POWERPLANT ENGINEERING PROJECT REPORT

Department of Mechanical Engineering

NED University of Engineering and Technology

Industrial Visit to Zaman Textile

Third Year
Section B
Batch: 2020

Group Member Names:

ABDUL BASIT SHAH ME-20035

IZHAN ME-20045
REHAN AHMED ME-20060
RAFAY TASLEEM MALLICK ME-20062
MUHAMMAD ANIQ KHAN ME-20063

Submitted to
MR. MIRZA HAMMAD BAIG

© NED University of Engineering & Technology. All Rights Reserved – January 2022
 ABSTRACT
We were assigned the task of visiting an industry, learning about the different power-
generation cycles, and writing a detailed report of our visit. We studied waste heat recovery
boiler, fire tube boiler, gas turbine and feed water treatment. This visit proved to be very
beneficial for us as it added to our theoretical knowledge and we saw the practical
implementation of the concepts we have studied in our class, such as gas turbine, water
treatment plant, fire tube boiler. For this valuable experience, we would like to thank our
course teachers, Dr. Mubashir Ali Siddiqui and Mr. Hammad Baig. For our assignment, we
visited Zaman Textiles Mills.
Mr. Nadeem Naseer, General Manager Utility, accompanied us throughout the visit and
explained the workings of their operations and guided us through the control room,
powerhouse, and water treatment plant. He briefly explained to us the gas turbine, waste
heat recovery boiler and fire tube boiler.

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 DECLARATION
I, Izhan ME-20045, the group leader, accompanied by my groupmates, visited Zaman Textile on
16th December 2022. All the information and data presented in the report are gathered and collected
from the technical personnel present at the industry. Being the group leader, I ensure you that each
and every member of my group was not only present at the visit but also added their input into
making this report.

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 TABLE OF CONTENTS
ABSTRACT.................................................................................................................................................. 2

DECLARATION .......................................................................................................................................... 3

STATEMENT OF CONTRIBUTION .......................................................................................................... 5

GANTT CHART ............................................................................................................................. 5

COMPANY PROFILE ................................................................................................................................. 6

ZAMAN TEXTILE MILLS ......................................................................................................................... 6

PLANT LAYOUT ........................................................................................................................................ 8

WATER TREATMENT .................................................................................................................. 8

STEAM & POWER GENERATION .............................................................................................. 8

FEED WATER TREATMENT .................................................................................................................... 9

 FILTRATION ............................................................................................................................... 9

 DEMINERALIZATION ............................................................................................................... 9

STEAM & POWER GENERATION ......................................................................................................... 11

POWERHOUSE 1 .................................................................................................................................. 11

POWERHOUSE 2 .................................................................................................................................. 12

GAS TURBINE ............................................................................................................................. 12

WASTE HEAT RECOVERY BOILER ................................................................................................. 13

FIRE TUBE BOILER ............................................................................................................................. 15

CALCULATION OF BOILER EFFICIENCY.............................................................................. 16

STEAM DISTRIBUTOR........................................................................................................................ 18

CONCLUSION ........................................................................................................................................... 19

PLAGIRISM REPORT ............................................................................................................................... 20

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 STATEMENT OF CONTRIBUTION
All group members contributed equally and our project was completed well before the submission
date.

GANTT CHART

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COMPANY PROFILE
ZAMAN TEXTILE MILLS

Established in 2003, Zaman Textile has been recognized for its Excellence, Trust & Quality. We
are honored to be recognized amongst the few vertically integrated manufacturing units of Pakistan
and we have full confidence in our ability to exceed customer expectations. We believe in crafting
& building excellence from the ground, by sourcing and selecting premier cotton locally and
organic cotton globally, while producing the highest quality fabric. Zaman has a rich legacy of
serving the industry and preserving its perception as a quality-first organization. We firmly believe
in customer & quality orientation which gives us a competitive advantage and allows us to lead in
the textile industry.
Our mission is to serve the textile industry with seamless fabric solutions by investing in top-
quality innovative infrastructure, and the latest technology to satisfy customers' requirements, and
drive our business forward while adopting socially responsible practices.
Our vision is to lead a legacy of excellence in global textile industry by inspiring our stakeholders
with brilliance, innovation and commitment.

