International Journal of Mechanical JOURNAL OF MECHANICAL0976 INTERNATIONAL Engineering and Technology (IJMET), ISSN 6340(Print), ISSN 0976 6359(Online)

e) Volume 3, Issue 2, May-August (2012), IAEME ENGINEERING AND TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 2, May-August (2012), pp. 256-262 IAEME: www.iaeme.com/ijmet.html Journal Impact Factor (2011): 1.2083 (Calculated by GISI) www.jifactor.com

IJMET
IAEME

SURPLUS STEAM UTILIZATION-A COST REDUCTION TECHNIQUE

NIDHEESH M SEM M.TECH (IEM) MANGALAM COLLEGE OF ENGINEERING
nidheeshcngr@gmail.com 4TH

ABSTRACT The project was done in the NPL Plant, FACT, Cochin division, Ambalamedu. FACT is a leading public sector industry that manages a major part of our nations fertilizer needs. The main problem the FACT is facing nowadays is the cost of production, but the company cannot increase the price of fertilizer because of its impact on Indian farmers. The aim of the project is to reduce the cost of production. All the reactions in the sulphuric acid plant are exothermic in nature. With that, a lot of steam is produced. After meeting all the requirements, about seven tones of steam is vented off. The project is to couple a steam turbine with a Glycol pump thereby replacing the 100 KW electric motor, thus to save a huge amount of electricity charges and this electricity can be used by the public. The steam turbine is a single stage impulse turbine. KEYWORDS- STEAM TURBINE, ELECTRICITY, STEAM, GLYCOL PUMP 1. INTRODUCTION 1.1 AIM 1. Minimize the loss of the company by the proper utilization of the surplus steam (i.e. reducing the production cost). 2. Saving the power and this huge amount of power can be given to the public for their use 1.2 METHODS 1. Reduce the raw material cost. 2. Increase the price of producing component. 3. Reducing the waste. 4. Reducing the man-power. 5. Increasing the production rate.
256

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

6. Minimize the power consumption etc. 1.3 METHODS ADOPTED The method we adopted is the minimization of the power consumption by coupling a steam turbine with a Glycol pump.

2. STUDY ON STEAM TURBINES 2.1 Steam Turbine: The steam turbine is a prime mover. In that the potential energy of the steam transformed into kinetic energy and later in its turn is transformed into the mechanical energy of the rotation of the shaft. The turbine shaft, directly or with the help of the reduction gearing, is connected with the driven mechanism. 2.2 Classification of Steam Turbine: There are several ways in which a steam turbine can be classified. According to the action of the steam they are classified as., 1. Impulse turbine 2. Reaction turbine 3. Combination of impulse and reaction type 2.3 According to the number of pressure stages, Single stage turbines with one or more velocity stages usually of small power capacities; these turbines are mostly used for driving centrifugal compressors, blowers and other similar machinery. Multistage impulse and reaction turbines: they are made in a wide range of power capacities varying from small to large. 2.4 Common Type of Turbines The common types of steam turbines are; Simple impulse turbine Reaction turbine The main difference between these turbines lies in the way in which the steam is expanded while it moves through them. In the former type steam expands in the nozzles and its pressure does not alter as it moves over the blades while in the latter type the steam expands continuously as it passes over the blades and thus there is gradual fall in the pressure during expansion. 3. GEAR BOX The gearbox shall be rated for the turbine rating of 690 HP. Gearbox shall be parallel shaft, helical type. It shall be provided with separate thrust bearing. The gearbox shall be designed to run safely to the tripping sped setting of drive steam turbine. Gearbox shall be suitable for mounting on a common base plate. Suitable mounting bolts shall be provided. Gearbox will be located inside the cooling pump house of sulphuric acid plant. The environment is corrosive due to the presence of SP2, NH3 etc. Hence the material of construction should be suitable for this. Gearbox shall have a suitable contained oil lubrication system. Pressurized lubrication system, if provided shall consists of shaft driven pump, integral reservoir, oil cooler, full flow oil filter, pressure regulating valve, temperature gauge, pressure gauge, low pressure alarm/trip switches, sight flow indicators, differential pressure indicator, relief valves, piping with fittings. Cooling water supply pressure is 4kg/cm2. Supply temperature is 330c. Noise level shall not exceed 90 dB at one meter from the equipment. High-speed coupling and low speed coupling shall be supplied by the gear vendor. Coupling shall be gear type with spacer. Coupling shall have service factor of minimum 1.5 over turbine rating. Coupling shall be supplied with pilot bore.
257

