Energy & Environmental Solutions

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Energy &EnvironmentalSolutionsCase Studies

Index Lean Fuels Firing . 03Hot Gas Generators . 10Thermal Oxidizers & Incinerators . 14Sulphur Combustion 25Fuel Conversion . 35Rotary Kiln Applications 43Biogas Application 472

Solutions For Lean Fuels FiringBLAST FURNACE GAS FIRED SOLUTIONM / s Jindal Steel & Power Angul, OrissaSUBMERGED ARC FIRING LEAN FUELSM / s SAIL ChandrapurFERRO ALLOY GAS SOLUTIONM/ s Chattisgarh Electricity Ltd.PRODUCER GAS FIRED SOLUTION WITH HYDROGEN GASM/ s DCW Ltd, T.N.BIO GAS FIRED SOLUTION FOR CO-GENERATION BOILERM/ s Kaset Thai Sugar, ThailandCase Studies3

Dual Fuel LDO & Blast FurnaceLean Gas FiringPlant: 4x460 TPH BoilerApplication: Fuel Conversion from LDO to DUAL FUEL LDO & BFGCustomer: Jindal Steel & Power Ltd. - OrissaProject Detail: M/s JSPL has Blast Furnace Gas as byproductJEPL Solution for Co-firing of BF Gas along with Coal for CFBC Boiler ( 4 x 460 TPH)BF Gas as low calorific value of 575 Kcal/kgScope: BF gas solution for existing boilerBF Gas Valve TrainFuel control StationCombustion Control system for Dual fuel operationAdvantages: Over bed inclined firing systemBF Gas firing for part load operationReduced coal consumption saving INR 75 lakhs /monthNo support fuel required when furnace temp goes above 500 Deg C3

Submerged Arc Furnace LeanGas firingIndustry: Metal – SteelApplication: SAF GasCustomer: SAIL ChandrapurPlant: 20 TPH Waste Heat Recovery BoilerLow Cv Fuel: Submerged Arc Furnance Gas (SAF) – 1250 Kcal/Nm3Project SynopsisGas Control Station Submerged Arc Furnace Gas firing Solution for Power generationMulti fuel firing option ( SAF HFO)PLC based fuel firing control system with instrumentation and automationAdvantages: Dual Fuel firing Solution for 20 TPH WHRB boiler100% heat duty with SAF gas firingSAF gas firing without any support fuel after initial start upSteam boiler application for power generation4

Ferro Alloy Gas (CO Gas) firingIndustry: Metal – SteelApplication: SAF GasCustomer: SAIL ChandrapurPlant: 20 TPH Waste Heat Recovery BoilerLow Cv Fuel: Submerged Arc Furnance Gas (SAF) – 1250 Kcal/Nm3Project SynopsisCO Gas Burner Lean fuel CO gas to be used for power generationMulti fuel firing solution (Oil CO)PLC based control system with instrumentation and automationJEPL Solution Scope : Vertical top down firing combustor for CO gasGas pressure booster blower for lean fuel firingCO Gas at 400º C to be firedOption for alternate fuel firingAdvantages: Process by product CO Gas as fuelSubstitute for fossil fuelFuel cost saving – OPEX advantageLow payback period5

DCW Ltd., T.NIndustry: ChemicalApplication: Various Process PlantsPlant: OPP Dryer – 4 PlantsUGI Calciner – 2 PlantsUTOX Calciner – 2 PlantsRoaster – 4 PlantsLow Cv Fuel fired: PG – 1200kcal/kgProject SynopsisMulti fuel Fired Burner Lean Fuel Firing and Modernization for saving on fuel cost with producer gasMulti fuel firing solutionPLC based control system with instrumentation and automationScope: To convert FO fired system of various plants to Dual Fuel / Tri fuel fired systemTo use excess H2 Gas available with in the plantProducer Gas from coal Gasification plant as low cost of fuel6

