GASIFIER HOURWISE START UP STEPS (TRAIN -1)

Time (hrs) -14 -13 -12

Pilot burner Wait

Fuel gas burner Wait

Purge
First stage mixer Wait N2 - 363 Kg/hr /mixer
Max - 1316 Kg/hr

Second stage Wait

mixer
 Start Purge , when all the
Start nozzle cooling water analysers in the syngas
Gasifier circulation and set flows path reads less than 1% of
in all the nozzles Oxygen ,Start pressure test

1.Fill Quench section with

HP Raw condensate upto During pressure test line up
50% HP Raw condensate to
Quench section Wait (keep all bottom XVs supply Head spray and
close) water wall
2. Start Quench camera
lens and nozzle purges

Isolate from Syngas path Start Purge and pressure

Char filter Wait test parrallel to Gasifeir

HTHR Wait

slurry
preparation / Rod Slurry circulation on SP : 77 m3/hr on recirculation 154 m3/hr on dis
mill
 1.Fill Chloride scrubber
with BFW (50% level) Start Purge and pressure
Chloride Scrubber Wait 2.Line up Chloride test with Char filter loop
scrubber for purge

Auxilliary Start ( Seal gas Line up for purging (if not Start Purge and pressure
Compressor and Lube oil) under Nitrogen pressure) test with Char filter loop

Slag water LP slag water is lined up to the HP slag water

Start LP slag water pump header of train 1
System

Slag dewatering Wait

tank

Slag solid system Wait

Start Purge and pressure

Tar removal Drum Wait Line up for purging test with Char filter loop
 Establish Nitrogen purge
Miscellaneous - in the PSV pilot : 45 Kg/hr

LRC / Tank LRC running LRC package is running

venting system
PSV pilot 45 45

Flame scaner Lens 0 0

Flame scanner nozzle 0 0

Burner camera lens 0 0
Burner camera nozzle 0 0
Nitrogen Flow Quench camera lens 0 140
Quench camera nozzle 0 1360
Main Burner Oxy line 0 0
Pilot burner Oxygen line 0 0
Mixer Oxygen space 0 726
Char filter heat up 0 0
Tar removal Drum heat up 0 0
Comp Seal 100 100

II quench nozzle 0 0

Residnece Vessel quench 0 0

LP Syngas Flame scanner nozzle 0 0
PSV Path 0 0
Camera nozle purge 0 0

II mixer 0 0

HP syngas Char ejector 0 0

Pulse back valves 0 0

Total 145 2371

IP steam HTHR 0 0

HHP BFW HTHR 0 0

 -8 hrs -4 -1

Purge Oxygen line to bleed of

the block and bleed XVs get
oxygen headerpurity

Purge Oxygen line to bleed of

the block and bleed XVs get
oxygen headerpurity

Purge Purge Start Nitrgoen pading b/n

N2 - 363 Kg/hr /mixer N2 - 363 Kg/hr /mixer block XVs
Max - 1316 Kg/hr
 Complete pressure test and depressurize to Start Burner and Flame
1.75 Kg/cm2g scanner N2 purges

1. Head spray and water wall

on
Change LP Slag water for Head 2.Quench sec water to lamella
thro' sacrificial valve and HIC

Complete pressure test and depressurize to under Nitrogen Under Nitrogen

1.75 Kg/cm2g

1.Keep the vent valve wide open

Start filling HTHR with BFW Steam drum @ 4.0 Kg/cm2g
Start heating using IP
Filling rate : 30000 Kg/hr pressure
steam
Filling time: 4 hrs Steam production : Fix at
9000 TPH until
Expect Temp Gradient :9 °C / hr 8000 Kg/hr
(Do not exceed 30°C )

on 154 m3/hr on discharge

Depressurize to 1.75 Kg/cm2g Isolate from loop (bypass chIsolated From the Syngas path

Fill LLP steam generators with LP BFW under Nitrogen

LP Slag water pump supply

head spray and Water wall

Fill tank A and B or C with water (water fill mode) using LP Slg water

Complete pressure test and depressurize to under Nitrogen Under Nitrogen

1.75 Kg/cm2g
 line up Gasifier to Flare /
Test High Oxy trip vent line close atmoshphere vent
valves

45 45 45

0 0 280

0 0 467
0 0 140
0 0 1360
140 140 140
1360 1360 1360
0 0 0
0 0 0
726 726 726
0 0 0
0 0 0
100 100 100

0 0 0

0 0 0
0 0 0
0 0 0
0 0 0

0 0 0
0 0 0
0 0 0

2371 2371 4618

0 0 0

30000 30000 30000

 0 1

When Gas Temp > 400 C , N2 purge

Start pilot burner A side intiated in Oxy/Air line/FG booster
- Light off 3.2 Kg/hr (Air 17:1) line @ 181 Kg/hr/burner (in both pilot
- Booster - 12.7 Kg/hr (O2 3.4:1) burners)

Flow : 191 Kg/hr

Start Fuel gas burner A side
LR Range N2 Mod 272 Kg/hr of Nitrogen in FG burner
Setpoint : 191 Kg/hr oxygen line in Side B

Purge
N2 - 363 Kg/hr /mixer
Temp rise to 400 Temp reches 400 C

1. Head spray and water wall is on at 17 m3/hr

2. LP slag water pump supplies the water requirement
3.Quench level controlled by the HIC in the d/s of Sacrificial valves
4. Both PRAs isolated

1.Close Start up bypass XV

2.Start Char filter low pressure Heatup
nitrogen flow 5708 Kg/hr
Heater temp ramp 7 C / m
Nitrogen heater outlet temp control at
350°C (should be less than 410°C)
Rise the char filter and tar removal
drum loop pressure 7.0 Kg/cm2g
Maintain Flow : 2995 Kg/hr /vessel
(total : 5990 Kg/hr)