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

4. HOW THE STEAM IS PRODUCED 1. A very large amount of steam is produced as bye-product or waste. 2. This huge amount of steam is produced during the manufacturing process of H2SO4. 3. The H2SO4 production is an exothermic reaction. 4. A very large amount of heat is liberated during the process. 5. The different stages of the H2SO4 production are as follows; a. First stage 1: sulphur sulphur dioxide

During this process high temperature gas is produced whose temperature is 1200c High volume of gas 120000cubic meter/hr. of gas is produced in this temperature.

b. Second stage 2: sulphur dioxide sulphur trioxide then the sulphur dioxide is converted into sulphur trioxide in which the reaction has to be carried under 450c. c. Third stage 3: sulphur trioxide H2SO4 6. At different stages of the H2SO4 production the temperature has to be brought down. 7. This can be done by using the water as the coolant. 8. 1000 ton H2SO4 is produced per day. 9. The coolant water can be used to reduce the temperature of gas. 10. The water is converted to steam when heat is absorbed and again converted to superheated steam when further absorption of heat. 11. When 1000 ton H2SO4 is produced per day, then 48 tons/hr. of steam is produced i.e., 1152 tons of steam per day. SPECIFICATION OF STEAM Pressure=38kg/cm2 Temperature=320c saturated steam.

5. PROJECT ANALYSIS In the sulphuric acid plant at FACT-CD, about 48 tones per hour of steam is generated at 37 atmospheric pressure and 3250c at 100% load. This is mainly consumed by the steam turbines of the air blower and the boiler feed water pump and to meet the low-pressure steam requirements of sulphuric acid plant and other phase two plants. Rest of the steam is vented off. The proposal is to utilize the surplus steam for driving the glycol pump in NPK plant that is presently driven by 100 KW high-tension motor. The purpose of this glycol pump is to circulate glycol through the ammonia vaporizer for vaporizing liquid ammonia and then through trickling heater for dehumidifying the air which is utilized in the NPK plant.
258

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

The steam turbine of the emergency boiler feed water pump in ammonia plant (Which is idle now) is matching the power requirement of the glycol pump. The turbine will consume 6 tones/hour of steam to drive the glycol pump. A gearbox is used to match the speed of the pump and turbine. A helical type parallel shaft speed reduction gearbox is used in this case. Steam turbine has a rated speed of 3000 rpm and glycol pump has a rated speed of 1450 rpm. In this process of manufacturing NPK fertilizer we require vaporized ammonia. Liquid ammonia (-330c) is brought into the vaporizer from the storage tank. Here ammonia is brought into coils inside the vaporizer through which glycol is circulated in the shell side. The glycol (50c) is pumped through the coils by the glycol pump from the coolant tank. The ammonia absorbs thermal energy from the glycol and gets vaporized and it is transferred to NPK plant. This cooled glycol is circulated through the coils of the trickle heater. Filtered atmospheric air which is sucked by the DH fan is brought into shell side of trickle heater. The moisture present in the air condenses and the condensed water is drained out through the drained pipe. The glycol gets heated again in this process and this taken back to the coolant tank. 6. EQUIPMENT DETAILS 6.1 STEAM TURBINE Make - Termomerccanica Italina Type - Single stage, back pressure Model - LCA Rated HP - 204 HP Rated speed 3000 RPM Trip speed - 4360 RPM 6.2 SHAFT END DETAILS Extension 100 mm Diameter of shaft 63.5 mm Diameter of shaft with key - 70.50 mm Key size 75*16*16mm CL elevation turbine shaft - 489 mm from its support Direction of shaft rotation - CCW (counter clock wise) when viewed from its coupling end. The turbine is a single stage, two-rim action turbine. Turbine and gear of this geared system turbine form one unit. After leaving the nozzle ring, the steam flows through the first blade rim of the wheel, is reversed in the reversing blades and then led through the second blade rim. It is equipped with a hydraulic trip valve. A carbon stuffing box with vapor and leakage water drains, serves to seal the turbine casing at the point of passage of the turbine shaft. The turbine shaft rotates in ball bearings lubricated by splash oil. The bearing casing has been designed as an oil container. Cooling is provided by a cooling coil incorporated into the bearing casing in such a way that a temperature of about 400c to 500c is maintained. The steam supply is automatically shut off, when the maximum admissible operating speed is reached. The oil pump is driven by the turbine through a spur gear. The single stage gear is equipped with a single helical toothing. 7. IMPLEMENT PROCEDURE 7.1. FOUNDATION 1. Proper foundation has to be created for the turbines, pipelines, gear boxes etc.
259

