Date 6TH AUGUST 2012

To
MR. G.V.KIRAN
BRPL
JAJPUR , ORRISA

Dear Sir,

Sub: TECHNICAL PROPOSAL No. DEV / 12 - 13 / P12 FOR COAL GASIFIER SYSTEMS

In reference to your email dt. 4-08-2012 and our meeting in your factory last week, please find
attached a detailed TECHNICAL PROPOSAL for the coal gasifier system we are offering for pellet plant.

We are associated with Yisheng Enterprises of china in the area of coal gasification and have
successfully supplied more than 120 gasifiers in India. Our Chinese partners are well versed and have
supplied gasifier systems to many pellet plants in china.

Please feel free to contact us for any further queries.

Thanking you,

Yours truly,

Varun Kumar
DIRECTOR, DEV TECHNOFAB LTD.

#1
 TECHNICAL PROPOSAL No. 12-13 / P12 / BRPL
FOR

4.0 MTPA PELLETIZATION PLANT

WITH

15 SET OF 3.4 m TWO STAGE COLD COAL GASIFIER SYSTEM

WITH

OUTPUT: 46150 Nm3 / HOUR

DEV TECHNOFAB LIMITED

901, GOPAL HEIGHTS, NETAHI SUBHASH PLACE, PITAMPURA,
NEW DELHI 110034 INDIA
TEL: 011-47508800 FAX: 011-47508820

Key person: Varun Kumar +91 9810085165

IN ASSOCIATION WITH
YISHENG, ZIBO, SHANDONG, CHINA

#2
 CONTENTS

PART A

1. BRIEF INTRODUCTION OF OUR COMPANY

2. TWO STAGE COAL GASIFICATION PROCESS THRORY
3. TECHNOLOGICAL FLOW
4. DESCRIPTION OF COAL GASIFIER SYSTEM
5. ADVANTAGES OF TWO-STAGE COLD GAS COAL GASIFIER
6. STANDARD COAL GAS PARAMETERS
7. EXISTING CUSTOMERS LIST IN INDIA

PART B: PROJECT SPECIFIC INFORMATION

8. REQUIREMENT ANALYSIS
9. INPUTS REQUIREMENT ANALYSIS AND TAKE OFF POINTS
a. COAL
b. WATER
c. ELECTRICITY
d. AREA
e. MAN POWER
f. EMERGENCY
10. SYSTEM MAIN EQUIPMENT DETAILS
11. EQUIPMENT LIST
12. GURANTEE PARAMETERS
13. SAVING ANALYSIS
14. TOTAL COST ESTIMATE SHEET

Annexure
D01: Layout drawing

#3
 PART A

1. BRIEF INTRODUCTION OF OUR COMPANY

We at DEV ENERGY have partnered with YISHENG Corporation in china who is one of the largest and

specialized coal gasification equipment manufacturers. They have the certificate of manufacturing

the first class of pressure vessels, integrated manufacturing system and advanced detecting methods.

A large group of experienced and technical experts work in India and china. Our professional team is

capable of supplying the services of design, manufacture, installation, training and technical

consultation, in the complete process in the field of gasification.

We have supplied more than one thousand of coal gasifier systems for both China and Asian market.

We have wide experience in the construction materials, ceramics, glassware, chemical,

fire-resistance, steel metallurgy and machinery industry applications

In India, we have experience of more than 9 years for implementing gasification technology. Our

systems are running successfully since 2003. The air cooling technology, where coal gas does not

come in contact with the water, was first installed by us in India. Till date our systems are the only

one using this technology.

We have complete infrastructure to implement all stages of the coal gasification projects in India
and value the service to customer as our prime objective.

#4
2. TWO STAGE COAL GASIFICATION PROCESS THRORY

Bituminous coal is lifted to the coal storage bin by lifting system; the coal is added in the carbonation
stage of two-stage coal gasifier by a programmable control feeding system. Air is blown in the bottom
of furnace by air blower, at the same time, low pressure steam goes through the blending bin and
blends with air, becomes the gasification agent, which will carry on the gasification reaction with
1200 Celsius degree semi coke in the gasification stage.

Producer gas is made by the gasification agent, which is mixture of steam and air, which goes through
red-hot fixed burning bed. The oxygen content in the air and steam react with the carbon in the fuel;
generating the producer gas with has ingredients like CO, CO2, H2, CH4, C2H4, N2 etc.

Reaction of steam and carbon is endothermic reaction:

C + H2O= CO + H2
When oxygen and carbon react, and then heat output:
2C + O2 =2CO
C + O2 = CO2
Some steam here reacts with carbon monoxide:
CO + H2O = CO2 + H2

In the reducing zone, quick reaction is occurred when the temperature is below 1200 Celsius degree
CO2 + C = 2CO and

H2O + C=H2 + CO
When the coal gas goes through the reducing zone, flammable gas content raises rapidly, carbon
dioxide and steam content decrease. Across the reducing zone, a part of coal gas is withdrawn
through a series of vent in the gasifier walls and is called “DOWN STAGE GAS”.
Its temperature is around 300-400 Celsius degree and container dust and ash particles.

This down stage gas is treated in the cyclone to remove the dust particles, and is then cooled through
a heat exchanger. In this heat exchanger the heat is given to the water in the steam drum. The gas is
further cooled in a wind cooler, where natural air cools the gas to a lower temperature.

#5
In the carbonation stage, the coals added in the gasifier are dried, preheated and carbonated,
generate steam, tar and coal gas, exported from the top of gasifier together, this part of gas is called
“up-stage coal gas”, its temperature is around 100-120 Celsius degree.

The temperature of upstage coal gas is about 100-150 Celsius degree, goes into electric detarrer to
remove tar. Water and tar come from the bottom of electric detarrer is sent to the tar tank.