1.Open HTHR o/l drin XV (syngas) and keep

it in Auto
e Syngas path

start compressor and line up for char

filter and tar removal drum heatup
Suction : 4.82 Kg/cm2g
LP pr : 6.37 Kg/cm2g
HP pr (to N2 heater) : 12.2 Kg/cm2g

Maintain Char filter / tar removal

Start Heat up , Heat up nitrogen flow 5708 drum loop pressure using Nitrogen
Kg/hr supply PV and Flare PV at the d/s of
Heater temp ramp 7 C / min char filter
Min Nitrogen flow thro; heater : 1600 Kg/hr Flow throgh Tar removal drum: 5987
Kg/hr
45 45

280 280

467 467
140 140
1360 1360
140 140
1360 1360
0 0
362 362
726 726
2854 5990
2854 5987
100 100

0 0

0 0
0 0
0 0
0 0

0 0
0 0
0 0

10688 16957
0 9000

30000 0
 2 - 9 hrs 10 11

181 Kg/hr 181 Kg/hr Start pilot burner B side

Maintain 400 C by adjusting Oxy Start Fuel gas burner B side

272 Kg/hr of Nitrogen in FG burner
to Fuel ratio from 1 hr to 11 hrs Setpoint :N2
LR Range Mod
oxygen line in Side B 191 Kg/hr
Maintain 400 C till 11 th hour

Heat up (Flow 5990)

Increase IP steam flow so that

10.1 Kg/cm2g is achieved at 28 th
hour , before gasifire pressure is
raised
Running for char filter and Tar Running for char filter and Tar
removal drum heat up removal drum heat up

Tank A / B or C water filled

Ready for start up Ready for start up

Heat up (Flow 5987 Kg/hr )

45 45 45

280 280 280

467 467 467

140 140 140
1360 1360 1360
140 140 140
1360 1360 1360
272 0 0
362 362 362
725 726 726
5990 5990 5990
5967 5987 5987
100 100 100

0 0 0

0 0 0
0 0 0
0 0 0
0 0 0

0 0 0
0 0 0
0 0 0
9000 9000

0 0
 12 13 14 15 16 17 18 19 20 21 22 23

181 Kg/hr / pilot burner untill reactor temp reduces less than 400°C

Rise temp 56 C/hr to achieve 675 C at 16th Maintain 675 °C by adjusting the Oxy to FG ration
hr untill 23 hours
FG flow : 191 Kg/hr/side FG Flow rate: 191 Kg/hr / Burner
Oxy to FG ratio : adjusted
Ramp 56 C/hr to achieve 675 C at 16 th hour Maintain 675°C untill 23 hours

1. IP steam 9000 Kg/hr continued

2. Steam drum outlet flow maintained at 8000 Kg/hr
3. Steam drum pressure 2.0 Kg/cm2g more than gasifier pressure
Running for char filter and Tar removal drum heat up
45 45 45 45 45 45 45 45 45 45 45 45

280 280 280 280 280 280 280 280 280 280 280 280

467 467 467 467 467 467 467 467 467 467 467 467
140 140 140 140 140 140 140 140 140 140 140 140
1360 1360 1360 1360 1360 1360 1360 1360 1360 1360 1360 1360
140 140 140 140 140 140 140 140 140 140 140 140
1360 1360 1360 1360 1360 1360 1360 1360 1360 1360 1360 1360
0 0 0 0 0 0 0 0 0 0 0 0
362 362 362 362 362 362 362 362 362 362 362 362
726 726 726 726 726 726 726 726 726 726 726 726
5990 5990 5990 5990 5990 5990 5990 5990 5990 5990 5990 5990
5987 5987 5987 5987 5987 5987 5987 5987 5987 5987 5987 5987
100 100 100 100 100 100 100 100 100 100 100 100

0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0
9000 9000 9000 9000 9000 9000 9000 9000 9000 9000 9000 9000

0 0 0 0 0 0 0 0 0 0 0 0
 24 25 26 27 28

1. Maintain 56°C/hr ramp to achieve 960°C at 28th hour

2.FG flow rate 318 Kg/hr
3.Introduce Steam at 1:2 ratio (steam to FG) when gasifier temp
Rise FG flow to 318 Kg/hr in 2 hrs ramp 871°C (auto ignition)
Maintain 56 °C / Hr ramp by adjusting Oxy Ramp rate Steam :
to FG ratio a) 1:2 in 30 minutes
b) 2:1 in 60 minutes

Start first stage slurry

circulation Purge
30 m3/hr - bump to 45 N2 - 363 Kg/hr /mixer
m3 for 15 min in every 2
hrs

Start second stage slurry ciruclation @ Wait

14m3/hr
Maintain 56°C/hr by adjusting Oxy to FG ratio (after 318 Kg/hr of FG flow) untill 28th hour

Keep the char filter in once through

Char filter skin heating mode
reaches 204°C N2 flow through heater (1600 Kg/hr)

Achieve 10.1 Kg.cm2g pressure in

steam drum and 180 C temp in steam
drum

Slurry circulation speed increases

to maintain recirculation flow at
77m3/hr
 Bring the compressor into total
circulation

Start HP slag water pump before 29th

hr pressure ramp

Keep the Tar removal drum in once

Tar removal drum through heating mode
N2 flow through heater (1600 Kg/hr)
45 45 45 45 45

280 280 280 280 280

467 467 467 467 467

140 140 140 140 140
1360 1360 1360 1360 1360
140 140 140 140 140
1360 1360 1360 1360 1360
0 0 0 0 0
362 362 362 362 362
726 726 726 726 726
5990 5990 5990 5990 800
5987 5987 5987 5987 800
100 100 100 100 100

0 0 0 0 0

0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0

0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
9000 9000 9000 9000 9000

0 0 0 0 0

16308
271.8
 29

1. Rise FG flow to 600 Kg/hr in one hour

1.Increase Nitrogen flow to 1360 Kg/hr/mixer during

FG ramp up

Wait
1.When FG flow reaches 450 Kg/hr start 1 hr pressure
ramp of gasifier using PIC135042 to 8.1 Kg/cm2g