Producer & Hydrogen GasSoln For Salt Bath HeaterEnd User: M / s DCW Ltd.Application: Salt Bath HeaterPlant – Fusion PlantScope: Modernization & Retrofit for Optimum Utilization of By – ProductTri Fuel Solution – (H2 PG FO)Producer & H2 Gas Valve TrainOil Valve TrainBMS – PLC Based – Redundant. & SCADACombustion Controls InstrumentsAdvantages: Using low cost fuel – Producer GasOption for H2 gas firing to prevent flaring of excess quantityAutomation & loop control for combination firing for energy efficiency7

Bio Gas Fired solution forCo generation BoilerIndustry: SugarCustomer: Kaset Thai Sugars, ThailandApplication: Bio Gas Fired solution for Co generationBoiler: 240 TPHBiogas CV: 4200 kcal/kg. Qty: 2000 Nm3/hr per burnerScope Biogas fired solution for 240 TPH Bagasse fired BoilerStand alone PLC based automation and Instrumentation systemBiogas control station for safe operationAdvantages: Co firing of Biogas along with BagasseBiogas generated from molasses by product of sugar industrySubstitution for Bagasse fuelEffluent is used as fuelIncreasing boiler per heater temperatureProven technology – many installation8

Solutions For HotGas GeneratorsCase Studies9

Kilburn Chemicals Ltd., Dahej,GujaratIndustry : Dye & PigmentApplication : Rotary Dryer for PigmentAdvantages: No contamination of suspended particulate matterProvision for HFO firing for Low fuel costCeramic Fiber blanket insulationInsulation installed at worksDesign for 1200º C.Refractory curing not requiredLess weightReduced life cycle costDescriptionSolution for HGG SystemFuelHFO / NGHeat Duty10 x 106 Mkcal/ hrHot Gas Temperature1050 – 1100 º C10

Petrovietnam - VietnamEPC: Thyssenkrupp Ind. Soln.Industry: FertilizerApplication: Rotary DryerScope: DescriptionSolution for Hot GasGenerator SystemFuelNatural GasHeat Duty7 x 106 Mkcal/ hrHot Gas Temperature150 – 600 º CNG fired HGGNG fuel control stationPLC Based BMS PanelCA / DA FanControl Dampers for CA / DAAdvantages: Low power consumptionMaintaining skin temperature 65º CHazardous for zone IIPre-installed ceramic insulationFurnace insulation design for 1200º CInsulation cladded with SS 310 to prevent wear11

Concast Steel & Power, OrissaIndustry : Power CFBC BoilerApplication: Hot Gas Generator for start up of 180TPH CFBC BoilerDescription : For CFBC Boiler the bed material needs to be Heated to 600 – 700 ºC prior to coal inductionHot Gas generated is introduced from the bottom of furnace heat up bed material being continuouslyfluidizedCrushed coal (8 – 10 mm) is introduced in the furnaceAdvantages:DescriptionSolution for Hot GasGenerator SystemFuelHSDHeat Duty12 x 106 Mkcal/ hrHot Gas Temperature850 – 900 º C High temperature hot gas at 850º C is generatedDesign for back pressure of 1800 mmWCHot gas bypass arrangement during coal firingArrangement of HGG hanging with sling support from main structureHigh efficiency due to high pressure atomizing12

Case Study for ThermalOxidizers & IncineratorsSTYRENE INCINERATION SYSTEMM / s IOCL – Panipat, IndiaPHENOL WASTE INCINERATIONM / s Mai Liao, TaiwanACID GAS INCINERATION SYSTEM FOR WSA PLANTM/ s Conoco Phillips - IrelandAMINE OFF GAS INCINERATION SOLUTIONM/ s Evonik Industries, ChinaHALOGENATED WASTE THERMAL OXIDIZERM/ s Maktheshim Chemical Works, IsraelOFF GAS INCINERATION & SNCRM/ s Novartis Pharma Technology Co. Ltd. ChinaAMMUNITION OFF GAS THERMAL OXIDIZERM/ s CETC, ChinaCase Studies13

Styrene Incineration SolutionIndustry: Refinery / PetrochemicalApplication: Styrene Incineration systemEPC: Toyo IndiaCustomer: IOCL, PanipatDescription: Styrene Combustor IncineratorStyrene - a bi-product of the crude oil refining process, used for Rubber ProductionOff spec styrene has shelf life, hence is a waste generated on a large scale and needs disposalIndustry needs to find safe and economic method of disposing this waste styrenewhich is a critical applicationJEPL Solution: Natural Gas as start up fuelSelf sustaining styrene combustion solutionsFlue gas emission controlSteam generation by incineration of waste styrene14