The Upstage and downstage coal gas are mixed in the entrance of indirect cooler, the temperature
after mixing and cooling in the indirect cooler is 35-40 Celsius degree. Then the mixed gas goes
through electric de-oilier to remove dust and light oil.

The coal gas pressure adder increases the pressure of the coal gas to the desired value and then
connects to the transmitting coal gas pipelines which take the gas to the equipment. Mixture from
the indirect cooler are separated, light tar is sent to light tar tank, water is sent to phenolic water
tank.

#6
3. TECHNOLOGICAL FLOW

3.1 PROCESS DESIGN

Coal Preparation

Electric hoister

Coal storage bin

3.4m Two-stage
Air blower coal gasifier Steam drum

Cyclone

Electric detarrer Heat exchanger

Wind cooler

Indirect cooler

Electric de oiler

Pressure adder

User

#7
3.2 PROCESS DESIGN

#8
4. DESCRIPTION OF COAL GASIFIER SYSTEM
Coal gasifier system consist of coal storage, lifting and conveying system, gas making system,
purification and cooling system, transportation system.

4.1 Coal storage system

The size of coal yard depends on the distance and reliability of the coal supply. As a minimum, ensure
to store coal for 15 days is advisable; the area of coal yard should be decided at 1.5 t/ sq. m stotage
rate. Due to the coal is easy to come into the coal powder during the long distance transportation, so
the coals need to sieve before they are fed into the gasifier. If the size of coal purchased is not even,
the coal is above 25 – 75 mm, need crushing system also.

4.2 Coal lifting and conveying system

Coal --- coal yard ---- sieving system---- conveyor system ---- coal storage bin.
The quantity of gasifier in coal is below five sets, use electric hoister to feed coal (dual system)
The volume of coal storage bin is 20m3, coal in it can use 8 hours for the gasifier.

4.3 Gasification system

Gasification system is NORMAL PRESSURE FIXED BED GASIFIER; it is consist of coal feeding system,
furnace body (up-stage & down-stage), grate, hydraulic driving system, ash removal system.

4.3.1 Hydraulic coal feeding system

Stoking uses two-way double faucet stoking valve. There is a surge bin in the middle of every two
stoking valves. Stoking is controlled by the PLC in the control room, including automatic,
semi-automatic and manual control. Faucet stoking valve is driven by the hydraulic system.

4.3.2 Furnace body system

At the carbonation stage, a 36-group ventilation hole refractory lining is laid in furnace body.
Heat-proof stainless central tube is fixed in the center of furnace body, which makes a heating space
both inside and outside; the coal entering the furnace will get heat transfer from the two relative
directions of inside central pipe and outside refractory material, that the coal can be carbonated
completely. Inside the refractory lining, on the coal gas pipe, there is an adjustable valve, it can adjust
the coal gas flow amount of gasification stage and carbonation stage, in turn adjust the proportion of
upstage and downstage gas. At the bottom of furnace body, there is a normal pressure water jacket;
it can produce steam itself for gasification.

#9
4.3.3 Grate system
Grate is made from heat-proof wear resistant alloy cast iron. It is fixed on the base of grate. The base
of grate is antifriction cast iron. Gasification agent goes through holes of grate and lay evenly in the
furnace for the gasification reaction.

4.3.4 Hydraulic ash handling system

There is a big ash plunge and a small ash knife on the furnace body symmetry fixed. Through the
rotation of ash tray, plunge out the ash, drop into ash bucket. This system uses wet ash removing, ash
driving uses hydraulic system.

4.3.5 Central grease lubrication system

The lubrication of gasifier stoking valve and ash driving machine is done by the grease lubrication
system and lubrication station can pour into every oil site automatically.

4.4 Purification and Cooling system

Purified cooling system can be divided in to dust separation system and cooling system. It mainly
does the dust separation and cooling treatment for the rough hot coal gas generated from the
gasifier. Upstage coal goes through the electric detarrer for ash and dust removing. Downstage coal
gas goes through the cyclone for ash removing, then is cooled by heat exchanger and then by wind-
cooler.
These 2 gases are mixed at the inlet of indirect cooler. This mixed upstage and downstage coal gas is
cooled in the indirect cooler at the same time and purified in the electric de oiler. The coal gas
temperature after treatment is 35-40 Celsius degree; coal gas dust content is below 40 mg/Nm3.

4.5 Soften water supply system

Because the water jacket is at the high temperature stage of gasifier, to avoid the water jacket scaling
and fouling, water jacket of gasifier must use softening water. We would supply the softening water
system for the required water input.

# 10
4.6 Coal gas transportation system
Coal gas transportation system is the system that the gas came out from the purification equipment,
after pressurized to send to the users. It consists of coal gas pressure adder and coal gas pipelines.

Coal gas pressure adding system aims to increase the gas pressure, it is easy to convey for long
distance and satisfy the requirements of users.

4.7 Light tar treatment system

Light oil, tar treatment system consists of light oil, tar pump, light oil, tar pool, conveying pipe, its
function is to collect, discharge the light tar.

4.8 Phenolic water treatment system

Phenolic water treatment system consists of phenolic water pump, transportation pipeline, and
phenolic water incinerator. Its function is to collect and incinerate. Use tar and coal gas produced
from as fuel, burn the phenolic water which is atomized in the incinerator, generate carbon dioxide
and steam, discharge to the air, then stop the phenolic water from polluting to underground water
and air.

# 11
5. ADVANTAGES OF TWO-STAGE COLD GAS COAL GASIFIER

1. Technology of two-stage coal gasifier is an updated gasification technology which is based on the

most advanced equipments and technology and is being constantly improved.

2. The system has high gasification efficiency, lower gas producing and running cost, higher

auto-immunization, lower working effort, safer and cleaner operating environment, less coal gas

impurity, higher heating value and stability.

