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Tata Sponge

Text of Tata Sponge

  • 19/29/2014

    DRI WASTE (CHAR) UTILIZATION IN POWER PLANT TO REDUCE POWER

    GENERATION COST

    BY T.M. DANDAPAT

  • 29/29/2014

    DRI PRODUCTION 390,000 MT PER ANNUM FROM 3 KILNS & 26 MW OF POWER PLANT

    2

    TATA SPONGE

    DRI UNIT 26 MW POWER PLANT

  • 39/29/2014

    TATA SPONGE IRON LTD.Corporate Office

    Coal Block in Angul

    Bhubaneswar Office

    TATA SPONGE IRON LTD.

    In the Orissa province (Eastern part of India) 275 KMs from the State Capital Remote mining cum agriculture area

    Location

  • 49/29/2014

    An associate company of Tata Steel Ltd., in the business of manufacturing of sponge iron. Based in Joda, in the district of Keonjhar, Odisha.

    4

    TATA SPONGE

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    INTRODUCTIONIN DRI (SPONGE IRON ) PRODUCTION

    RAW MATERIAL :A) IRON OREB) NON COKING COALC) DOLOMITE

    PRODUCTS:A) SPONGE IRON (DRI)B) POWER FROM WASTE HEAT (WHRB)

    SOLID WASTE: A) COAL CHAR , B) DE DUST, C) FLY ASH,

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    BAGILTERS

    DE DUST

    FLOW CHART OF THE DRI PROCESS

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    PER TON OF DRI SOLID WASTE GENERATION IS

    0.5 MT

    0.15 MT CHAR 30%

    0.08MT DE DUST 16%

    0.225 MT FLY ASH 45%

    0.045 MT OTHERS 9%

    GENERATION OF SOLID WASTE

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    45

    30

    16

    9

    KILNS SOLID WASTE BREAKUP %

    FLY ASH CHAR DE DUST OTHERS

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    COOLER DISCHARGE CHAR & DE DUST

    IN DRI MAKING THROGUH ROTARY KILNS NON MAGNETIC CHAR CONTAINS ALONG WITH FINISHED PRODUCT.

    THIS NON MAGNETC CHAR HAVING GOOD F.C & GCV.

    CHAR IS 30% OF TOTAL SOLID WASTE

    DE DUST 16% OF TOTAL SOLID WASTE HAVING GOOD F.C & GCV

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    SIZE ANALYSIS in %

    CHAR

    +6mm -6 +3mm 0 3mm

    12.3 22.2 65.5

    DE DUST

    SIZE ANALYSIS in %

    75 Mesh -75 to 100 Mesh

    25 75

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    COAL SOURCE V.M % ASH % F.C % GCV Kilo Calories/Kg.

    IMPORTED COAL S.A

    25 - 27 14 - 16 57 - 60 6500 - 6700

    INDIGENIOUSCOAL

    25 - 26 26 - 30 45 - 48 5000 - 5500

    IN PUT COAL ANALYSIS

    SOLID WASTE CHAR & DE DUST ANALYSIS V.M % ASH % F.C % GCV Kilo

    Calories/Kg.

    CHAR 1 2 55 - 60 35 - 40 3200 - 3400

    DE DUST 2 4 60 - 65 30 - 35 2800 - 3000

  • 129/29/2014

    TYPEOF FUEL V.M ASH F.C GCV K.Cal./Kg.

    F GRADE COAL 25 - 28 35 -40 30 - 35 3000 -3200

    CHAR 1 2 55 - 60 35 - 40 3200 - 3400

    DE -DUST 2 4 60 - 65 30 - 35 2800 - 3000

    COMPARISION OF THE F- GRADE COALWITH

    CHAR & DE DUST

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    DEVELOPED A VALUE ADDED PRODUCT FROM SOLID WASTE, CHAR IS BEING UTILISED AS FUEL IN CFBC / AFBC BOILERS FOR POWER GENERATION

    DE DUST GENERATES THROUGH BAG FILTERS FROM FINISHED PRODUCT CIRCUITS AND IT CONTAINS GOOD CARBON IN PULVERISED CONDITION (-75 to 100 MESH). IS ALSO BEING USED IN CFBC BOILERS (10% MIXED WITH F GRADE COAL 50 & 40% CHAR)

  • 149/29/2014

    FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBC BOILERS (100% F Grade coal @ Rs.3000/MT)

    TYPE OF BOILER

    BOILER CAPACITY

    MAIN STEAM PRESSURE

    MAIN STEAM TEMP.

    COAL REQUIREQUIREMENTPER HOUR.

    FUEL REQUIREMENT PER DAY

    FUEL COSTPER DAY(Rs. Laks)

    COST OF STEAM PER MT(Rs.)

    AFBC15 MW 70 TPH 60Kgf/cm

    2 500 0C 17 MT 410 MT 12.3 732

    AFBC25 MW 110 TPH 60Kgf/cm2 500

    0C 27 MT 648 MT 19.44 736

  • 159/29/2014

    FUEL REQUIREMENT FOR POWER GENERATION THROUGH CFBC BOILERS (100% F- GRADE COAL @ Rs.3000/MT )

    TYPE OF BOILER

    BOILER CAPACITY

    MAINSTEAM

    PRESSURE

    MAIN STEAM TEMP.

    COAL REQUIREQUIREME

    NT /Hr.