Solution For Phenol & TarIndustry: Petrochemical (Plastic)IncinerationApplication: Phenol Waste IncinerationEPC: Durr System GmbHCustomer: Mai Liao, TaiwanDescription: Liquid waste incineration systemIncineration of combined phenolic waste from plastic industry & Heat recoveryVertical top down firing constructionWASTE A75 kg/hr.Phenol0.42 wt.%IPP2.84 wt. %Tar96.19 wt.%NaOH0.54 wt. %WASTE B300 kg/hr.Acetone0.03 wt. %Phenol49.85 wt. %P35.16 wt.%O7.98 wt. %Others6.97 wt.%200cP @ 213 º C182cP @ 182 º C15

Acid Gas Incineration System forIndustry: Oil RefineryWSA PlantApplication: SRU Tail Gas IncineratorEPC: Jacobs Nederland B.V.Customer: Conoco Phillips - IrelandDescription: Conoco Phillips WSA plant a combustions chamber for firing H2S gases (SWS and H2S gas).Downstream equipment waste heat boiler for steam generation.Capacity8 MWOperating Temp.975ºCCombustion ChamberDim.Ǿ 1.5 x 6.0mFuel ConsumptionNatural Gas300 Nm3/hr.SWS Gas115 Nm3/hr.Acid Gas300 NmCapacity8 MWOperating Temp.975ºCCombustion ChamberDim.Ǿ 1.5 x 6.0mFuel ConsumptionNatural Gas300 Nm3/hr.SWS Gas115 Nm3/hr.16

Amine Off Gas IncinerationIndustry: Gas ProcessingSolutionApplication: Amine Off Gas IncineratorEPC: Envirotec GmbH.Customer: Evonik Industries, ChinaDescription: Off gases with NH3 and HCNLiquid waste with nitrogenous hydrocarbonsHeat duty capacity 13.5 MWLiquid and gaseous waste incineration systemCapacity13.5 MWOperating Temp.1,100 ºCCombustion Air38,500 Nm3/hrFuel ConsumptionLine A (Liquid)80 – 420 Kg/hr.Line B ( Liquid)40 – 270 kg/hr.Line C ( Liquid)1,200 kg/hr.Line D ( Gas )200 – 810 Nm3/hrLine E ( Gas)1,000 – 4,000 Nm3/hrNatural Gas125 – 1,350 Nm3/hrCapacity13.5 MWOperating Temp.1,100 ºC17

Halogenated Waste ThermalIndustry: ChemicalOxidizerApplication: Halogenated Waste Thermal OxidizerEPC: CTU - Conzepte Technik Umwelt AG Customer: Maktheshim Chemical Works, IsraelDescription: Chemical industry process wasteHazardous Waste comprising of chlorinated hydrocarbons, organics and solventsVertical top down firing incinerator with a central multi fuel burner and additional liquid waste lances.Control systemsCapacity14.0 MWOperating Temp.Max 1,200 ºCCTU – Conzepte Technik Umwelt AGCombustionChamber Dim.Ǿ 3.4 x 13.5 mCombustion AirCase 2Case 18,500 – 15,000 Nm3/hr.0 – 10,000 Nm3/hr.Fuel ConsumptionLPG40 – 400 Nm3/hr.Natural Gas110 – 1,100 Nm3/hr.Heavy Fuel Oil No. 6350 – 1300kg/hr.Off Gas10 – 60 kg/hr.Waste Liq. No. A1100 – 500 kg/hr.Waste Liq. No. B120 – 80 kg/hr.Waste Liq. No. B220-105 kg/hr.18

