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PROJECT SUBMITTED FOR PARTIAL FULFILMENT OF THE REQUIREMENT Under Presented Guidance By: of:

Project Report on DOJ Training


DOJ TRAINING COMPLETION

Shri S Konda P.P.Singh Reddy

FOR THE

(DGM, Srinivas Chemistry) R Abhishek Das

ACKNOWLEDGEMENT

Learning embodied in this project entitled Project Report on DOJ Training was initiated in 23rd January 2012, at Sipat. A brief description of nature of the learning has been delineated in the introduction. In these small efforts of us, first of all we would like to express our deep gratitude to our revered Shri P. P. Singh (DGM, Chemistry). We feel extreme pleasure in expressing our deep sense of gratitude to him for his constructive and valuable suggestions, active cooperation throughout the learning. Also we are much grateful to Shri P Mohapatra (GM I/C, NTPC Sipat), Shri Rakesh Samuel (GM O & M, NTPC Sipat), Shri R C Kamath (AGM, Operation, NTPC Sipat), Shri V Chandrasekharan (Sr. Manager, Chem.), Shri GBP Srivastava (Sr. Manager, Chem.), Shri R C Shyam (Sr. Manager, Chem.), Shri K K Rao (Sr. Manager, EMG), Shri K Satyanarayana (Dy. Manager, Chem.), Shri N K Roy (Dy. Manager, Chem.). We are thankful to Shri Dilip Mishra, Shri Durgesh Lohiya, Shri Pranav Dogra, Shri Swarup Khan, Shri Ghanshyam Singh, Shri Abhishek Anand, Shri Vikas Aggrawal, Shri Vijay Verma, Shri Shyam Bihari Gupta, Shri S K Modi for their co-operations whenever we needed. We are also thankful to Deptt. of Chemistry & Deptt. of HR-EDC (NTPC Sipat). In fine, we dedicate this project report to the honour of our beloved parents.

Sipat Super Thermal Power Station, NTPC Ltd. Sipat, Bilaspur, Chhattisgarh

S Konda Reddy Srinivas R Abhishek Das

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POWER PLANT CHEMISTRY


INTRODUCTION:
One of the factors which distinguish the NTPC stations from State Electricity Boards is role & importance of Power Plant Chemistry. Whether we compare number of tube leakages, availability factor, heat rate etc., the performance of NTPC stations is always above than other utilities/ boards. It is necessary to give importance to power plant chemistry. The cost to power plant from corrosion and deposition is high; fifty percent of power plant maintenance cost is due to corrosion. One half of the unit forced outages are some way related to water/ steam side corrosion. The life of power plant is affected by corrosion. The deposit of various contaminants affect the heat transfer induces corrosion and reduces overall efficiency. It is the involvement of chemistry which minimizes the loss due to corrosion & deposition. Besides the treatment of available raw water it is the chemistry which gives solution to reuse effluent and various discharge of power plant. This role is significant in areas where availability of raw water is less. Now a days environment is one area where stringent norms have been adopted by Government. We have to decrease the level of emission, utilize the ash, maintain the quality of effluent etc. It is the chemistry which helps in reduction of emission by conditioning of coal, flue gas desulphurization and carbon sequestration etc. The role of chemistry is thus vital for power plant. The areas where chemistry plays a key role are: Water treatment Operation & maintenance Quality of coal & Oil Environment

WATER TREATMENT:
It is the key area of chemistry related activities. It involves: A. PRETREATMENT: Pre-treatment is the first stage of water purification. The importance of pre-treatment increases due to day by day deterioration of water quality and also during rainy season.
B. DEMINERALIZATION:
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Demineralization is the second stage of water purification. It involves the removal of TDS by ion-exchange process.

C. CONDENSATE PURIFICATION: The corrosion product accumulated in water steam cycle need to be removed to avoid their deposition on heat exchange surfaces. Also any cooling water ingress to water steam cycle is to be treated. For this Condensate Polishing Units are provided.

OPERATION AND MAINTENANCE:


It is the chemistry which decides operational parameters of water & steam cycle, use of chemicals during shut down conditions, procedure for initial cleaning of boilers, control of cooling water quality etc.

QUALITY OF COAL & OIL:


The quality control and characterization of fuel is the area where chemistry plays vital role. Proximate & ultimate analysis of coal, calculation of gross calorific value & useful heat value of coal, lubricating oil/ transformer oil analysis etc. are the areas where chemistry is involved.

ENVIRONMENT:
Chemistry is mainly involved in maintaining the norms or standards laid down by the Government. It is involved in flue gas analysis, conditioning of coal, effluent treatment etc. The above mentioned aspects are important to enhance the availability and life of power plant. Also there is need to enhance further the role of chemistry in power plant in national interest as natural resources cant be increased but role can be increased.

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RAW WATER MAKEUP PUMP HOUSE: The raw water is coming from the Right bank canal of Hasdeo Barrage by a canal up to Hardivishal where a raw water make pump house is constructed. From the pump house water is pumped by four (04) pumps in two pipelines of 1400mm dia. Water from the raw water pump house is received to the reservoir number-I. There are three interconnecting reservoir for stage I and II. But presently water is stored in only one reservoir. From that water is pumped to both St-I and St-II. Max. Water level = 280.5m (Sea level) Top of embankment = 282.0m (Sea level) Bed level = 272.0m. (Sea level) Total Height = 10m Water level = 8.5m Total area covered = 17500 m2

Fig: RAW WATER LINE


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RAW WATER ANALYSIS:

Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Constituent(as CaCO3) Calcium Magnesium Sodium Potassium Total cations Bicarbonates Carbonates Nitrares Chlorides Sulphates Total anions Silica Iron PH value (no units) Turbidity

Amount/Value(ppm) 26 14 25 0 65 40 0 0 8 17 65 11 1 7.6-8.2 700NTU(Max.)

