needed to dry & transport coal either
directly from the coal mills to the
furnace or to the intermediate bunker.
 These fans are usually of the radial
aerofoil type.
• FD (Forced draft fan) : These fans supply
the air necessary for fuel combustion
and must be seized to handle the
stoichiometric air plus the excess air
excess air needed for proper burning of
the fuel.
 These fans are usually of the radial
aerofoil or variable pitch axial type.
• ID (Induced draft fan) : These fans
evacuate combustion products from the
boiler furnace in atmosphere through
stack by creating sufficient negative
pressure .
Generator Specifications
• Rated Power : 77 MW
• Rated Voltage : 11.5 kV
• Rated Current : 4800 A
• Rated Speed : 3000 rpm
• Power Factor : 0.8 lag
• Rated Frequency : 50 Hz
• Efficiency : 98.5%
2 ) TURBINE
rinciple Of Turbine
• Turbine is a Prime Mover Which Converts “Thermal
Energy Of Fuel Into Mechanical Energy”.
• Steam is allow to expand through narrow orifice, it
assumes kinetic energy at the expenses of enthalpy,
this kinetic energy is converted into mechanical
energy through the impluse or rection of steam
against the blade.
• Steam moves continuously through blades as a result
Centrifugal pressure exerted on the blade.
• TOTAL MOTIVE FORCE =
 CENTRIFUGAL FORCE + CHANGE OF
MOMENTUM (ROTATIONAL ENERGY)
•
urbine are Multistage
 Turbine Auxiliaries
 NAME  FUNCTION
• CONDENSE Ø Condense the steam &
R maintain the vacuum at
• the exhaust of LP Turbine.
• Ø
• Ø Main the vacuum by
• MAIN AIR extracting the non
EJECTOR condensable gases from
the condensate.
•
Ø
•
Ø To circulate cooling water
• CW PUMPS
through condenser tubes
for cooling the system.



 Turbine Auxiliaries
NAME
  FUNCTION
• CEP Ø Extract condensate from
• condenser hot well &
• passes it to deaerator.
• Ø
• LPH Ø To raise the temperature of
condensate by
•
transferring heat taken
• from turbine extraction.
• Ø
• DEAERATOR Ø To remove dissolved gases

from feed water by
 increasing there
temperature with pegging
steam taken from APRDS.
 Turbine Auxiliaries
NAME

 FUNCTION
• BFP Ø To pump the feed water
• from deaerator to Boiler
• (Economiser) at a very
high pressure.
•
Ø
• HPH
Ø Before going to boiler it is
• again heated by turbine
• extractions.
• Ø
• OIL PUMPS Ø
1.MAIN OIL Ø
PUMP(MO Ø To supply lube oil & control
P) oil during “Normal
 operation of Turbine”.
1.
 Turbine Auxiliaries 

 NAME  FUNCTION
 Ø
 2. AUXILIARY OIL Ø To supply lube & control oil
PUMP (AOP) during “ Start up & Shut

down of Turbine ”.
 3. EMERGENCY 
OIL PUMP
(EOP)_ Ø To supply lube oil to
 bearings during “ AC

4. JACKING OIL failure ”.
PUMP (JOP) Ø

Ø For lifting turbine shaft

during startup & shut
1. down.
 
TURBO GENERATOR
 DEFINITION
A Generator is an electromechanical device that converts
mechanical energy to alternating current electrical energy by
using a rotating magnetic field. Any AC generator can be
called as an Alternator.

• ,
POWER OUTPUT OF TURBO GENERATOR :
P  D2 . L . B . A . n

P : Power in MVA
D : Bore Diameter of Core in meters
L : Length of Active Rotor Body in meters
B : Air Gap Flux Density in Tesla
A : Stator Ampere-Turn Loading in Amp./meter
n : Speed in rpm
MAIN PARTS OF TURBO GENERATOR
Stator Core Cooler

Insert
Cover

Oil
Catcher
Rotor

Bearing

Shaft Seal

Stator
Terminal Bushing
Stator End Winding Assembly
Rotor Body
Rotor Fan Blades
 Excitation System
•
•Magnetizes the rotor poles and creates the required magnetic
intensity for stator conductors thereby developing the stator voltage .
•
•Regulates terminal voltage of the machine.
•
•Meet excitation power requirements under all normal operating
conditions.
•
•Enables maximum utilization of machine capability.
•
•Guard the machine against inadvertent tripping during transients.
•
•Improve dynamic & transient stability thereby increasing
availability.
3) ESP
 ESP

An electrostatic precipitator is a Device which removes dust or
other finely divided particles from flue gases by charging the
particles inductively with an electric field, then attracting them to
highly charged collected plates.