Off Gas Incineration & SNCRIndustry: PharmaceuticalApplication: Off Gas Incineration & SNCRCustomer: Novartis Pharma Technology Co. Ltd. ChinaDescription: Thermal Oxidizer Plant for pharmaceutical process wasteProcess Off gas IncinerationSelective non catalytic reduction (SNCR) with ammonia injectionNOx control and emission monitoringCapacity6.0 MWOperating Temp.750 – 1,200 ºCCombustion Chamber Dim.Ǿ 1.7 x L1 4.3m. L2 7.16 mAmmonia Water1 l/h / 20% for SNCRFuel ConsumptionOff Gas 11,000 – 7,500 Nm3/hr. without H2Off Gas 20 -100 Nm3/hr.with H2Natural Gas90 -600 Nm3/hr.Quench air18,000 Nm3/hr.Capacity6.0 MWOperating Temp.750 – 1,200 ºCCombustion Chamber Dim.Ǿ 1.7 x L1 4.3m. L2 7.16 m19

Refinery Waste Gas IncinerationIndustry: RefineryApplication: Waste Gas IncinerationEPC: Selas Linde AGCustomer: Shell Pernis, NetherlandsDescription: Off Gases from gasification of heavy residue from thermal cracking process for hydrogen gas generationSour gas from recti sol treating of Syngas for Sulphur and CO2 removalSulphur and CO2 removal from downstream of CO – ShiftOff gases from the first stage contains absorbed hydrogen gasHydrogen rich off gases from catalytic reformerCapacity7 MWCombustion Air9,000 Nm3/hr.Control Range1:10 for Natural GasFuel ConsumptionGaseous Fuels600 Kg/hr.Waste Gas1,650 kg/hr.20

Ammunition Off Gas ThermalOxidizerIndustry: AmmunitionApplication: Ammunition Destruction Off Gas THOEPC: Dynasafe Germany GmbHCustomer: CETC, ChinaDescription: Off gas resulting from the pyrolysis process in the SDC (Static Detonation Chamber)The THO accepts off gases resulting from one feed cycle in a period of max. 180 sec.The oxidizer is de-signed to be oversized to handle peak flow and is able to take twice the anticipated flow.The THO has a residence time of three seconds or more at 1.100 C.Off gas is fed tangentially using a four lance system to ensure complete treatment of the contaminated gases.Capacity400kWOperating Temp.1,100 ºCCombustion Air850 Nm3/hr.Control Range1:10 for Natural GasNatural Gas40 Nm3/hr.21

Solution For Phenol & TarIncinerationIndustry: Petrochemical (Plastic)Application: Phenol Waste IncinerationEPC: Durr System GmbHCustomer: Mai Liao, TaiwanDescription: Liquid waste incineration systemIncineration of combined phenolic waste from plastic industry & Heat recoveryVertical top down firing constructionWASTE A75 kg/hr.Phenol0.42 wt.%IPP2.84 wt. %Tar96.19 wt.%NaOH0.54 wt. %WASTE B300 kg/hr.Acetone0.03 wt. %Phenol49.85 wt. %P35.16 wt.%O7.98 wt. %Others6.97 wt.%200cP @ 213 º C182cP @ 182 º C22

Acid Gas Incineration System forWSA PlantIndustry: Oil RefineryApplication: SRU Tail Gas IncineratorEPC: Jacobs Nederland B.V.Customer: Conoco Phillips – IrelandDescription: Conoco Phillips WSA plant a combustions chamber for firing H2S gases (SWS and H2S gas).Downstream equipment waste heat boiler for steam generation.23

Case Study for SulphurCombustionVISCOSE - SULPHURIC ACID PLANT – WSAM/s Lenzing - PT. South Pacific Viscose, IndonesiaMANGANESE SULPHATE - SULPHURIC ACID PLANT – WSAM/s Rio Seco, PeruPULP & PAPER - SO2 PRODUCTION PLANTM/s M Real Hallein, AG, AustriaVISCOSE - SULPHURIC ACID PLANTM/s South Pacific Viscose Ltd., IndonesiaSPENT ACID REGENERATIONM/s BASF AG, Ludwigshafen, GermanySPENT ACIDM/s Dead Sea Bromine, IsraelSULPHURIC ACID RECOVERY - WSAM/s Ningbo Haiyue New Materials, ChinaSPENT ACID RECOVERYM/s Evonic, GermanySPENT ACID RECOVERYM/s Petrochemia Blachownia S.A., Poland24