Ensure char filter pressure is more than gasifier

pressure during pressure rise
When gasifier pressure reaches 3.5 Kg/cm2g , Line up
HP slag water for gasifier quench section
- Throttle open the bypass of HP slag water main train
isolation valve (8") and maintain less than 50
Kg/cm2g in the isolation valve d/s

Start filling Slag water tank A and B or C if not already

filled
45

280

467
140
1360
140
1360
0
362
2720
800
800
100

0
0
0
0

0
0
0
9000

0
 30 31 32 33 34

Rise FG flow to 1270 Kg/hr in 4 hrs ramp up

(ramp up 42 Kg/hr/15 min against 32.5
Kg/hr/15 min (given in the heat up curve))
Maintain 960°C in gasifier by adjusting Oxy to FG ratio Maintain a temp ramp rate of 70 °C/hr at 3
& 35 th hour to ahcieve 1093°C
Adjust Oxy to FG ratio as required

N2 Flow : 1360 Kg/hr

Start HP syngas in the following

1. II mixer - 1600 Kg/hr
Start LP syngas in the following
1.Quench Nozzle - 6800 Kg/hr
(II temp reaches > 400°C )
(if temp reaches more than 400°C , when comp not available intiate 454 Kg/hr of
nitrogen)
 Maintain a temp
ramp rate 70°C/hr to
Maitain 960°C untill 33 hrs achieve 1093°C at
35th hour

1.Start HP syn gas in char ejector: 900 Kg/hr/ejector

(Maximize flow though char ejector 900 Kg/hr is wabash
reading at 100 % valve opening) Once through Heating
2.When HP syngas XV opened flow control valve enabled
with a setpoint of 9270 Kg/hr(CCN)

Start LP syngas flow in residence vessel quench nozzle flow :

9000 Kg/hr Ramp up pressure to 25 Kg/cm2
(otherwise when II stage temp exceeds 580°C minimum in 34 - 36 hrs (3 hrs)
purge 1800 Kg/hr to be started in quench nozzles)
Line up HP and LP syngas header
Keep
LP stage antisurge - close completely Supply / LP and HP syngas to the nozzle / mixer and charfiter
HP Stage antisurge - 40 % open
Ensure the compressor is running in the safe zone and
maximise the recycle ( in quench nozzles)
Line up LP syngas in the following
a. PSV nozzle purge : 1136 Kg/hr
b. Camera nozzle purges :
c. Flame scanner nozzle purges

45 45 45 45 45

280 280 280 280 280

0 0 0 0 0
140 140 140 140 140
0 0 0 0 0
140 140 140 140 140
0 0 0 0 0
0 0 0 0 0
362 362 362 362 362
2720 2720 2720 2720 2720
800 800 800 800 800
800 800 800 800 800
100 100 100 100 100

6800 6800 6800 6800 6800

8900 8900 8900 8900 8900

467 467 467 467 467
1168 1168 1168 1168 1168
2720 2720 2720 2720 2720

1600 1600 1600 1600 1600

1800 1800 1800 1800 1800
0 0 0 0 0
9000 9000 9000 9000 9000

0 0 0 0 0
 35 36 37 38 39

w to 1270 Kg/hr in 4 hrs ramp up

2 Kg/hr/15 min against 32.5
min (given in the heat up curve)) 1. Maintain 1270 Kg/hr untill 39th hour
temp ramp rate of 70 °C/hr at 34 2. Adjust Oxy to FG ratio to maitain 1093°C
ur to ahcieve 1093°C
to FG ratio as required

N2 Flow : 1360 Kg/hr

Maintain a temp
ramp rate 70°C/hr to Maitain @ 1093°C untill 40th hour
achieve 1093°C at
35th hour

Stop IP steam at 36.2 hrs (Pr 25.0 Kg/cm2g)

Ramp up pressure to 25 Kg/cm2g (Ensure process heat is sufficient to generate Pr : 54.72 Kg/cm2g Pr : 69.58
minimum of 8000 Kg/hr steam)
in 34 - 36 hrs (3 hrs) Flow : 15 TPH Flow : 20 TPH
Start pressure ramp to 114.2 Kg/cm2g in 6 hrs
ramp (42 hrs)

Start first rod mill With

thin slurry if not already
started
nozzle / mixer and charfiter

Line up Slag water to PRA u/s line (keep TIC

minium open)
45 45 45 45 45

280 280 280 280 280

0 0 0 0 0
140 140 140 140 140
0 0 0 0 0
140 140 140 140 140
0 0 0 0 0
0 0 0 0 0
362 362 362 362 362
2720 2720 2720 2720 2720
800 800 800 800 800
800 800 800 800 800
100 100 100 100 100

6800 6800 6800 6800 6800

8900 8900 8900 8900 8900

467 467 467 467 467
1168 1168 1168 1168 1168
2720 2720 2720 2720 2720

1600 1600 1600 1600 1600

1800 1800 1800 1800 1800
0 0 0 0 0
9000 9000 0 0 0

0 0 8000 15000 20000

 40 41 42

1. When Pressure 14.1 Kg/cm2g Swap to High

range FG (Swap to be completed between 14.1 -
17.6 Kg/cm2g)
Intial SP : 1388 Kg/hr
(HR Steam enabled with HR FG CV , Oxy
enabled after FG flow reaches 318 Kg/hr and Rrise FG to 3200 Kg/hr in 4 2. Adjust Oxy to FG ratio at
follows previous ratios) hrs 42 hr to rapidly raise the
2.Low range valves closed when HR flow temp from 1150 to 1325 C
reaches 1388 Kg/hr for 30 secs
3. After Swap rise FG flow to 2200 Kg/hr in 1 hr
Ramp
4.Increase the Oxy to FG ratio over 2.0 to get
the temp