    FUEL REQUIREMENT /

    DAY

    FUEL COST

    PER DAYRs. Laks

    COST OF STEEM

    PER TON (Rs)

    CFBC15 MW 75 TPH 66Kgf/cm

    2 480 0C 20 MT 480 MT 14.40 800

    CFBC25 MW 110 TPH 66Kgf/cm

    2 480 0C 28 MT 672 MT 20.16 763

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    FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBE BOILERS (15 MW PLANT)

    (IN COMBINATION OF F- GRADE COAL AND CHAR) CONSIDERING THE STEEM GENERATION FROM 15MW AFBC BOILER

    IS 1680 MT

    FUEL COMBINATION IS 60% F- GRADE COAL & 40% CHAR

    REQUIREMENT OF F GRADE COAL = 24*10.9 =261 MT/DAYREUIREMENT OF CHAR = 24*8 = 192 MT/DAY

    COST OF THE F-GRADE COAL = 3000*261= Rs.7.83 LAKHCOST OF THE CHAR = 1300*192= Rs.2.496 LAKH

    TOTAL FUEL COST IS 10.326 LAKHS

    SO THE COST SAVINGS BY USING THE CHAR COMBINATION FUEL IS = 12.3 10.326 = 1.974 LAKH /DAY

  • 179/29/2014

    TYPE OF BOILER

    STEAMGENERATION /DAY MT

    FUEL COSTFOR F-GRADE COAL 100% IN

    (Rs. LAKH) (A)

    FUEL COMBINATION

    COAL AND CHAR 60:40 IN

    (Rs.LAKH)(B)

    COST SAVINGS IN STEEM /TON (Rs.) (C) =A-B

    AFBC15 MW 1680 12.3 10.326 117.50

    AFBC25 MW 2640 16.44 16.147 124.74

    FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBC BOILERS (60% F Grade coal @ Rs.3000/MT & 40% char

    @Rs.1300/MT)

  • 189/29/2014

    FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBE BOILERS (25 MW PLANT)

    (IN COMBINATION OF F- GRADE COAL AND CHAR) CONSIDERING THE STEEM GENERATION FROM 25MW AFBC BOILER

    IS 2640 MT/DA

    FUEL COMBINATION IS 60% F- GRADE COAL & 40% CHAR

    REQUIREMENT OF F GRADE COAL = 24*17.4 =417.6 MT/DAYREUIREMENT OF CHAR = 24*11.6 = 278.4 MT/DAY

    COST OF THE F-GRADE COAL = 3000*417.6= Rs.12.528 LAKHCOST OF THE CHAR = 1300*278.4= Rs. 3.619 LAKH

    TOTAL FUEL COST IS 16.147 LAKHS

    SO THE COST SAVINGS BY USING THE CHAR COMBINATION FUEL IS = 19.44 16.147 = 3.293 LAKH /DAY

  • 199/29/2014

    TYPE OF BOILER

    STEAMGENERATION /DAY MT

    FUEL COSTFOR F-GRADE COAL 100% IN

    (Rs. LAKH) (A)

    FUEL COMBINATION

    COAL AND CHAR 60:40 IN

    (Rs.LAKH)(B)

    COST SAVINGS IN STEEM /TON (Rs.) (C) =A-B

    CFBC15 MW 1800 14.40 11.136 181.33

    CFBC25 MW 2640 20.16 15.590 173.10

    FUEL REQUIREMENT FOR POWER GENERATION THROUGH AFBC BOILERS (60% F Grade coal @ Rs.3000/MT & 40% char

    @Rs.1300/MT)

  • YEARLY SAVINGS

    AFBC 15 MW: 06.31 Cr. AFBC 25 MW: 10.54 Cr. CFBC 15 MW: 10.44 Cr. CFBC 25 MW: 14.62 Cr.

  • 219/29/2014

    LIST OF THE PARTIES USING CHAR M/S ADHUNIC METALIKS Ltd., M/S MSP STEEL & POWER LTD. M/S VISA STEEL LTD. M/S SHREE GANESH METALIKS LTD M/S SHYAM METALIKS AND ENERGY LTD M/S K P TRADING M/S VIKASH COAL COMPANY M/S SHREE JAGANNATH METALLIC INDUSTRIES

  • 229/29/2014

    AN APEAL TO THE GOVT. OF INDIA INORDER TO DECLARE CHAR IS NOT A WASTE

    IT IS TO BE MANDATED TO UTILISE THE CHAR GENERATED FROM DRI PLANTS IN AFBC /CFBC BASED PLANTS.

    ADVISE RAILWAYS TO GIVE SUBSIDY IN FRAIGHT FOR TRANSPORTING.

    GIVING TAX EXEMPTIONS ON UTILISING THE CHAR IN POWER PLANTS.

  • 239/29/2014

    CONSERVE NATURAL RESOURCES BY USINGCHAR GENERATED FROM COAL BASED DRIPLANTS IN AFBC / CFBC BOILER BASED POWERPLANT WHICH OTHERWISE CALLED AS WASTE.

    GENERATE WEALTH FROM CHAR (ENERGYSOURCE) WHICH OTHERWISE DECLARED ASWASTE

  • 249/29/2014

    CORPORATE OFFICE : 202,2nd Floor HMP HOUSE ,4 FAIRLEY PLACE , KOLKATA-711101

    REGISTERED OFFICE : 206, 2nd Floor SHREENIKETAN APARTMENT,BARBIL,KEONJHAR ,ODISHA

    CONTACT NO : +91 9007819992 ; +91 9830870011 ; +91 9937754992 ; +91 9668423900

    CONTACT PERSON - SHAKEEL ANSARI (DIRECTOR)EMAIL ID : aryavarta.mn @gmail.com

  • 259/29/2014

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