Viscose Staple Fiber - SAPIndustry: Viscose Staple FiberApplication: Sulphuric Acid Plant -WSAEPC: Lenzing-PT. South Pacific ViscoseCustomer: Lenzing-PT. South Pacific Viscose, IndonesiaDescription: For a new WSA plant combined system for different media with 27.8 MWNatural gas or Diesel as start up fuelAdjustable lances for Sulphur injectionHigh excess air for optimum SO2 generationCapacity27.8 MWOperating Temp.850ºCCombustion Air88000 Nm3/hr. ( Pri. Sec.)Combustion Chamber Dim.Ǿ 3.3 m x 12.5 mFuel ConsumptionNatural Gas300 – 2970 Nm3/ hr.Rich Gas175 – 600 Nm3 / hr.Sulfur870 – 2970 Kg / hr.Diesel Oil230 – 1753 Kg / hr.Capacity27.8 MWOperating Temp.850ºCCombustion Air88000 Nm3/hr. (Pri. Sec.)25

Manganese SulphateLeaching - SAPIndustry: Manganese Sulphate Leaching processApplication: Sulphuric Acid Plant - WSACustomer: Rio Seco, PeruDescription: Capacity3 MWCo-firing of H2S Gas and liquid sulphurOperating Temp.1,000ºCWSA Process for Sulphuric Acid plant inCombustion Chamber Dim.Ǿ 2.1 x 6.9 mRio Seco PeruCombustion Air10,800 kg/hr.Acid gas is injected by a gas ring withFuel ConsumptionFuel Gas140 Kg/hr.H2S Gas340 – 1,400 kg/hr.Liq. Sulfur150 – 850 kg/hr.four separate adjustable gas lancesLiquid Sulfur is added through a centrallymounted ultrasonicLow Pressure steam atomizationNatural gas fired through a gas Capacity3 MWOperating Temp.1,000ºCCombustion Chamber Dim.Ǿ 2.1 x 6.9 mCombustion Air10,800 kg/hr.sleeve tube around Sulfur lanceThe combustion air stream divided intotwo air layersFirst layer directly to the burner housing and the secondary stream is tangentially fed to }combustion chamberOperation of the system with high air excess26

Pulp & Paper - SO2 GasIndustry: Pulp & PaperApplication: SO2 Production PlantCustomer: M Real Hallein, AG, AustriaDescription: Revamping of SO2 Production Planthorizontal combustion chamber placed in existing buildingNatural gas and sulfur firing solutionCombustion chamber temperature of 1.500 CSO2 - content in the flue gas is higher than 19%Capacity2.9 MWOperating Temp.1500 – 1600 ºCCombustion Chamber Dim.Ǿ 1.86 m x 6.4 mFuel ConsumptionNatural Gas50 – 200 Nm3/hr.Sulfur200 – 750 Kg/hr.287

Viscose Staple Fibre- SAPIndustry: Viscose Staple FibreApplication: Sulphuric Acid PlantCustomer: South Pacific Viscose Ltd., IndonesiaDescription: Sulfuric acid production plant for South Pacific Viscose Ltd.Horizontal combustion sulfur and H2S gas firingFor heating up procedure diesel fuel / HFOIn the downstream installed WSA process equipmentsThe sulfur dioxide, from the combustion of sulfur and H2S gas, is converted into sulfuric acidCapacity25 MWOperating Temp.900 – 950 ºCCombustion Air.37,000 Nm3/hr. Lean gas /start up operation with ambient airFuel ConsumptionDiesel / HFOStart upFuel Gas (H2S)350 – 1000 Nm3/hr.298

Petro-Chemical – Spent acidregenerationIndustry: Petro-Chemical (Polyurethane)Application: Spent Acid RegenerationEPC: CTU – Concepte Technik Umwelt, AG Customer : BASF AG, Ludwigshafen, GermanyDescription: For MDI and TDI ProductionIn a vertical combustion chamber spent acid is combustedFor start-up operation and additional heating the burner is equipped with a natural gas lance and is also possible tooperate the burner with waste liquid fuels as visbreaker tar and EDA residueThe spent acid is fed via four lances into the combustorIn the centre of the lances is a multi fuel burner - top down mountedFor enrichment the SO2, additional liquid sulfur is firedCapacity33 MWOperating Temp.1050ºCComb. Chamber Dim.Ǿ 3.1 mCombustion AirPre Heated @ 250 º CFuel ConsumptionNatural Gas80 – 1000 Nm3/hr.Spent Acid15950 Kg/hrSulphur4460 Kg/hrVisbreaker Tar200 – 1600 Kg/hrEDA Residue200- 1300 Kg/hrHigh Boiling residues200 – 1600 Kg/hr309