1.TIC controls the LP syngas flow

II stage temp control set at 1010 C 2. HP syngas thro' mixer : 1600 Kg/hr
Start 3 hrs Pressure Rampup from 8.1 Kg/cm2g
to 50.6 Kg/cm2g (40 - 42 hrs) 1. rise temp rapidly from
(pressure ramp as per start up checklist(OMG) rise temp to 1150 1150 - 1325 C
0.25 Kg/cm2/min) 2. Gasifier at 50.6 Kg/cm2g
Heat up curve 2 hr ramp up

1.Line up Swirl water & make up water

2.Line up Quench section to any one of the PRA
when pressure reach 17.6 Kg/cm2
4.Switch control to make up control
3.Start Slag grinders

1.Start pulse gas heater

2.Preform manual pulse
cycle in char filter

1. Pr : 84.4 , Flow : 22.5 TPH

2.When pressure reaches more than 10.6 Pr : 99.26 pr : 114.2
Kg/cm2g or HTHR o/l temp more than 260 C Flow: 25 TPH Flow : 30 TPH
drain XV disabled
1.When pressure more than 17.Initiate BFW
flow through chloride scrubber (minimum
flow?)
2. Line up chloride scrubber bottom to SWS
3.Line up syngas derived syngas bypassing the
tar removal drum
4.Take tar removal drum preheater in line

Track the discharge pressure SP of compressor At full supply pressure

HP at - 118.7
untill it reaches 118.7 Kg/cm2g LP at - 56.6 Compressor capacity control by suction
Till then keep the suction valve full open

Line up PRA outlet to slag dewatering tanks B or

C bypassing CRP

CRP in bypass (raw slag fill mode) CRP in bypass (raw slag fill mode)

1.Tar removal drum is in once thorugh heating

mode
Adjust manual Nitrogen / LP syngas purges to Line up extraction gas to
camera during pressure ramp to maintin the flare - when crossing the
flow ash fusion temp

45 45 45

280 280 280

0 0 0
140 140 140
0 0 0
140 140 140
0 0 0
0 0 0
362 362 362
2720 2720 2720
800 800 800
800 800 800
100 100 100

6800 6800 6800

8900 8900 8900

467 467 467
1168 1168 1168
2720 2720 2720

1600 1600 1600

1800 Flow will increase when pressure is rised
0 0 0
0 0 0

22500 25000 30000

 43 44

FG:3200 Kg/hr/burner
FG:3200 Kg/hr/burner adjust oxy to FG to achieve 1482 C

N2 Flow : 1360 Kg/hr

Maintain 1325 C for 1 hr Raise to 1482 C

1.Line up char filter with derived syngas

open inlet XVs
2.Open bottom XV if ejector flow more
than 4630 Kg/hr

1.Float steam dum with HHP header

2.Set 114 Kg/cm2g setpoint for header
control 4. Line up sourwater to residence
3.Set 115 Kg/cm2g for vent PV vessel quench nozzle , set TIC at 871 C
 Establish sour water flow to chloride
scrubber(107 m3/hr) and reduce the
BFW to minimum (454 Kg/hr) (CCN)

capacity control by suction throttling

Line up tar remova drum with syngas

Lineup to OGBL

45 45

280 280

0 0
140 140
0 0
140 140
0 0
0 0
362 362
2720 2720
800 0
800 0
100 100

6800 6800

8900 0
467 467
1168 1168
2720 2720

1600 8172
18540
0 0
0 0
 45 45

FG:3200 Kg/hr/burner FG 3200 Kg/hr

Initiate Mixer A tranfer

1.Slurry flow 14 m3/hr
2.N2 flow 2750 Kg/hr
3.Preflush done
4.Slurry Swap
5.Density proving + pipe volume replacement

Mix B : N2 Flow 2750 Kg/hr before mix A transfer

Both II mixer HP syngas atmozation flow to 4086 Kg/hr

Gasifier under goes temp drops during slurry tranfer maintain temp more than 1200°C

1.Set Charfilter cycle to 5 sec and observe

the DP and valve movement
2.Ejector flow set to 9270 Kg/hr
45 45

280 280

0 0
140 140
0 0
140 140
0 0
0 0
362 362
2720 5500
0 0
0 0
100 100

as per rqrmnt (min 3260 Kg/hr) as per rqrmnt (min 3260 Kg/hr)

0 0
467 467
1168 1168
2720 2720

8172 8172
18540 18540
22500 22500
0 0

As per steam production

 45 45 46

Both FG burner shutdown

Nitrogen purge intiated in Burner
oxygen line 272 Kg/hr
Blast gas started : 907 Kg/hr with
a blast of 1814 Kg/hr for 30 sec in
every 10 minutes

1.Oxygen valve enabled open , if slurry

density is proved (ratio 1.1)
2.Slurry flow ramped to 30 m3/hr when Transfer Mixer B (after mixer A 1. Increase slurry flow rate
oxygen valve enabled reaches RUN step) 1m3/hr
3.Slurry flow ramped to 38 m3/hr Ensure Gasifier temp more than 2.Take slurry heater in line
4. At 38 m3/hr , HP nitrogen shuts 1200°C before Transfer Ramp at
Mix B : N2 Flow 2750 Kg/hr before mix A
transfer

Coupled II mixer swaps to slurry Enable ratio controller at 0.4

Coupled II mixer swaps to slurry quench quench ratio
Enable first stage Oxygen
Temp trim controller
Take CRP in line
45 45 45

280 280 280

0 0 0
140 140 140
0 0 0
140 140 140
0 0 0
0 0 0
362 362 362
2750 2750 0
0 0 0
0 0 0
100 100 100

as per rqrmnt (min 3260

as per rqrmnt (min 3260 Kg/hr) as per rqrmnt (min 3260 Kg/hr) Kg/hr)
0 0 0
467 467 467
1168 1168 1168
2720 2720 2720

8172 8172 8172

18540 18540 18540
22500 22500 22500
0 0 0
GASIFIER HOURWISE START UP STEPS (TRAIN -2)