3. Compared to the traditional single-stage gasifier, it has improved heat efficiency of 10% and coal

gas heating value higher by 200 – 300 Kcal/Nm3.

4. With the use of closed cycle cooling including air cooler and indirect cooler to cool the gas

indirectly, no waste water is discharged.

5. The tar produced is low-temperature carbonization tar, with low viscosity, good liquidity, good

quality, and easy to store and burn. It is can be sold for chemical material.

6. Coal feeding machine made up of two-way double faucet valves machine, with compact

conformation is very safe, easy to maintain and reliable

7. Use of heat-proof stainless steel central pipe improves heat transformation and lowers heat loss.

8. High pressure of fan and high gasification intensity makes it possible to transport the gas to far

distance.

9. Heat resisting abrasion resistant casting of the grate and its design makes the gasifier

performance high.

10. Coal feeding and ash tray drive uses hydraulic system which has stable running, simple structure,

long life-span, is easy to maintain, safe and reliable.

11. High degree of automation and increased controls makes the system easy to operate and

manage, and requires less skilled labor.

# 12
6. STANDARD COAL GAS PARAMETERS

6.1 Coal gas heating value 1300 Kcal/m3

6.2 Maximum Coal consumption 2500 kg / h per gasifier
6.3 Maximum Coal gas Output 3750 Nm3 / h
(At F grade coal, specified in 10.1)
6.4 Cold coal gas content (%)

CO H2 CO2 N2 CH4 O2

>22 >8 <6 >52 >2 < 0.6

6.5 Coal gas quality index

No. Name Unit Index

1 TAR Mg /Nm3 < 40

2 DUST Mg /Nm3 < 40

3 MOISTURE % < 1%

6.6 Main Gasification Index

6.6.1 Gasification Capacity 250 - 300 kg/m2h

6.6.2 Steam Consumption Rate 0.3 - 0.5 kg/kg Coal

6.6.3 Air Consumption Rate 2.3 - 2.5 Nm3/kg Coal

6.7 Pressure >6 Kpa , < 10 Kpa (Constant as per set value +/-)

6.8 Temperature Ambient ( 40 ⁰C )

# 13
7. LIST OF EXISTING CUSTOMERS IN INDIA

2003 AJANTA CERAMICS GUJARAT 5 3.2 M TWO STAGE COLD

2004 EURO CERAMICS GUJARAT 2 3.2 M TWO STAGE COLD
2004 DECO TILES GUJARAT 1 3.2 M TWO STAGE COLD
2006 H & R JHONSON MAHARASHTRA 2 3.2 M TWO STAGE COLD
2006 MADHAV UDYOG PUNJAB 1 3.0 M SINGLE STAGE HOT
2006 MADHAV ALLOYS PUNJAB 1 3.0 M SINGLE STAGE HOT
2006 BHARAT POTERIES RAJASTHAN 1 2.6 M TWO STAGE COLD
2006 KAMAL SPONGE M. P. 1 3.0 M SINGLE STAGE HOT
2006 C.P. REROLLER W.B. 1 3.0 M SINGLE STAGE HOT
2006 AAR KAY INDUSTRIES PUNJAB 1 3.0 M SINGLE STAGE HOT
2006 CHANDIGARH IRON & STEEL H.P. 1 3.2 M TWO STAGE HOT
2006 ADHUNIK ISPAT W.B. 1 3.2 M TWO STAGE HOT
2007 UTTAM ROLLING MILL PUNJAB 1 3.0 M SINGLE STAGE HOT
2007 MAGADH INDUSTRIES BIHAR 1 3.0 M SINGLE STAGE HOT
2007 BHAWANI STEEL IND. PUNJAB 1 3.0 M SINGLE STAGE HOT
2007 SBSAL W.B. 1 3.0 M SINGLE STAGE HOT
2007 SPS STEEL & POWER ORISSA 2 3.2 M TWO STAGE HOT
2007 JAI BHARAT ROLLING H.P. 1 3.2 M SINGLE STAGE HOT
2007 V.A. ISPAT PUNJAB 1 3.0 M SINGLE STAGE HOT
2007 KAMAL SPONGE RAJASTHAN 1 3.0 M SINGLE STAGE HOT
2008 H.M.STEEL H.P. 1 3.0 M SINGLE STAGE HOT
2008 ADHUNIK METTALIC W.B. 1 3.2 M TWO STAGE HOT
2008 SRMB W.B. 1 3.2 M SINGLE STAGE
2008 SHIVAM INDIA W.B. 1 3.0 M SINGLE STAGE
2008 GAGAN W.B. 1 3.2 M SINGLE STAGE
2008 ARORA IRON & STEEL PUNJAB 1 2.6 M SINGLE STAGE
2008 MODI MILLS PUNJAB 1 3.2 M SINGLE STAGE
2008 GROVER STEEL MILL GHAZIABAD 1 3.2 M SINGLE STAGE
2008 BHAMBRI STEEL ROLLING PUNJAB 1 3.0 M SINGLE STAGE
2008 BANSAL ROLLING PUNJAB 1 3.2 M SINGLE STAGE
2008 SHREE PARASNATH U.P. 1 3.2 M SINGLE STAGE
2008 PRS STEEL ROLLING PUNJAB 1 3.0 M SINGLE STAGE
2008 S P STRIPS PUNJAB 1 3.0 M SINGLE STAGE
2008 BMW INDUSTRIES W.B. 2 3.2 M SINGLE STAGE
2008 BRHAM ALLOYS W.B. 1 3.2 M SINGLE STAGE

