RR Energy Plans to Set Up Ferro Alloys Plant with Captive Power
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RR Energy Plans to Set Up
Ferro Alloys Plant with Captive Power
R R Energy Limited plans to set up a Ferro Alloys Plant having Capacity of 30,000 TPA along with a 25 MW Cpative Power Plant at Gadh Umariya, Darramuda Raigarh, Chhatisgarh.
Capacity :
1. Ferro Alloys Plant : 30000 TPA
2. Captive Power Plant : 25 MW
(Coal/ CharDolochar based)
3. Bio Mass Power Plant : 1 MW
Total Working Days : 330 days
Location :
Village : Garh-Umaria,Dist.: Raigarh,Chhattisgarh
As 0n August 23, 2012 : The Project is in planning stage.
Please note that the company has now:
- Semi Finished Steel -100000 TPA
- Bio-mass Power Plant – 14 MW
- Fly Ash Bricks Plant- 19800TPA
It is their expansion plant.
The expansion of the entire unit is coming up on
17 hectare of existing Land.
Aditionally the company has 4 hectare for Ash Pond.
Existing Green Belt is about 1.2 hectare, this will be increased
to about 5.5 hectare, thus 4.3 hectare extra Green Belt will be there.
IMPORTANT: As per the discussion we had last on 10.08.2012 with of R R Energy Limited the Project is under planning stage.
The company has received Environmenta clearance.
The project work is likely to start from
September,2012.
The Ferro Alloys is Scheduled to be Completed
by March,2013 , whereas the Captive Power Plant to be completed by March,2014.
So, this is the RIGHT TIME to contact and Follow Up at following address obtain the detailed Enquiry of each product in time and to
submit your quotation subsequently.
The Main Scope of Supply includes:
Circulating Fluidized Bed Boiler (CFBC) Boiler:
Boilers : 105 TPH - 1 No.
Fuel : Coal and Char
(Coal : 158400 TPA
will be sourced rom SECL mines Kusmunda , Deepika, Gevra/
Coal Middling /Char/Dolochar : 79200 TPA
will be sourced rom From Local Sponge Iron Plant)
ESP : 1 No, Chimney – 1 No.
Stack : Height- 60 Meter,
Dia : TOD- 1400 mm , BOD – 2300mm
Dolochar will be used in CFBC Boiler along with coal to generate electricity. The flue-gases will be treated in high efficiency ESP and then discharged through stack into the atmosphere.
.
Heat Exchangers, Air Pre-heater/Economiser) to be included both type of Boilers.
1. Submerged Arc furnace (3 Nos)
: 3 X3.6 MVA
The furnace will be fitted with smoke hood & bag filters for arresting the
small portion of particulate likely to be generated during smelting. A gas
cooling mechanism with air cooling system will be provided to cool the
gases before cleaning in the bag filters.
2. Steam Turbine (1 No ): 25 MW
The plant will require one no 25 MW Steam Turbine and have uncontrolled extraction connected to one constant pressure deaerator normally working at 125DegC feed water temperature.
3. Iron Ore Crusher
4. Coal crusher
5. Coal/Char Preparing & Handling Plant
Raw Materials
Raw Material for Ferro Alloys Plant plant :
a. Mn Ore : 60000 TPA
b. Sludge : 6000 TPA
a. Coke : 15000 TPA
b. Coal : 7500 TPA
a. Dolomite : 10500 TPA
b. Paste : 750 TPA
Manufacturing Process for Ferro Alloys Plant:
Standard High Carbon Ferro/Silico Manganese will be smelted at about 1700-1800OC. A conventional Submerged Arc Electric Furnace achieves this. The three carbon electrodes, partially submerged in the charge, are supported on hydraulic cylinders for upward and downward movements to maintain the desired electrical conditions in the furnace.
The body of the furnace will cylindrical in shape, and is lined with firebricks, silicon carbide bricks and carbon tamping paste. Two tap-holes are provided at 120O. Apart for draining out both the molten alloy and the slag. During the repair works of one of the tap holes the other will function as standby.
The raw material will thoroughly mixed in the proper proportion before being charged into the furnace. Manual poking rods or stoker car are used for stoking the charge on the furnace top.
As the charge enters the smelting zone, the alloy formed by chemical reactions of the oxides and the reluctant, being heavy gradually settles at the bottom. The slag produced by the unreduced metal oxides and the flux, being relatively lighter, floats on the alloys surface.
At regular intervals the furnace will be tapped. The tap hole is opened by Oxygen lancing pipe and after tapping will be completed, it will be closed by clay plug. The liquid Silicon manganese and the slag flow the C.I. Pan. The slag being lighter overflows from the C.I. pan and will be taken into the sand mould.
The alloy cake from C.I. pan is removed and broken manually with hammer to required lump size. The slag produced in the process, generally free from metal after lorries to the slag dump remove cooling
Air Pollution Control Equipment :
Electrostatic Precipitators/ Bag Filters
Particulate emissions from the plant will be controlled within 50 mg/Nm3.
The plant shall be provided with Electrostatic Precipitators
having high efficiency (above 99.98%) for collection of the fly ash that would
be produced from the Process of coal combustion in Boiler Furnace.
An Electro Static Precipitator would be provided for the cleaning / detarring of the Producer gas and the flue gases.
Stack of adequate height will be provided at the respective units. Water sprinkling will be done along the haul roads to control dust arising from vehicular movement. Dry quenching of coke shall be explored.
Coal from the coal yard will be crushed in a Crusher and conveyed to coal storage bunkers of Boilers through a system of Conveyor Belts, Crusher and Vibrating Screens and is fed to the furnace.
ESP, Dust Extraction systems for Conveyor Transfer Points, Crusher and Screen house with Hoods, Bag filter and Fans will be provided.