Time (hrs) -14 -13

Pilot burner Wait

Fuel gas burner Wait

First stage mixer Wait

Second stage Wait

mixer
 Start nozzle cooling water
Gasifier circulation and set flows in all
the nozzles

1.Fill Quench section with

HP Raw condensate upto
50%
Quench section (keep all bottom XVs
close)
2. Start Quench camera
lens and nozzle purges

Char filter Wait

HTHR Wait

slurry
preparation / Rod Slurry circulation on SP : 77 m3/hr on recirculation 154 m3/hr on dis
mill

Chloride Scrubber Chloride scrubber recevies sygas from Train 1 and Train 2 XV and isolation valves closed until train
Compressor Supplies HP and LP Syngas For Train 1 , and Isolated from Train 2

Slag water HP and LP slag water pumps running for Train 1

System

Slag dewatering Slag dewater ing tank receives slag from Train 1 /
tank Train -2 isolation valves are closed
 Slag solid system recevices slag from Train 1
Slag solid system Train - 2 XV / isolation valves are closed

Tar removal Drum Receives Syngas from Train 1 untill Train 2 reaches delivery pressure and train isolation XV opened

Establish Nitrogen purge

Miscellaneous - in the PSV pilot : 45 Kg/hr

LRC / Tank Start LRC package and line up to LRC package is running
venting system SRU

PSV pilot 45

Flame scaner Lens 0

Flame scanner nozzle 0

Burner camera lens 0
Burner camera nozzle 0
Quench camera lens 0
Quench camera nozzle 0
Main Burner Oxy line 0
Pilot burner Oxygen line 0
Mixer Oxygen space 0
Char filter heat up 0
Tar removal Drum heat up 0
Nitrogen Flow Comp Seal 100

II quench nozzle 0

Residnece Vessel quench 0

Flame scanner nozzle 0
 PSV Path 0
Camera nozle purge 0

II mixer 0
Char ejector 0
Pulse back valves 0

II quench nozzle 0

Residnece Vessel quench 0

LP Syngas Flame scanner nozzle 0
PSV Path 0
Camera nozle purge 0

II mixer 0

HP syngas Char ejector 0

Pulse back valves 0

Total 145

IP steam HTHR 0

BFW HTHR 0
 -12 -8 hrs -4

Purge Purge Purge

N2 - 363 Kg/hr /mixer N2 - 363 Kg/hr /mixer N2 - 363 Kg/hr /mixer
Max - 1316 Kg/hr Max - 1316 Kg/hr
 Start Purge , when all the analysers Complete pressure test and
in the syngas path reads less than 1% depressurize to 1.75 Kg/cm2g
of Oxygen ,Start pressure test

During pressure test line up HP Raw

condensate to supply Head spray and
water wall

Start Purge and pressure test with

Gasifier Keep inlet valve isolated and Complete pressure test and under Nitrogen
line up oultlet throgh start up bypass depressurize to 1.75 Kg/cm2g
line

1.Keep the vent valve wide open

Start filling HTHR with BFW Start heating using IP
Filling rate : 30000 Kg/hr steam
Filling time: 4 hrs 9000 TPH until
Expect Temp Gradient :9 °C / hr
(Do not exceed 30°C )

hr on recirculation 154 m3/hr on discharge

nd Train 2 XV and isolation valves closed until train 2 isolation XV is opened at 43rd hour
 Isolated from Train 2

1/
1

hes delivery pressure and train isolation XV opened

Test High Oxy trip vent line

running

45 45 45

0 0 0

0 0 0
0 0 0
0 0 0
140 140 140
1360 1360 1360
0 0 0
0 0 0
726 726 726
0 0 0
0 0 0
100 100 100

0 0 0

0 0 0
0 0 0
0 0 0
0 0 0

0 0 0
0 0 0
0 0 0

0 0 0

0 0 0
0 0 0
0 0 0
0 0 0

0 0 0
0 0 0
0 0 0

2371 2371 2371

0 0 0

0 30000 30000
 -1 0

Start pilot burner A side

- Light off 3.2 Kg/hr (Air 17:1)
- Booster - 12.7 Kg/hr (O2 3.4:1)

Start Fuel gas burner A side

LR Range N2 Mod
Setpoint : 191 Kg/hr
Oxy Ratio : 1.7 : 1

Start Nitrgoen pading b/n Purge

block XVs N2 - 363 Kg/hr /mixer
Start Burner and Flame Temp rise to 400
scanner N2 purges

1. Head spray and water wall 1. Head spray and water wall is on at 17 m3/hr
on 2. LP slag water pump supplies the water requirement
2.Quench sec water to lamella
thro' sacrificial valve and HIC 3.Quench level controlled by the HIC in the d/s of Sacrificial valves and lined up to lamel
4. Both PRAs isolated

Start heatup nitrogen and keep the

charfilter pressure 0.5 Kg/cm2g higher than
the gasifeir pressure by throttling startup
Under Nitrogen bypass XV
Nitrogen heater outlet temp control at
350°C (should be less than 410°C)

Steam drum @ 4.0 Kg/cm2g

preaaure 1.Open HTHR o/l drin XV (syngas) and keep
Steam production : Fix at it in Auto
8000 Kg/hr
Line up LP Slag water in the
HP slag water header of
Train 2
line up Gasifier to Flare /
close atmoshphere vent
valves

45 45

280 280

467 467
140 140
1360 1360
140 140
1360 1360
0 0
0 362
726 726
0 2854
0 2854
100 100

0 0

0 0
0 0
0 0
0 0

0 0
0 0
0 0

0 0

0 0
0 0
0 0
0 0

0 0
0 0
0 0

4618 10688

0 0

30000 30000
 1 2 - 9 hrs 10

When Gas Temp > 400 C , N2 purge

intiated in Oxy/Air line/FG booster
line @ 181 Kg/hr/burner (in both pilot 181 Kg/hr 181 Kg/hr
burners)