# 14
2008 GEE ISPAT HARYANA 1 3.2 M SINGLE STAGE
2008 MAITHAN STEEL W.B. 1 3.2 M TWO STAGE
2008 SEIL A.P. 2 3.2 M TWO STAGE
2008 MALWA MIRAGE CERAMIC MAHARASHTRA 1 3.4 M TWO STAGE COLD
2008 SHRI RATHI STEEL U.P. 2 3.0 M SINGLE STAGE
2008 DURGAPUR STEEL W.B. 1 3.0 M SINGLE STAGE
2008 SHRI RATHI DAKSHIN RAJASTHAN 2 3.0 M SINGLE STAGE
2008 SARDA ENERGY CHHATTISGARH 5 3.2 M SINGLE STAGE
2008 MAHESHWARY ISPAT W.B. 2 3.2 M TWO STAGE
2009 ADVANCE IMPEX U.P. 1 3.2 M SINGLE STAGE
2009 RATHI UDYOG RAJASTHAN 2 3.0 M SINGLE STAGE
2009 RATHI STEEL & POWER M.P. 2 3.0 M SINGLE STAGE
2009 SARVANA INSULATOR T.N. 2 3.2 M TWO STAGE COLD
2009 MSP STEEL & POWER CHHATTISGARH 1 3.4 M TWO STAGE HOT
2009 JAI BHARAT UNIT 2 H.P. 1 3.2 M SINGLE STAGE
2009 BANSAL UDYOG PUNJAB 1 3.2 M SINGLE STAGE
2009 RANA GLOBAL U.P. 1 3.2 M SINGLE STAGE
2009 JOOLA STEEL W.B. 1 2.6 M SINGLE STAGE
2009 SABOO TOR H.P. 1 3.0 M SINGLE STAGE
2009 MAGADH STEEL 2 BIHAR 1 3.2 SINGLE STAGE
2009 TEHRI IRON & STEEL UTTARANCHAL 1 3.2 M SINGLE STAGE
2009 BARNALA STEEL 2 U.P. 1 3.2 M SINGLE STAGE
2009 VISCO H.P. 3 3.0 M SINGLE STAGE
2010 JHV STEEL U.P. 1 3.2 SINGLE STAGE
2010 RANA ALLOYS U.P. 1 3.2 SINGLE STAGE
2010 SAYANJI ISPAT ASSAM 1 3.2 SINGLE STAGE
2010 UTTRANCHAL STEEL UTTARANCHAL 1 3.2 M SINGLE STAGE
2010 FORTUNE METAL PUNJAB 1 3.0 M SINGLE STAGE
2010 KVS GROUP UTTARANCHAL 2 3.0 M SINGLE STAGE
2010 SUN STEEL MAHARASHTRA 1 3.2 M SINGLE STAGE
2010 SHIVAM MELTTECH W.B. 1 3.0 M SINGLE STAGE
2010 ALLIED STEEL PUNJAB 1 3.2 M SINGLE STAGE
2010 BMW INDUSTRIES W.B. 2 3.2 M SINGLE STAGE
2010 SAYANJI ISPAT 2 ASSAM 1 3.2 M SINGLE STAGE
2010 KALPATRU STEEL KARNATAKA 1 3.4 M SINGLE STAGE
2010 S R STEEL H.P. 1 3.0 M SINGLE STAGE
2010 FORTUNE METALIK CHHATTISGARH 2 3.0 M SINGLE STAGE

# 15
 2010 RASIK INDUSTRIES PUNJAB 1 3.2 M SINGLE STAGE
2010 NALAGARH STEEL H.P, 1 3.0 M SINGLE STAGE
2010 VSP UDYOG W.B. 2 3.2 M TWO STAGE
2010 VVSL W.B. 1 2.6 M SINGLE STAGE
2010 UNION ENTERPRISES JHARKHAND 1 3.2 M SINGLE STAGE
2011 STEMCORE ALLOYS A.P. 1 3.4 M SINGLE STAGE
2011 SHARDA SHREE ISPAT MAHARASTRA 3 3.2 M SINGLE STAGE
2011 CHETAN INDUSTRIES CHHATTISGARH 1 3.2 M SINGLE STAGE
2011 ANKIT METAL & POWER W.B. 1 3.2 M SINGLE STAGE
2011 ANKIT METAL & POWER W.B. 4 3.4 M TWO STAGE COLD
2011 CLAY CRAFT RAJASTHAN 1 2.6 M TWO STAGE COLD
2011 SHYAM FERRO W.B. 1 3.2 M SINGLE STAGE
2011 SHAYAM SEL ORRISA 1 3.2 M SINGLE STAGE
2012 JAIDEEP ISPAT M.P. 1 3.4 M SINGLE STAGE
2012 SHIVAM DHATU W.B. 2 3.4 M SINGLE STAGE
2012 RAK CERAMIC A.P. 2 3.4 M TWO STAGE COLD
2012 VENNAR CERAMIC A.P. 1 2.6 M TWO STAGE COLD
2012 SUPER SMELTERS W.B. 1 3.4 M TWO STAGE COLD
2012 SBQ STEEL T.N. 2 3.4 M TWO STAGE COLD

TOTAL ORDERS IN INDIA: 125

# 16
 PART B

8. REQUIREMENT ANALAYSIS

Please note that as per your inputs we have taken the following assumptions in the selection of the
system to:

1. You will be using the coal gas for the firing the burners in the Pellet in duration furnace grate.
2. Your heat requirement being maximum at 1,50,000 Kcal / ton of pellet at a production rate of
400 tons / hour, total being 60,000,000 Kcal / hour.
3. The burner for the Kiln etc will be designed as per the quality of gas output as per our
specification in 6.1 to 6.8.
4. That we will be provided with minimum coal as per specifications in 10.1

1 HEAT REQUIRED 60000000 K CAL / HR

2 CV OF THE COAL GAS 1300 K CAL
3 COAL GAS REQUIRED 46150 CCM / HR
4 DIAMETER OF PROPOSED GASIFIER 3.4 M
5 AVG. GAS OUTPUT AT 10.1 spec COAL 3750 CUM
5 NO. OF UNITS REQUIRED 13
7 TOTAL AVG. GAS OUTPUT 48750 CUM / HR
SHORT / EXCESS CAPACITY 6%