De-mineralised water from the storage tank will be pumped to the boiler with the
aid of Boiler Feed Pump. The boiler feed water through an Economizer will
the Steam drum and water walls where it is heated and converted to
saturated steam.
The steam from the main steam header will be taken to the
Turbo–Generators. After rotating the turbinethe exhaust steam is
condensed in the Air Cooled Condensers and the
condensed water is pumped to the De-Aerator and fed back to the boilers.
Auxiliary Coolingwater system :
Direct Flow .
DG Set : . 1 No.
will be installed for stand by arrangement..
Material Handling Equipment
Conveyor
Crusher
Vibrating Screens
Pneumatic Conveying system
Other Systems
- Fuel handling system : 40 TPH
Fly Ash will be collected in the ESP hopper, economizer hopper and APH hoppers will be conveyed to the buffer hopper by means of pneumatic conveying system.
- Ash handling system : 15 TPH
The bottom ash will be generated from combustion of coal and collected in bottom ash hopper will be evacuated by using a continuous operating submerged scraper chain system for collection of bottom ash.
- Air Cooled Condenser
- Fuel system
- Compressed AirSystem : 2 x 600 cfm
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Centralized Control System
One centralized Control System will be installed for the operation of major equipment (Boiler, STG, CW System) in the plant and other auxiliary systems (Compressors and DM plant) shall be operated from their relay based local control panels/stations.
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The following air pollution control systems/ measures are proposed in the Plant
1. All Conveyors will be completely covered with G.I. sheets to control fugitive dust.
2. All bins will be totally packed and covered so that there will not be any chance for dust leakage.
3. All the Dust Prone Points Material Handling systems to be connected with de-dusting system with bag filters.
4. All Discharge Points and Feed points, wherever the possibility of dust
generation is there a de-dusting suction point will be provided to collect the dust.
5. The collected Dust from the Bag house of Steel Melting to be taken to a dust storage bin through a Pneumatic Conveying system.
Water Treatment Plant :
Oxdisation Chamber, Filter, D.M. Plant, Tube Settler
Pumps Valves, Custom Pipeline Work
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The total consumption of water will be
247 m3/Day..
Source Of Water :
The requirement of water for these units will be met from Kelo River/ Ground Water.
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It is proposed to install Air Cooled Condenser.
Hence the water consumption will be much low as well as the effluent generation will also be low.
The Reverse osmosis system is proposed to generate make up DM water.
Thus also the effluent generation will be much low. All the generation effluent will be collected and neutralized and used for the ash quenching as well as party for the green belt irrigation. The domestic effluent will be treated in the conventional septic tank and soak pit the out flow will be used in the green belt plantation. The zero discharge condition will be maintained.
The plant will be designed as a zero discharge plant. The entire treated waste water will be recycled for various purposes inside the plant. The water will be recirculated through cooling and treatment.
This includes Make-up water for Ferro Alloys ,Power plant and Domestic water.
WATER BALANCE DETAIL:
From Ferro Alloys & Power Plant
1. Boiler blow down : 50 m3/ day
2. Cooling Tower blow down : 168 m3/ day
3. Other : 14 m3/ day
4. Domestic :15 m3/ day
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Total 247 m3/day
There will be no discharge out side the premises.
1. The Above loss of water is mainly due to evaporation, but other losses are also inclusive.
2. The quantity of water wasted in softening or DM water backwash will be fully utilized after neutralization, Ash Quenching & dust suppression backwash.
Effluent Generation For the Entire Project:
1. Boiler blow down : 8 m3/ day
2. Cooling Tower blow down : 8 m3/ day
3. R.O. back wash water : 12 m3/ day
4. Domestic Effluent : 2 m3/ day
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Total 30 m3/day
Zero wastewater discharge: The entire wastewater generated from the
project will be reutilized keeping zero discharge outside the factory
premises. All blow downs regeneration effluent of DM plant will be
neutralized and used in dust suppression and ash quenching. Sanitary and
domestic wastewater will be sent to septic and soak pits and over flow
will be used for Green Belt irrigation.
The quality of waste water generated from various processes (blow downs
regeneration overflow etc.) will be regularly measured using ‘V’ notches or flow
meters.
Wastewater samples will be collected and analyzed for critical
parameters like suspended solids and oil. The frequency of monitoring will be
once a week.
Other Equipments :
Material Handling Equipment : Conveyor, Hydraulic Equipment/Cranes,
DG Set, Air Compressor. Gear Box, Insulation, Valves, Pipes & Tubes, Cables, Automatic Weighing Machines for Bulk & Liquid Materials. Pressure Filler, Storage Tank, Cooling Tower/ Plant, Air Conditioning Plant,
Complete Laboratory Equipments etc
Fire Fighting System shall be as per the TAC Norms.
5.5 hectare of Greenbelt will be Developed and a scheme for Rainwater Harvesting have to be put in place.
Scope Of Entire Civil & Construction Work:
Construction of Office Building, Factory Shed- Boiler House, Substation-Control Panel- Electrical Work, Plumbing Work, Structural Steel fabrication and Erection Work, Fabrication Storage Tank, Vessels etc. etc.
Companies/ General Industries/ Contractors/ Sub Contractors/ Manufacturers of Boiler, Material Handling Equipment , Water Treatment Plant, Effluent Treatment Plant, Air Pollution Control Equipments, Cooling Tower, Blowers, Cranes, Hydraulic Equipments, Water line Valve, Pump, Pipeline etc. related to Power Plant may Contact for Specified Enquiry at :
R R Energy Limited
NH 200, Jharsuguda Road
PO : Garh-Umaria, Chhattisgarh- 496001, India.
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Tel : +91-7762- 233385, 233387
Fax : +91-7762- 233386
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Email : rrenerg...@rediffmail.com
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