Flow : 191 Kg/hr Maintain Max 400 C by adjusting

272 Kg/hr of Nitrogen in FG burner Oxy to Fuel ratio from 1 hr to 11
272 Kg/hr of Nitrogen in FG burner oxygen line in Side B hrs
oxygen line in Side B
 Temp reches 400 C Maintain 400 C till 11 th hour

on at 17 m3/hr
the water requirement
he HIC in the d/s of Sacrificial valves and lined up to lamella

Maintain Nitrogen flow

Maintain Flow : 2995 Kg/hr /vessel Heat up (Flow 5990) in once thro
(total : 5990 Kg/hr)
 Ready for start up

45 45 45

280 280 280

467 467 467

140 140 140
1360 1360 1360
140 140 140
1360 1360 1360
0 272 0
362 362 362
726 725 726
5990 5990 5990
5987 5967 5987
100 100 100

0 0 0

0 0 0
0 0 0
0 0 0
0 0 0

0 0 0
0 0 0
0 0 0

0 0 0

0 0 0
0 0 0
0 0 0
0 0 0

0 0 0
0 0 0
0 0 0

9000 9000

0 0
 11 12 13 14 15 16 17 18 19

Start pilot burner B side 181 Kg/hr / pilot burner untill reactor temp reduces less than 400°C

Start Fuel gas burner B side rise temp 56 C/hr to achieve 675 C at 16th hr Maintain 675 °C by adjusting the Oxy to FG ra
LR Range N2 Mod FG flow : 191 Kg/hr/side hours
Setpoint : 191 Kg/hr Oxy to FG ratio : adjusted (1.6 min) FG Flow rate: 191 Kg/hr / Burner
th hour Ramp 56 C/hr to achieve 675 C at 16 th hour Maintain 675°C untill 23 hours

5990) in once through mode

1. IP steam 9000 Kg/hr continued

2. Steam drum outlet flow maintained at 8000 Kg/hr
3. Steam drum pressure 2.0 Kg/cm2g more than gasifier pressure
Ready for start up

45 45 45 45 45 45 45 45 45

280 280 280 280 280 280 280 280 280

467 467 467 467 467 467 467 467 467

140 140 140 140 140 140 140 140 140
1360 1360 1360 1360 1360 1360 1360 1360 1360
140 140 140 140 140 140 140 140 140
1360 1360 1360 1360 1360 1360 1360 1360 1360
0 0 0 0 0 0 0 0 0
362 362 362 362 362 362 362 362 362
726 726 726 726 726 726 726 726 726
5990 5990 5990 5990 5990 5990 5990 5990 5990
5987 5987 5987 5987 5987 5987 5987 5987 5987
100 100 100 100 100 100 100 100 100

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0

9000 9000 9000 9000 9000 9000 9000 9000 9000

0 0 0 0 0 0 0 0 0
 20 21 22 23 24 25 26 27

0°C

1. Maintain 56°C/hr ramp to achieve 960°C at 28th

2.FG flow rate 318 Kg/hr
3.Introduce Steam at 1:2 ratio when gasifier temp 8
y adjusting the Oxy to FG ration untill 23 Rise FG flow to 318 Kg/hr in 2 hrs ramp ignition)
Maintain 56 °C / Hr ramp by adjusting Ramp rate Steam :
Kg/hr / Burner Oxy to FG ratio a) 1:2 in 30 minutes
b) 2:1 in 60 minutes

Start first stage slurry

circulation Purge
30 m3/hr - bump to N2 - 363 Kg/hr /mixer
45 m3 for 15 min in
every 2 hrs

Start second stage slurry ciruclation @ Wait

14m3/hr
ntill 23 hours Maintain 56°C/hr by adjusting Oxy to FG ratio (after 318 Kg/hr of FG flow) untill 28th hour

Char filter skin

reaches 204°C

Slurry circulation speed

increases to maintain
recirculation flow at 77m3/hr
45 45 45 45 45 45 45 45

280 280 280 280 280 280 280 280

467 467 467 467 467 467 467 467

140 140 140 140 140 140 140 140
1360 1360 1360 1360 1360 1360 1360 1360
140 140 140 140 140 140 140 140
1360 1360 1360 1360 1360 1360 1360 1360
0 0 0 0 0 0 0 0
362 362 362 362 362 362 362 362
726 726 726 726 726 726 726 726
5990 5990 5990 5990 5990 5990 5990 5990
5987 5987 5987 5987 5987 5987 5987 5987
100 100 100 100 100 100 100 100

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0

9000 9000 9000 9000 9000 9000 9000 9000

0 0 0 0 0 0 0 0

16308
271.8
 28 29

hr ramp to achieve 960°C at 28th hour

8 Kg/hr
m at 1:2 ratio when gasifier temp 871°C (auto
1. Rise FG flow to 600 Kg/hr in one hour
:
tes
tes

1.Increase Nitrogen flow to 1360 Kg/hr/mixer

during FG ramp up

Wait
/hr of FG flow) untill 28th hour Maintain 960 C

Maintain minimum flow of nitrogen

throgh char filter if heat up achived
(1600 Kg/hr should be maintained
45 45

280 280

467 467
140 140
1360 1360
140 140
1360 1360
0 0
362 362
726 2720
800 800
800 800
100 100

0 0

0 0
0 0
0 0
0 0

0 0
0 0
0 0

0 0

0 0
0 0
0 0
0 0

0 0
0 0
0 0

9000 9000

0 0
 30 31 32 33 34

Rise FG flow to 1270 Kg/hr in 4 hrs ramp up

Maintain 960°C in gasifier by adjusting Oxy to FG ratio
(ramp up 42 Kg/hr/15 min against 32.5
Kg/hr/15 min (given in the heat up curve))
Maintain a temp ramp rate of 70 °C/hr at 3
& 35 th hour to ahcieve 1093°C
Adjust Oxy to FG ratio as required