So, 13 units of 3.4 TWO STAGE COLD GASIFIER are required for gas production, but we recommend to
install 1 set of gasifier extra for

a. Breakdown and standby buffer

b. Maintenance and cleaning of any one gasifier
c. Feed the extra requirements of heat
d. Capability to use lower grade of coal

FINAL SELECTION IS 14 SET OF 3.4 M TWO STAGE COLD COAL GASIFIER

# 17
9. PROJECT INPUT REQUIREMENT ANALYSIS AND TAKE OFF POINTS

9.1 COAL
Your specified coal specifications:

SPECIFICATION REQUIREMENT
GCV > 3500 kcal / kg
ASH < 40 %
VOLATILE MATTER > 23 %
FIXED CARBON > 30 %

In order to guarantee the quality of coal gas and meet the estimated output of the system as
required above, we would need the following parameters in the coal also.

SPECIFICATION REQUIREMENT
MOISTURE 5–6%
SULPHUR < 1%
GRANULARITY AND SIZE 25 – 60 mm
WASTE CONTENT < 1.0 %
ASH SOFTENING TEMPERATURE (AST) ≥ 1250°C
THERMAL STABILITY (RW+6) > 60 %
CRUSHING STRENGTH (> 25 mm ) > 60 %
ROGA INDEX < 20
ADHESIVE LAYER THICKNESS (Y) < 12 mm

MAX. COAL REQUIREMENT: 2.50 T / HOUR PER GASIFIER

725.00 T / DAY
Take off point for the system would be the coal feeding hoister bucket at 0.0 level.

# 18
9.2 WATER

The system requires two types of water input for different circuits.

The evaporation water in steam jacket of the gasifier and the heat exchanger is required as soft water
with following parameters:

pH 7 - 7.5
Total hardness ( in CaCO3 ppm ) < 10
Chlorides ( ppm) < 50
Alkalinity ( in CaCO3 ppm ) < 150
Total dissolved solids ( ppm) < 500
Total suspended solids ( ppm) < 10

Softened water consumption ~ 1000 l/hr per gasifier

Total requirement < 13000 l / hour
< 300 m3 / day
The circulation water required for cooler and water seals requires regular make up water assuming
2 % rate.
Make up water ~ 7500 l / hour
Total requirement < 180 m3 / day

TOTAL FEED WATRE REQUIRED < 480 m3 / day

Take off point for the system would be the raw water inlet line at the inlet of the softening water
system at 0.0 level.

# 19
9.3 ELECTRICITY
THE LIST OF INSTALLED LOAD IS AS FOLLOWS:

Install
KW power Use Actual power
No Name Model Qty /set kW ％ usage
1 Coal Conveyors 2 95 190 80% 152
Hydraulic system
2 motor 28 11 308 25% 77
Coal feeder dry oil
3 pump DDB-18 28 0.55 15.4 25% 3.85
4 Ash try dry oil pump GDB-4 28 0.55 15.4 15% 2.31
5 Electric Detarrer C - 21 14 6.5 91 75% 68.25
6 Electric Deoiler C - 97 4 12 48 75% 36
7 Air Blower 26-Sep 6 90 540 60% 324
8 Gas pressure adder MJG300-2550 6 160 960 60% 576
9 Cooling water pump 6 45 270 60% 162
10 Phenolic pump FLGH-32-200 6 22 132 60% 79.2
11 Soft water pump IS50-32-200B 6 5.5 33 50% 16.5
12 Cooling tower 4 5.5 22 90% 19.8
13 Lighting 2 40 80 40% 32
TOTAL 2704.8 1548.91

TOTAL INSTALLED LOAD: 2704.8 KW

TOTAL RUNNING LOAD: APPROX 1500 KVA

Take off point for the system would be the feeder line of 415 V after incoming LT SWITCH PANEL at
panel room inside the system at +9.075 level.

# 20
9.4 AREA

As indicated in the layout the gasifier system need the space of 150 m x 90 m.
The space required for coal storage is 4000 m2

The layout submitted along with is indicative and can change after detailed technical discussion and
as per the site.

9.5 MANPOWER

Post Shift I Shift II EXTRA Total

STATION HEAD 1 1 2

OPERATORS 8 8 2 18

COAL & POKING 10 10 5 25

LAB 1 1 2

COAL HELPERS 10 10 20

Total 30 30 7 37

9.6 EMERGENCY
The coal gasifier system needs uninterrupted supply of soft water and electricity
So the system will have to be provided with
A. Overhead tank of capacity ~ 100 m3
B. Auto switch on generator of capacity ~ 500 Kw

# 21
10. SYSTEM MAIN EQUIPMENT DETAILS

10.1. Gasifier
The Main Gasifier of 3.4 m diameter is two stage gasifier with upstage being internal lined with fire
bricks including a intricate 36 vents and a centre pipe.
The main parameters are given below:
No. Name Specification & Parameter
1 Hearth Diameter 3.4 m
2 Hearth cross-stage area 9.07 m2
3 Water jacket heated area 17 m2
Outlet coal gas Upstage coal gas 100 - 120 ⁰C
4 temperature Downstage coal gas 300 - 400 ⁰C
Outlet coal gas Upstage coal gas
980-1960 Pa
5 pressure Downstage coal gas
1960-2940 Pa
6 Saturated steam temperature 55 - 65 C
7 Water jacket steam pressure < 294 kPa
8 Water jacket steam output 550 kg/h
9 Ash tray rotary speed 1.5 r/h
10 Hydraulic station power 11 kW
11 Poking hole steam pressure 294 kPa
Up stage 500 mm
12 outlet size Down stage 866 X 866
13 Gasifier bottom fan pipe diameter 400 mm

10.2. Down-stage coal gas cyclone

It is purification equipment in the coal gas purification area outdoor. It will remove dust in
down-stage coal gas. The cyclone is designed for 3000 Nm3 /hr flow of coal gas at 400 ⁰C. The
cyclone is insulated with refractory from inside to prevent the heat loss.