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LOCATION OF ZAMAN TEXTLE

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 PLANT LAYOUT
WATER TREATMENT

STEAM & POWER GENERATION

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 FEED WATER TREATMENT
They use bored water having 2000 TDS, since it may contain impurities like calcium and
magnesium salts, sodium and potassium salts, fluorides, silica, microorganisms, and many others
which are undesirable and harmful for the boiler as many problems arises due to it such as scaling,
sludge, corrosion, caustic embrittlement and carry over. To remove any such impurities and avoid
these problems, followings feed water treatment processes are performed there.

 FILTRATION
They pass the impure water through filters of different microns in different stages. As a result, the
TDS of water decreases from 2000 to 100.

FILTRATION PLANT

 DEMINERALIZATION

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They had a demineralization plant setup for the further filtration of the impure water.
Demineralization is the process of complete removal of all ions present in water, achieved by using
ion exchange resin. The following reactions take place in their demineralization plant:

 The cation exchange resin, exchanges the cation with the salts dissolved in hard-water.
NaCl + RSO3H = RSO3- Na + + HCl
As a result, Na + removed but water becomes acidic.
 The anion exchange resin, exchanges the anion with the salts dissolved in hard-water.
HCl + R4NOH = R4NCl + H2O
In this step Cl- ion is eliminated which removes the acidity of water.
 Now water is moved to degasser. The function of degasser tower is to remove carbonate
ions by forming carbon dioxide. In degasser tower stream of water is poured from top &
air is blown from bottom to top. As a result, following reaction occurs,
H2CO3 = H2O + CO2
 The H2CO3 free water is now collected in degasser sump and then pumped to Silica
absorber where Magnesium hydroxide is used to adsorb silica from water.

After undergoing the demineralization process, the TDS of the feed water further decreases from
100 to 10 TDS. Now the purified water is stored in the tank having capacity of 10,000 Gallons.
From the tank with the help of the pump feed water is pumped to the boilers at a pressure of 4 bars.

FEED WATER PUMPS DEMINERALIZATION

PLANT

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 STEAM & POWER GENERATION

POWERHOUSE 1
Two Jenbacher gas engines were present there.
SPECIFICATIONS:
MODEL: J-624GS
POWER OUTPUT: 4MW Each
FUEL INTAKE: NATURAL GAS
OPERATING SPEED: 1500 RPM
ENGINE TYPE: V-type 24-cylinder

JENBACHER-624GS

The exhaust of these engines was the input of Waste Heat Recovery boiler.

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 POWERHOUSE 2
It consists of a gas turbine cycle and a waste heat recovery boiler.

GAS TURBINE

POWER OUTPUT: 5.2MW

EXHAUST TEMPERATURE: 480oC
FUEL INTAKE: NATURAL GAS
A Taurus-60 single shaft gas turbine was installed which operated in three stages. First, the air is
compressed and attains a pressure 16 bar. It then goes into the combustion chamber where it is
combusted with natural gas. The hot air-fuel mixture moves through the gas turbine blades, making
them spin. The fast-spinning turbine drives a generator that converts the spinning energy into
electricity, power output of 5.2MW is generated and the exhaust gas leaves the turbine at a
temperature 480oC.

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The exhaust gases leaving the gas turbine still have a high temperature, and to utilize their high
temperature for increased efficiency, they are transferred into a Waste Heat Recovery Boiler.

WHRB

GAS TURBINE

WASTE HEAT RECOVERY BOILER

To recover heat from the exhaust of turbine and generator, and heat generated from various from
chemical reactions taking place in the powerplant, a waste heat recovery boiler is installed. It
utilizes the heat, which would otherwise be wasted into the atmosphere, to generate low to medium
pressure steam. It is useful to have in any powerplant because it can also remove heat from fluids
that need to be cooled. The steam generated in a WHRB is used for various applications such as,
heating, pump liquids, drive turbines, but here it was used for a dying process.