Chemical (Elemental Bromine)Spent Acid RecoveryIndustry: Chemical ( Elemental Bromine)Application: Spent AcidEPC: CTU – Concepte Technik Umwelt AGCustomer: Dead Sea Bromine, IsraelDescription: Hazardous Waste Heat recovery Plant for liquid and gaseous waste fuels (with Bromine, Sulfuric Acid, halogenatedHydrocarbons and Waste Water)The waste fluids fired in a vertical incinerator with a central multifuel burner mounted in a top down orientationSolution for Spent acid recovery along with Incineration of Halogenated waste & other process wasteCapacity6 MWOperating Temp.1200 – 1300 ºCCombustion Chamber Dim.Ǿ 2.6 x 9.4 mCombustion AirVent Gas 6000 – 10000 kg/hr. ( Halogenated CxHy & Organics)Fuel ConsumptionNatural Gas66 – 330 Kg/hr.Melt Residues470 – 1400 kg/hr(50wt % Bromine)Spent Acid900 Kg/hrLiquid Waste50 – 300 kg/hrCapacity6 MWOperating Temp.1200 – 1300 ºCCombustion Chamber Dim.Ǿ 2.6 x 9.4 m30

Refinery - Spent Acid RecoveryIndustry: Refinery (Propylene )Application: Sulphuric Acid Recovery - WSAEPC: Haldor Topsoe ASCustomer: Ningbo Haiyue New Materials, ChinaDescription: MTBE phase out needs alkylation of propyleneStrong sulphuric acid is used as catalyst for reaction of propylene/butylene & amylene with Isobutane to getbranched paraffin alkylate.Alkylates used as oxylate instead of MTBE.These alkylate have high Octane & very low sulphur.Alkylates are used as blendstock for clean burning fuel.MTBE is water soluble & difficult to detect contamination in ground water & also is toxicCapacity3.7 MWOperating Temp.975ºCCombustion Chamber Dim.Ǿ 2.65 x 9.0mCombustion Air11000 kg/hrFuel ConsumptionNatural Gas45 – 400 kg/hr.Spent Acid400 – 4610 kg/hr.31

Specialty Chemical – SpentAcid RecoveryIndustry: Specialty ChemicalApplication: Spent Acid RecoveryCustomer: Evonic, Marl, GermanyDescription: The spent acid decomposition plant was revampedThe combustion plant consists of a horizontal combustion chamber with a front side located multi fuel burner forheating gas, sulfur and Oxo oil3 separate lances are provided for 6.1 t/h spent acid firingGas sleeve tubes provided for firing H2S gasIn the combustion chamber the spent acid and the sulfur are thermally converted into SO2 gasIn the downstream sulfuric acid is recoveredCapacity11.2 MWOperating Temp.1050 ºCCombustion ChamberDim.Ǿ 2.5 x 8.0mCombustion Air Temp.400 º CFuel ConsumptionFuel Gas970 Nm3/hr.H2S Gas1300 Nm3/hr.32

Petro-chemicals - Spent AcidRecoveryIndustry: Specialty ChemicalApplication: Spent Acid RecoveryCustomer: Evonic, Marl, GermanyDescription: Chemical Synthesis (Benzene / Toulene)MDI & TDI production for polyurethane IndustryToulene – di – isocynite manufacturing processCoke oven g

Application: Bio Gas Fired solution for Co generation Boiler: 240 TPH Biogas CV: 4200 kcal/kg. Qty: 2000 Nm3/hr per burner Scope Biogas fired solution for 240 TPH Bagasse fired Boiler Stand alone PLC based automation and Instrumentation system Biogas control station for safe o

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