10.3. Wind cooler

It is coal gas indirect cooling equipment in the coal gas purification area outdoor. We provide one set
wind cooler, maximum disposing capacity is 4000 m3/h. Wind cooler cools the downstage coal gas
until about 100 Celsius degree.

# 22
10.4. Electrical Detarrer
It is coal gas purification equipment using the principle of high voltage ionization and precipitation to
achieve the main function removing tar and dust.

The main parameters are given below:

No. Name Unit Index

1 Disposing gas quantity m3/h 2000
2 Dust removing efficiency % ≥95
3 Inlet gas temperature C 35-110
4 Anode quantity stick 21
5 Anode diameter mm 250
6 Effective sectional area m2 1.03
7 Working pressure KPa 0.4-1.5
8 Steam pressure MPa 0.3-0.4
9 Voltage kV 40-60
10 Matching power 72 kV/100mA

10.5. Indirect Cooler

The main function is to cool the upstage coal gas which has been purified by detarrer and down stage
coal gas which has been cooled by wind cooler, removes most water in the coal gas and condenses
light oil tar. It is designed to prevent water from coming in contact with coal gas directly so that the
highly poisonous phenols are not produced and the system is good for environmental protection.

One indirect cooler can maximum dispose coal gas 10000 m3/h and heat exchange area is 480 m2
No. Name Unit Target
Hull side 0.080
1 Design pressure M Pa
Pipe side 0.010
Hull side 0.060
2 Working pressure M Pa
Pipe side 0.006
3 Test pressure Hull side M Pa 0.100
Hull side 60
4 Design temperature ⁰C
Pipe side 90
Hull side 25
5 Working temperature ⁰C
Pipe side 70-80

# 23
10.6. Electrical De-oiler
It is coal gas purification equipment using the principle of high voltage ionization and precipitation to
achieve the main function removing light tar and oils, which has been created by cooling of coal gas
in indirect cooler.
The main parameters are given below:
No. Name Unit Target
1 Coal gas treating value m3/h 10000
2 Dust removing efficiency % >95
3 Outlet coal gas temperature C 35-110
4 Pole quantity Pc 97
5 Corona diameter Mm 250
6 Effective sectional area m2 4.75
7 Power 60KV/200mA

10.7. Air Blower

It’s kind of centrifugal blower equipment arranged inside fan room whose main function is to
pressurize air and feed into coal gasifier furnace, which could mix with steam and gasify the coal and
generate coal gas.
As the design, four units of 9-26-7.1D air blowers are equipped, and main parameters are full wind
Pressure P ＝ 11.415 KPa, Air quantity is Q = 17000 m / h, power of motor is 90 kW, with two
3

running and one for standby. This blower is equipped with variable frequency drive to control the
quantity of air as per the requirement of the gasifier system.

10.8. Coal Gas Pressure Adder

It is coal gas delivery equipment in the coal gas pressure adder room. Its main function is to pressure
the coal gas which has been purified and sent it to users. This design has four units of MJG300-2550
pressure adders, with Q = 18000 m3/ h, maximum Pressure P = 25 Kpa, Motor power is 160 kW, with
two running and one for standby

10.9. Hydraulic system

There is 1 set of hydraulic system, including 1 set of hydraulic station, 2 sets of ash pan driving
hydraulic cylinders, and 4 sets of coal filler hydraulic cylinders in the hydraulic system per gasifier. The

# 24
 ash tray hydraulic system’s working pressure is 16MPa and its testing pressure is 20 MPa. Coal filler
hydraulic system’s working pressure is 12.5 MPa, and testing pressure is 16MPa.

10.10. Power supply circuit

Power supply is three-phase four-wire system 415 V and single phase 220. The system has
independent cabling input for each part. All the brands for the electrical and electronic system used
are of international brands.

10.11. Automatic Control

The system has the following instruments of control and measure:
Instrument measurement
Measured Meters Normal
Measured Measured meter Measured
project name & installed unit Operation
Equipment medium character range
symbol position parameter
Upper-stage
coal gas Central
T1 Coal gas target Celsius 120 0-400
outlet control
degree
temperature
Upper-stage
coal gas Central
P1 Coal gas target Pa 3500 0-5000
outlet control
pressure
Lower-stage
coal gas Central
T2 Coal gas target Celsius 600 0-1000
outlet control
degree
Φ3.4 m temperature
two-stage Lower-stage
coal coal gas Central
P2 Coal gas target Pa 4500 0-6000
gasifier outlet control
pressure
Saturation Saturation Central
P3 target Pa 7000 0-10000
air pressure air control
Air main Central
P4 air target Pa 9000 0-12000
pressure control
Saturation
Saturation Central
air T3 target Celsius 58 0-150
air control
temperature degree
Gasifier
Central
checkpoint’s T4 Coal gas target Celsius 1100 0-1500
control
temperature degree
Tar Insulator Central
catcher box T5 air control, target Celsius 115 0-200
C-21 temperature local degree