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COMPANY: ENERKON

Powerhouse 1:
 Heat is recovered from the exhaust of gas generator by means of a 4 Ton heat recovery
boiler is used.
 Output: Steam at 7 bar and 160oC
 2 safety valves
 Steam rate: 4 ton/hour
Powerhouse 2:
 Heat is recovered from the exhaust of the gas turbine by means of a 15 Ton Waste Heat
Recovery Boiler.
 Output: Steam at 7 bar and 160oC
 2 safety valves
 Steam rate: 10 ton/hour

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 FIRE TUBE BOILER
Fire tube boilers are those in which the combustion products pass through tubes (Hence ‘fire tube’)
surrounded by water in the shell. An externally fired fire tube boiler is used at Zaman Textile. This
type of boiler has its furnace outside of the boiler shell. Bituminous coal is manually transferred
into the furnace, on the grate by opening fire door. There is an air flow below the grate that is
controlled by dampers. Heat is transferred by the hot combustion gases travelling through the tubes
which raise the temperature of the water present in the shell. As a result, steam is produced and
collected from the boiler at a rate of 21972 Kg/hour.

FUEL: COAL
COAL TYPE: BITUMINOUS COAL
GROSS CALORIFIC VALUE: 6000 Kcal/Ton
FIRING TYPE: EXTERNALLY FIRED
CAPACITY: 15 Ton
COMPANY: SITONG BOILER, CHINA
EFFICIENCY: 82%
NUMBER OF PASSES: 3 PASSES

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 CALCULATION OF BOILER EFFICIENCY

THE DIRECT METHOD

Also known as the “input-output method” as it requires only two parameters to calculate the
efficiency of boiler i-e boiler output (steam) and the heat input. Following formula used to calculate
boiler efficiency:

(Energy output)
𝐸𝐹𝐹𝐼𝐶𝐼𝐸𝑁𝐶𝑌 = × 100
(Energy input)

Steam flow rate × (steam enthalpy − feed water enthalpy)

𝐸𝐹𝐹𝐼𝐶𝐼𝐸𝑁𝐶𝑌 = × 100
Fuel firing rate × 𝐺𝑟𝑜𝑠𝑠 𝑐𝑎𝑙𝑜𝑟𝑖𝑓𝑖𝑐 𝑣𝑎𝑙𝑢𝑒

Basic Boiler Schematic

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 STEAM DISTRIBUTOR
To maintain the supply of steam to all steam using equipment present in the industry, a steam
distributor in essential. Steam generated in Powerhouse 2 i.e., Steam generated from Waste Heat
Recovery Boiler and Fire Tube Boiler is collected in a common steam header which distributes
the steam to different workshops to be utilized for different textile related processes. Steam enters
the common header at 160oC and 7 bar which is supplied throughout and carried out according to
the requirement of each workshop.

Distribution pipes Steam output from Steam output from fire

Waste Heat tube boiler

Recovery Boiler
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 CONCLUSION
We would like to thank our course teachers for assigning us with this task of visiting an industry
as it was very helpful for us to fully understand the concepts taught to us in the class. We completed
our visit to Zaman Textile where we studied the working of the boilers and gas turbine present
there. We were quick to write down the various parameters and readings that were important to
the process and other important information that they told us, using these we calculated the boiler’s
efficiency by means of the direct method. After surveying the site, we were able to grasp the layout
of the power plant and we managed to produce schematics of the feed water treatment, and steam
generation power plant. Reviewing our class notes regularly made it easier for us to better
understand the different aspects of the boiler, putting theory to practice. Using Microsoft Project,
we have made a Gantt chart which has helped us to keep track of our work and manage time
effectively to maximize our productivity in the midst of our tight schedule and other deadlines.

A brief summary of the steam generation powerplant at Zaman Textiles:

o 2 Gas Generators
o 2 Waste Heat Recovery Boiler
o 1 Fire Tube Boiler
o 1 Gas Turbine
Total Power Production:
o Power House 1: 8MW
o Power House 2: 5.2MW

Zaman Textile is making use of latest technology in their water treatment plant to ensure that the
feedwater is suitable for the whole process.

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 PLAGIRISM REPORT
We use the following websites

https://studymoose.com/free-plagiarism-checker

https://www.customwritings.com/check-paper-for-plagiarism

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