FUNDAMENTAL PARTS OF ESP:

Casing
Hopper
Gas Distributor Screen
Collecting System
Emitting System
Rapping Mechanism of collecting system
Rapping Mechanism of Emitting System
Insulator Housing
Application of ESP
• Removal of dirt from flue gases in steam
plants.
• Cleaning of air to remove fungi and
bacteria in establishments producing
antibiotics and other drugs.
• Cleaning of air in ventilation and air
conditioning systems.
• Removal of oil mists in machine shops and
acid mists in chemical process plants.
• Cleaning of blast furnace gases.
• Recovery of valuable materials such as
oxides of copper, lead, and tin.
• separation of rutile from zirconium sand.
4 ) COOLING TOWER
Definition
• Cooling tower is an application where the
plant heat exchangers are cooled with
water.
• The pump keeps the water re-circulation
through the heat exchangers where it
picks up heat and distributes on to the
cooling tower. The heat is released from
the water through evaporation.
• The cold water enters the heat exchangers
for cooling. The resulting hot water from
heat exchangers is sent to cooling tower.
• The cold water exits the cooling tower and
is sent back to the exchangers for cooling.
• Make up water source is used to replenish
around 2 % of water lost due to
Classification Of Cooling Tower

ATMOSPHERIC AIR AIR COOLED

MECHANICAL
NATURAL DRAFT COOLED HEAT
DRAFT CONDENSER EXCHANGER
 Types of cooling tower
 Natural draft cooling towers :
• Distinct shape much like a tall cylinder,it operates on a
chimney principle that allows air movement on density
differential.
• Such towers have the advantage of not requiring any
fans, motors,gear boxes etc.
•
 
Due to the tremendous size, these type of towers are
used only for very high flow rates.
 Mechanical Draft cooling towers.
• These are more widely used. These towers utilize large
fans to force air through circulating water.
• The water falls downward over fill surfaces which help
increase the contact time between the water and the
air.This helps maximize heat transfer between the two.

6 ) DE - MINERALISING PLANT
De-Mineralization (DM) is the process of Removing
mineral salts from water by using the Ion Exchange
process which produces water with high quality & purity
that used in “Boiler as a Feed Water”.

De- Mineralization System consisting of:-



• PSF (PRESSURIZED SAND FILTER)

• ACF (ACTIVATED CARBON FILTER)
• SAC (STRONG ACID CATION EXCHANGER)
• DEGASSER
• WBA (WEAK BASE ANION EXCHANGER .
• SBA (STRONG BASE ANION EXCHANGER).
• MB (MIX BED).
• UF FILTER
 a
Goshunda Dam Chlorine Dosing For Killing
w Bacteria & Algae

w
Clarifier CWST

PCF
a
t
e Remove
r Dead
Alum Poly Dosing For Suspended
p
Dosing For For Storage Particles
o
coagulation Flocculation
n
d Remove Odour &

ACF
Organic Matters
Remove
Anions e.g.
Cl-,SO4-. Remove REMOVAL OF CO2Remove
Cations
Carbonates & e.g.
Bi-carbonates Ca+,Mg+,Na+.
DEG
A

SAC
S .
SBA

WBA

S
E
R
From SBA

DMST
MB

UF

CST
Membrane Filter to
Remove Remove Colloidal Silica
Remaining Silica:
PH: 6.8-7.0
Cond.:<1.00ųS/c
m Hot well make up
Silica:0.02ppb pumps

HOTWEL
TO CST L
7 ) COAL HANDLING PLAN
COAL Transportation by RAIL
Overview Of CHP
Through wagon
Tippler
Apron
feeder

Through belt conveyor

Vibratin non vibrating
g type type

PULVERISE TO BURNERS Reduced size

R from 600mm to
100mm

Reduced size Separate

COAL BUNKER magnetic
from 100mm to Primary crusher
particles
Through Tippler

20mm
Allow only 20mm i.e. iron
sized coal

SECONDARY CRUSHER HOUSE MAGNETIC

COAL SEPRATOR
DRIER
Wagon Tippler Bottom Discharge
Wagon
 Coal System
• Through Wagon Tippler the Raw coal is
fed to primary crusher house via belt
conveyor where the size of coal is
reduced from 600mm to 100mm.
Magnetic separator, separates the iron
particles & then to secondary crusher
house for further reduction of coal
(20mm sized).
• Vibrating screen allows only 20mm sized
coal to drier & through tippler or trolley
,it passes over to coal bunker & then
pulverizers for further crushing through
volumetric feeder .
• The Pulverized Coal is then mixed with
primary air which carries the coal air
mixture each four corners of the furnace
burners.
) ASH HANDLING PLANT
 ASH HANDLING PLANT

ESP

FLY ASH
SILO

Fly ash Plate valve

COMPRESSOR

Unloading
BULKE
R
Compressed air
 ASH HANDLING PLANT

Fly ash is captured and removed from the flue

gas by electrostatic precipitators located at the
outlet of the furnace and before the induced draft
fan. The fly ash is periodically removed from the
collection hoppers below the precipitators.
Generally, the fly ash is pneumatically
transported to storage silos for subsequent
transport by trucks.
BOTTOM ASH SYSTEM

At the bottom of every boiler, a hopper has been

provided for collection of the bottom ash from
the bottom of the furnace. This hopper is always
filled with water to quench the ash and clinkers
falling down from the furnace. Some
arrangement is included to crush the clinkers and