# 25
 Coal gas
outlet T6 Coal gas local target Celsius 80 0-150
temperature degree
Insulation
box T7 air local target Celsius 115 0-200
Light oil
temperature degree
catcher
Coal gas
C-97
outlet T8 Coal gas local target Celsius 35 0-100
temperature degree
Coal gas
outlet T9 Coal gas local target Celsius 35 0-100
Indirect temperature degree
cooler Coal gas
outlet P5 Coal gas local target Pa 3000 0-5000
pressure
Steam
Steam
outlet P6 steam local target MPa 0.3 0-0.5
drum
pressure
Coal gas low
pressure gas Central
P7 Coal gas target Pa 2500 0-5000
main pipe control,
pressure
Coal gas pressure
high adder
pressure gas P8 Coal gas operation target Pa 23000 0-30000
Pressure
main room,
adder
pressure local
High
pressure gas
T10 Coal gas local target Celsius 35 0-100
main
degree
temperature
Fan outlet
P9 air local target Pa 12000 0-15000
pressure
Filled air Central
Flow Q air target Nm3/h 4500 0-6000
quantity control

10.12. Earthing Connection

Main workshop and coal gas pressure adder are high safety areas. We use cast lighting in purification
equipments area, emergency lighting in machine room, central control room and main passage. Part
lighting is set for meters. Main workshop, purification equipments, diffusing pipe should be earthed
static, fix a lightning rod on the diffusing pipe.

# 26
11. EQUIPMENT LIST

NO. NAME OF ITEM UNIT QTY

1 COAL HANDLING SYSTEM
1.1 COAL GROUND HOPPER SET 2
1.2 COAL-LIFTTING SYSTEM SET 2
1.3 CONVEYOR BELT SYSTEM SET 2
1.4 VIBRATING SCREEN SET 2
1.5 SHIFTER FEEDER SET 14
2 ASH HANDLING SYSTEM
2.1 ASH BELT SET 2
2.2 INCLINED CONVAYOR SET 2
2.3 ASH SILO SET 2
3 GASIFIER SYSTEM
3.1 3.4 M DOUBLE STAGE COLD GASIFIER SET 14
3.2 COAL FEEDING SYSTEM SET 14
a. HOIST SET 4
b. BUCKET SET 4
c. AUTOMATIC HYDRAULIC FEEDER SET 28
d. FLASH BOARD VALVE SET 28
e. AMORTIZE COAL BIN SET 14
3
f. COAL BIN 20M SET 14
g. COAL FEEDING VALVE SET 56
h. AIR AJUSTING VALVE PC 84
i. COAL DISTRIBUTOR SET 14
3.3 GASIFIER COVER SET 14
3.4 RING-SHAPED STEAM PIPE SET 14
3.5 POKING HOLE SET 154
3.6 OUT GASING PIPE SET 14
3.7 GASIFIER BODY SET 14
a. COMPLETE WATER JACKETED BODY SET 14
b. GASIFIER SKIRT SET 14
c. RING-SHAPED STEAM PIPE SET 14
d. RING-SHAPED WATER INLET PIPE SET 14
e. SMALL ASH KNIFE SET 14
f. UP STAGE GASIFIER BODY SET 14
g. CENTRE PIPE SET 14

# 27
 3.8 STEAM DRUM 1000L SET 14
3.9 LOW PRESSURE STEAM DRUM 1000L SET 14
3.1 BRACKET OF GASIFIER BODY SET 14
3.11 BIG ASH PLOUGH SET 14
3.12 SMALL ASH PLOUGH SET 58
3.13 ASH TRAY AND TRANSMISSION SET 14
a. RACHET WHEEL SET 14
b. SLIDE WAY SET 14
d. ASH TRAY SET 14
e. FIRE GRATE ASSEMBLY SET 14
g. GRATE SUPPORT SET 14
3.14 HYDRAULIC SYSTEM SET 14
a. GREASE LUBRICATING PUMP FOR ASH TRAY GDB-4 SET 28
b. GREASE LUBRICATING PUMP FOR COAL FEEDING DDB-20 SET 28
c. SEAMLESS PIPE FOR COAL FEEDER AND ASH TRAY SET 28
d. CYLINDER FOR COAL FEEDER AND ASH TRAY SET 112
3.15 AIR BLOWER FAN WITH MOTOR SET 6
a. MIXING ROOM OF AIR AND STEAM PC
b. CHECK VALVE DN400 PC 14
c. SUPPORT OF THE BOTTOM SET 14
d. BOTTOM AERATE ROOM SET 14
3.16 FIRE BRICK SET 14
3.17 INSULATION SET 14
4 COOLING AND CLEANING SYSTEM
4.1 CYCLONE SET 14
4.2 DIFFUSING VALVE SET 14
4.3 WET PLATE VALVE SET 14
4.4 DETARRER C 21 SET 14
a. DETARRER BODY SET 14
b. HIGH VOLTAGE POWER 100MA/72KV SET 14
c. INSULATION , BOX, CUP INSULATOR SET 14
d. CONNECTORS, ELECTRODE Φ, BALANCE 21 pcs SET 14
e. HIGH VOLTAGE CONTROLING SET 14
4.5 AIR COOLER SET 14
a. FIRST GRADE AIR COOLER = 273 × 5 , 10 PCS SET 14
b. SECOND GRADE AIR COOLER = 273 × 5, 10 PCS SET 14
4.6 MAIN HEADER PIPE SET 14