N2 Flow : 1360 Kg/hr

When II stage temp reaches 400°C

Start HP Nitrogen in the following
1. II mixer - 454 Kg/hr / mixer
Start HP Nitrogen syngas in the following
1.Quench Nozzle - 1900 Kg/hr
 Maintain a temp
ramp rate 70°C/hr to
Maintain 960 C achieve 1093°C at
35th hour

1.Start HP Nitrogen in char ejector: 900 Kg/hr/ejector

(HP nitrogen flow can be increased for early heatup of Once through Heating
HTHR)

Start HP Nitrogen in residence vessel quench nozzle flow :

1816 Kg/hr Ramp up pressure to 25 Kg/cm2
(otherwise when II temp exceeds 580°C minimum purge to in 34 - 36 hrs (3 hrs)
be started in quench nozzles)
45 45 45 45 45

280 280 280 280 280

0 0 0 0 0
140 140 140 140 140
0 0 0 0 0
140 140 140 140 140
0 0 0 0 0
0 0 0 0 0
362 362 362 362 362
2720 2720 2720 2720 2720
800 800 800 800 800
800 800 800 800 800
100 100 100 100 100

1900 1900 1900 1900 1900

1816 1816 1816 1816 1816

467 467 467 467 467
1168 1168 1168 1168 1168
2720 2720 2720 2720 2720

908 908 908 908 908

1800 1800 1800 1800 1800
0 0 0 0 0

9000 9000 9000 9000 9000

0 0 0 0 0
 35 36 37 38

w to 1270 Kg/hr in 4 hrs ramp up

2 Kg/hr/15 min against 32.5
min (given in the heat up curve)) 1. Maintain 1270 Kg/hr untill 39th hour
temp ramp rate of 70 °C/hr at 34 2. Adjust Oxy to FG ratio to maitain 1093°C
ur to ahcieve 1093°C
to FG ratio as required

N2 Flow : 1360 Kg/hr

Maintain a temp
ramp rate 70°C/hr to Maitain @ 1093°C untill 40th hour
achieve 1093°C at
35th hour

Stop IP steam at 36.2 hrs (Pr 25.0 Kg/cm2g)

Ramp up pressure to 25 Kg/cm2g (Ensure process heat is sufficient to generate Pr : 54.72 Kg/cm2g
minimum of 8000 Kg/hr steam)
in 34 - 36 hrs (3 hrs) Flow : 15 TPH
Start pressure ramp to 114.2 Kg/cm2g in 6 hrs
ramp (42 hrs)

Start first rod mill With

thin slurry if not already
started
45 45 45 45

280 280 280 280

0 0 0 0
140 140 140 140
0 0 0 0
140 140 140 140
0 0 0 0
0 0 0 0
362 362 362 362
2720 2720 2720 2720
800 800 800 800
800 800 800 800
100 100 100 100

1900 1900 1900 1900

1816 1816 1816 1816

467 467 467 467
1168 1168 1168 1168
2720 2720 2720 2720

908 908 908 908

1800 1800 1800 1800
0 0 0 0

9000 9000 0 0

0 0 8000 15000
39
Start 4 hrs Pressure Rampup from 1.75 Kg/cm2g to 50.6 Kg/cm2g (39 - 42 hrs)
(pressure ramp as per start up checklist(OMG) 0.25 Kg/cm2/min)
Heat up curve 2 hr ramp up

Pr : 69.58
Flow : 20 TPH
When gasifier pressure reaches 3.5 Kg/cm2g , Line up HP slag water for gasifier
quench section
- Throttle open the bypass of HP slag water main train isolation valve (8") and
maintain less than 50 Kg/cm2g in the isolation valve d/s
Adjust manual Nitrogen / LP syngas purges to camera during pressure ramp to
maintin the flow

45

280

0
140
0
140
0
0
362
2720
800
800
100

1900

1816
467
1168
2720

908
1800
0

20000
 40 41 42

1. When Pressure 14.1 Kg/cm2g Swap to High

range FG (Swap to be completed between 14.1 -
17.6 Kg/cm2g)
Intial SP : 1388 Kg/hr
(Steam enabled with FG CV , Oxy enabled after
318 Kg/hr and follows previous ratios) Rrise FG to 3200 Kg/hr in 4 2. Adjust Oxy to FG ratio at
2.Low range valves closed when HR flow hrs 42 hr to rapidly raise the
reaches 1388 Kg/hr for 30 secs temp from 1150 to 1325 C
3. After Swap rise FG flow to 2200 Kg/hr in 1 hr
Ramp
4.Increase the Oxy to FG ratio over 2.0 to get
the temp

1.TIC controls the LP syngas flow

II stage temp control set at 1010 C 2. HP syngas thro' mixer : 1600 Kg/hr
- 42 hrs) 1. rise temp rapidly from
rise temp to 1150 1150 - 1325 C
2. Gasifier at 50.6 Kg/cm2g

1.Line up Swirl water & make up water

2.Line up Quench section to any one of the PRA
when pressure reach 17.6 Kg/cm2
4.Switch control to make up control
3.Start Slag grinders

1.Start pulse gas heater

(HP Nitrogen as pulse gas)
2.Preform manual pulse
cycle in char filter (40
cycles)

1. Pr : 84.4 , Flow : 22.5 TPH

2.When pressure reaches more than 10.6 Pr : 99.26 pr : 114.2
Kg/cm2g or HTHR o/l temp more than 260 C Flow: 25 TPH Flow : 30 TPH
drain XV disabled
 Compressor running
HP at - 118.7
LP at - 56.6

Line up PRA outlet to slag dewatering tanks B or

C bypassing CRP
Train 2 not lined up to CRP Train 2 not lined up to CRP

Line up extraction gas to

flare - when crossing the
ash fusion temp

45 45 45

280 280 280

0 0 0
140 140 140
0 0 0
140 140 140
0 0 0
0 0 0
362 362 362
2720 2720 2720
800 800 800
800 800 800
100 100 100