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

2. So that only the whole system can be perform the process in a proper aligned way. 7.2. PIPE LINE SELECTION 1. Pipe lines are one of the most important in this system. 2. Specially designed pipes have to be used as it has to pass the super-heated steam. 3. (IBR pipes) pipes which are manufactured under Indian Boiler Regulatory Act are used. 4. Ordinary manufacturing are not producing this type of pipes and ordinary pipes cant pass the super-heated steam. 5. There are many specifications for these pipes. 6. These pipes are being manufactured under govt. supervision and permission. 7. All the pipes are manufactured and fabricated under the pressure of IBR director of the state where it is produced. 8. The director will inspect each and every pipe, valves, flanges etc. separately and will certify and then only will be given to the company. 9. State govt. permission is needed for using these pipes (i. e govt. of the state where it is manufactured and govt. of state where it is used). 10. Govt. is involving in all these activities because of the safety measures. 11. Accident occurrence is very high leads to explosion, leakage etc. 7.3. TURBINE SELECTION 1. Many criteria's are followed for the selection and installation of the turbine. 2. It is done only under the rules. 3. Suitable turbines are selected whose power and speed matches with the electric motor which has to be substituted. If the speed get varied and power is same, then gear boxes can be used for attaining the required speed. 7.4. FABRICATION 1. Each and every part included in this system has to be fabricated very carefully. 2. All the pipe lines including valves, flanges, coupling, turbines etc. has to be fabricated with extreme care. 7.5. GOVERNMENT AUTHORIZATION 1. The govt. authorization is required for the working. 2. For that proper inspection regularly, availabilities of company, limitations of the company etc. will be checked. Then only the government will give the permission to run the system. 3. The company should prepare the report on the project. 4. IBR inspector in whose presence only the turbine can be started to work at first. 5. The IBR certification needed and the permission will be given for two years and then the license has to be renewed.

260

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

7.5 CAUSES OF TROUBLE AND THEIR REMOVAL Trouble Control oil pressure too low Insufficient pressure of lubricating oil Steam or oil packing of regulating and trip value untight Steam packing of turbine shaft untight Water in oil 1 Cause Filter dirty Filter dirty warm out Wear Clean filter bearings Reverse the fitter, clean the disconnected part, check bearings Tighten the gland slightly Removal

Wear

Tighten the gland spare parts Install new packing Check clearance and install new parts Balance the rotating elements dynamically Check mechanism and replace damaged parts.

Steam packing at turbine shaft untight Unsteady running Wear of bearings Rotor deformed Unbalance in rotor Emergency trip mechanism Corrosion does not release Fig. 1: Causes of trouble and their removal 8. COST ANALYSIS

Procurement of gear box : Rs. 13 Lakhs Foundation, supports & other civil jobs : Rs. 4 Lakhs Base plate, pipe, fittings & piping erection: Rs. 5 Lakhs Insulation : Rs. 3 Lakhs Contingencies : Rs. 7 Lakhs TOTAL : Rs. 23 Lakhs COST BENEFIT ANALYSIS Power : 100 KW Efficiency of the motor : 70 % Number of days : 365 days Number of hours per day : 24 Hours Unit charge : Rs. 4.20 Electricity charge, Q charge = Power x Number of days x Number of hours x Unit x Efficiency = 100 x 365 x 24 x 4.20 x 0.70 = Rs. 26 Lakhs Payback Period = 11 Months 9. CONCLUSION The aim of the project was to save a large amount of electricity thereby reducing the production cost in the NPK plant, FACT Cochin Division, Ambalamedu. Even though the initial cost is high, the money spend on the project would be regained within eleven months of successful plant running. About 26 lakhs of rupees is saved every year, by the implementation of this project.

261

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

10. REFERENCE 1. www.howstuffworks.com 2. www.fedo.com 3. www.wikipedia.com 4. www.termomeccanica.com 5. Termomeccanicca turbine manual 6. Plant manual, NPK plant, FACT-CD 7. Thermal engineering, R.S.Khurmi 8. Startup equipments manual, FACT-CD

262