# 28
4.7 WATER SEAL SET 28
4.8 INDIRECT COOLER SET 4
4.9 DEOILER C 97 SET 4
a. DETARRER BODY SET 4
b. HIGH VOLTAGE POWER 250 mA/72KV SET 4
c. INSULATION , BOX, CUP INSULATOR SET 4
d. CONNECTORS, ELECTRODE Φ, BALANCE,97 PCS SET 4
e. HIGH VOLTAGE CONTROLING SET 4
4.1 PRESSURE ADDER SET 6
5 PUMPS AMND PIPELINES
5.1 SOFT WATER DISPOSITION SYSTEM SET 2
5.2 SOFT WATER PUMPS IS50-32-200 5.5KW SET 6
5.3 COLD CIRCULATING WATER PUMP / 45 KW SET 6
5.4 PHENOLIC WATER PUMP / 22KW SET 6
5.5 COOLING TOWERS SET 4
5.6 COOLING TOWER WATER PUMPS / 5.5 KW SET 4
5.7 PIPELINE & VALVES OF THE STATION SET 14
5.8 TAR PUMPS SET 4
5.9 COAL GAS TRANSMISSION PIPELINE 720 MM SET 2
5.1 GAS TRANSMISSION LINE SUPPORT SET 20
6 ELECTRIC CONTROL SYSTEM
6.1 LT POWER PANEL SET 1
6.2 LCD CONTROL PANEL SET 2
a. PLC CONTROL SET 14
b. INSTRUMENTS & METERS SET 14
c. ELECTRIC CONTROL CABINET SET 14
d. FAN FREQUENCY CONVERSION 90 KW SET 6
e. PANEL AND FAN FREQUENCY FOR ADDER 160 kW SET 6
f. HIGH VOLTAGE TRANSFORMENR FOR DETARRER SET 14
g. HIGH VOLTAGE TRANSFORMENR FOR DEOILER SET 14
i. PUMPS CONTROL PANEL SET 2
6.3 WIRES AND CABLES SET 2
6.4 CABLE TRAY SET 2
7 STRUCTURE STEEL
7.1 STEEL STRUCTURE FOR THE PLATFORM SET 2
7.2 STEEL STRUCTURE FOR THE PLATFORM SET 2
7.3 STEEL STRUCTURE FOR THE COAL HANDLING SET 2

# 29
 7.4 STEEL STRUCTURE FOR THE ASH HANDLING SET 2
7.5 STEEL STRUCTURE FOR THE GAS TRANSMISSION SET 2
8 SPARES
8.1 BASIC ERECTION SPARES SET 1
8.2 MANDATORY SPARES SET 1

WEIGHT DETAILS

STEEL STRUCTURE 600 TONS

GASIFIER AND CLEANING EQUIPMENT 650 TONS

(STEEL FABRICATION + CASTINGS)

MECHANICAL + HYDRAULIC EQUIPMENT 200 TONS

REFRACTORY AND INSULATION MATERIAL 800 TONS

PIPELINES (WATER , STEAM & GAS) 300 TONS

MISCELLANEOUS 100 TONS

COAL HOPPER AND CONVEYOR 200 TONS

ASH CONVEYOR AND SILO 150 TONS

TOTAL NET WEIGHT 3000 TONS

# 30
12. PERFORMANCE GURNATEE PARAMETRS

COAL GAS USAGE PELLET PLANT IN DURATION FURNACE

12.1 COAL GAS PARAMETERS

QUANTITY 46150 Nm3 / hour ± 2%
CALORIFIC VALUE 1300 Kcal / Nm3 ± 2%
QUALITY
TAR < 40 mg/Nm3
DUST < 40 mg/Nm3
MOISTURE < 2%

12.2 COAL CONSUMPTION

COAL CONSUMPTION PER HOUR 31.1 ton / hour
SPECIFIC COAL CONSUMPTION 0.675 Kg / Nm3

12.3 RESIDUE GENERATION

ASH PER HOUR < 15 t / hour
TAR GENERATION > 1200 kg / hour

# 31
13. SAVING ANALYSIS ( IN CASE OF FURNACE OIL)

1 HEAT REQUIRED PER TON OF PELLET Kcal / ton 150,000

2 OUTPUT PER HOUR Ton / h 400
3 TOTAL HEAT REQUIRED PER HOUR Kcal / h 60,000,000
3
4 GCV OF THE FUEL Kcal / Nm 1,300
5 GAS REQUIREMENT Nm3 / h 46150
6 COAL REQUIRED PER NM3 Kg / Nm3 0.675
7 AVERAGE COAL CONSUMPTION Kg / h 31150
8 COST OF FUEL - COAL Rs / Kg 3.10
9 SPEND ON COAL Rs / h 96565
10 TAR GENERATION @ 4.5 % Kg / h 1400
11 SAVING ON SALE @ 25/ KG OF TAR Rs / h 35000
12 OPERATIONAL COSTS Rs / h 2500
13 ELECTRICITY COST PER HOUR Rs / h 5000
14 NET SPEND ON COAL Rs / h 69065

15 NET SPEND ON COAL PER TON Rs / Ton Pellet 173

16 FURNACE OIL REQUIRED PER HOUR Kg / h 6000

17 COST OF FUEL - FURNACE OIL Rs / Kg 36
18 SPEND ON FURNACE OIL Rs / h 216,000

19 SPEND ON FURNACE OIL PER TON Rs / Ton Pellet 540

18 NET SAVINGS PER TON Rs. / Ton Pellet 367

19 SAVINGS PER DAY ( 24 Hours) Rs. ( In LACS ) 35.25

20 PAYBACK DAYS 127

INVESTMENT OF LACS 4500

# 32
14. PROJECT COST ESTIMATE SHEET ( in lacs )

GASIFIER (EQUIPMENTS – HIGH SEAS SALE COST) RS 3650.00

ERECTION & FABRICATION Rs 300.00

CHA & PORT ; FREIGHT EXPENSES Rs 50.00

CIVIL WORK AT SITE ( 5000 m3) Rs 450.00

MISC. EXPENSES Rs 50.00

TOTAL Rs 4500.00

PLEASE NOTE:
• CUSTOMS DUTY HAS NOT BEING TAKEN INTO ACCOUNT AS THE SAME COULD BE SAVED BY
EPCG
• CVD (MODVATABLE AS EXCISE) ON HIGH SEAS SALE VALUE @10.35 + 4.12% AS APPLICABLE
ON THE ACTUAL CIF VALUE IN NOT INCLUDED IN ABOVE LIST
• THE ESTIMATED CIVIL COST WILL VARY AS PER THE SITE SOIL DETAILS

# 33