1900 1900 1900

1816 1816 1816

467 467 467
1168 1168 1168
2720 2720 2720

908 908 908

1800 1800 1800
0 0 0

0 0 0

22500 25000 30000

 43 44

FG:3200 Kg/hr/burner
FG:3200 Kg/hr/burner adjust oxy to FG to achieve 1482 C

N2 Flow : 1360 Kg/hr

Maintain 1325 C for 1 hr Raise to 1482 C

1.Line up char filter with derived syngas

open inlet XVs
2.Open bottom XV if ejector flow more
than 4630 Kg/hr (after line up of HP
Syngas)

1.Float steam dum with HHP header

2.Set 114 Kg/cm2g setpoint for header 4. Line up sourwater to residence
control vessel quench nozzle , set TIC at 871 C
3.Set 115 Kg/cm2g for vent PV

Increase sourwater to chloride

scrubber to (178 m3/hr) and Keep
BFW to minimum (454 Kg/hr) (CCN)
Line up HP and LP syngas to Train 2, Load train 2 header slowly
1. LP Syngas pr : 56.6 Kg/cm2g - where as HP N2 pressure is 64 Kg
/cm2g,
a. Throttle HP N2 XV u/s manual isolation valve and reduce XV d/s
pressure to 54 Kg/cm2g
b. Line up LP Syngas XV and slowly open the u/s isolation valves a
ensure LP syngas flow established throgh FT134118
c.Slowly isolate HP Nitrogen XV u/s valve and close the XV
2. HP Syngas pr :118.7Kg/cm2g - where as HP N2 pressure is 64 Kg
a. Throttle HP N2 XV u/s manual isolation valve and reduce XV d/s
pressure to 60 Kg/cm2g
b. Line up HP Syngas XV and slowly open the u/s isolation valves a
ensure HP syngas flow established throgh FT134120
c.Slowly isolate HP Nitrogen XV u/s valve when line pressure incre
to 64 Kg/cm2g and close the XV
 Receives syngas from both trains

Lineup module to Chloride Scrubber

45 45

280 280

0 0
140 140
0 0
140 140
0 0
0 0
362 362
2720 2720
800 0
800 0
100 100

1900 0

1816 0
467 0
1168 0
2720 0

908 0
1800 0
0 0

As per rqrmnt

1816
467
1168
2720

8172
18540
0

0 0
 45 45

FG:3200 Kg/hr/burner FG 3200 Kg/hr

Initiate Mixer A tranfer

1.Slurry flow 14 m3/hr
2.N2 flow 2750 Kg/hr
3.Preflush done
4.Slurry Swap
5.Density proving + pipe volume replacement

Mix B : N2 Flow 2750 Kg/hr before mix A transfer

Both II mixer HP syngas atmozation flow to 4086 Kg/hr

Gasifier under goes temp drops during slurry tranfer maintain temp more than 1200°C

1.Set Charfilter cycle to 5 sec and observe the DP

and valve movement
2.Ejector flow set to 9270 Kg/hr
 gas to Train 2, Load train 2 header slowly
Kg/cm2g - where as HP N2 pressure is 64 Kg

/s manual isolation valve and reduce XV d/s

2g
V and slowly open the u/s isolation valves and
established throgh FT134118
trogen XV u/s valve and close the XV
Kg/cm2g - where as HP N2 pressure is 64 Kg m2g,
/s manual isolation valve and reduce XV d/s
2g
V and slowly open the u/s isolation valves and
established throgh FT134120
trogen XV u/s valve when line pressure increased
se the XV
45 45

280 280

0 0
140 140
0 0
140 140
0 0
0 0
362 362
2720 5500
0 0
0 0
100 100

0 as per rqrmnt (min 3260 Kg/hr)

0 0
0 467
0 1168
0 2720

0 0
0 0
0 0

As per rqrmnt as per rqrmnt (min 3260 Kg/hr)

1816 1816
467 467
1168 1168
2720 2720

8172 8172
18540 18540
22500 22500

0 0

As per steam production

 45 45 46

Both FG burner shutdown

Nitrogen purge intiated in Burner
oxygen line 272 Kg/hr
Blast gas started : 907 Kg/hr with
a blast of 1814 Kg/hr for 30 sec in
every 10 minutes

1.Oxygen valve enabled open , if slurry

density is proved (ratio 1.1)
2.Slurry flow ramped to 30 m3/hr when Transfer Mixer B (after mixer A 1. Increase slurry flow rate
oxygen valve enabled reaches RUN step) 1m3/hr
3.Slurry flow ramped to 38 m3/hr Ensure Gasifier temp more than 2.Take slurry heater in line
4. At 38 m3/hr , HP nitrogen shuts 1200°C before Transfer Ramp at
Mix B : N2 Flow 2750 Kg/hr before mix A
transfer

Coupled II mixer swaps to slurry Enable ratio controller at 0.4

Coupled II mixer swaps to slurry quench quench ratio
Enable first stage Oxygen
Temp trim controller
 Take CRP in line

45 45 45

280 280 180

0 0 0
140 140 140
0 0 0
140 140 140
0 0 0
0 0 0
362 362 362
2750 2750 0
0 0 0
0 0 0
100 100 100

as per rqrmnt (min 3260

as per rqrmnt (min 3260 Kg/hr) as per rqrmnt (min 3260 Kg/hr) Kg/hr)
0 0 0
467 467 467
1168 1168 1168
2720 2720 2720

8172 8172 8172

18540 18540 18540
22500 22500 22500
as per rqrmnt (min 3260
as per rqrmnt (min 3260 Kg/hr) as per rqrmnt (min 3260 Kg/hr) Kg/hr)
1816 1816 1816
467 467 467
1168 1168 1168
2720 2720 2720

8172 8172 8172

18540 18540 18540
22500 22500 22500

0 0 0