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16

Organic matter

CLARIFIED WATER ANALYSIS:

Sl.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Constituent(as CaCO3) Calcium Magnesium Sodium Potassium Total cations Bicarbonates Carbonates Nitrares Chlorides Sulphates Total anions Silica Iron PH value (no units) Turbidity Organic matter

Amount/Value(ppm) 51.2 14 25 0 90.2 35.7 0 0 15 39.5 90.2 11 0.3 6.8-8.0 20NTU(Max.)

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0.05

RAW WATER PUMP HOUSE

MCC
TRANSFORMER

CLARIFIER (DM)
OH T

CASCADE AERATOR
CHEMICAL

CLARIFIER (POT)

GSF

SUM P

HOUSE

SLUDGE PIT

BW PIT

CLARIFIERA

FILTER WATER ANALYSIS:


CASCADE Same as clarified water except that the turbidity shall be about 2.0 NTU. AERATOR

DOJ Report of ACT Batch-2011

CLARIFIERB

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Fig: PT PLANT, STAGE-I

AERATOR:

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Aeration is a process, which brings water into close contact with air to expedite transfer of a gas between the two phases. [Air] O2 (free) O2 (Dissolved) [Water]

FACTORS AFFECTING GAS TRANSFER PROCESS: Gas transfer depends upon following factors: Relative concentration or partial pressure difference. Rapidity with which new surfaces are formed & exposed to air to maintain a concentration gradient of the concerned gas so that equilibrium is not reached. Volatility characteristics of organic substances PH of water depending on nature of gas Temperature of water. PURPOSE SERVED BY AERATION: Volatile organic contaminants like methane, ethane, ethylene etc, & dissolved gases (CO2, H2S, NH3 etc.) are reduced, which are thought to be contributing to odour & taste. It is cheap and valuable means to controlling taste, odour & corrosion. Aeration removes soluble Fe(II) & Mn(II) compounds to a great extent through oxidation that produces insoluble oxides or hydrated oxides. 4 Fe II + O2 + 10 H2O 4 Fe (OH) 3 + 8 H+

2 MnII + O2 + 2 H2O 2 MnO2 + 4 H+ Oxygen dissolved in this process also removes H2S through oxidation. 2 H2S + O2 2 H2O + 2 S Carbon dioxide Calcium bicarbonate equilibrium is also distributed due to stripping out of Carbon dioxide. Ca(HCO3)2 CaCO3 + H2O + CO2

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CHLORINE GAS DOSING:

Chlorine is used for oxidation in the gaseous stage. It also has the bactericidal properties. In common practice, chlorine and sodium hypochlorite solution are widely used for the process of oxidation.

Chlorine cannot be used directly in its gaseous state. It is first dissolved in water. It reacts in water according to the reactions given below.

Cl2

H2O

<=====>

HOCl +

HCl

HOCl

<=====>

OCl-

H+

The above equilibrium is pH dependent.

At pH below 2, all chlorine is in molecular form At pH below 5, all chlorine is in the form of Hypochlorous acid (HOCl). At pH below 10, all chlorine is in the form of hypochlorite ion OCl -. The bactericidal effect of chlorine is maximum when chlorine is in the form of hypochlorous acid. The oxidising action is best in the form of hypochlorite ion.

Thus chlorine brings about the oxidation of organic matter as well as iron and manganese. With the necessary pH conditions the ferric hydroxide floc formed can be flocculated.
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Chlorine reacts with ammonia and compounds containing ammonium salt according to the following reactions. HOCl + NH3 NH2Cl + H2O monochloro amine

HOCl + NH2Cl NHCl2 + H2O

dichloro amine

HOCl + NHCl2 NCl3 + H2O

trichloro amine

NH3 + NCl3 N2 + 3 HCl

The overall reaction is: 3 HOCl + 2 NH3 N2 + 3 HCl + 3 H2O

STILLING CHAMBER: After the aerator, water is collected in stilling chamber. Here, chlorine is injected into raw water generally at the rate of 2.5 mg/l. This is not only destroying high bactericidal count, but also oxidises and precipitates Iron & Manganese, kills algae, reduces colour and slime formation and generally assists settlement. After the stilling chamber, water goes through flume and then enters into the reactor clarifier through inlet cum draft chamber.

REACTOR CLARIFIER: After treating with the chlorine, goes to the reactor clarifier through flume and inlet cum draft chamber. The clarifier is a circular RCC structure. It consists of a central zone, which contains motor driven impeller and helps to mix the chemical. The Alum and Lime are added directly to this zone. It also contains the sludge scrapper at the bottom of the clarifier, which helps to collect the sludge to dispose from the centre of clarifier by gravity to the sludge pit. After mixing, it goes to the flocculation zone. Where the colloidal particles gets neutralize with the alum and coagulate to form the larger particle.
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Then the water starts the upward journey in the clarifier zone where it gets entrapped into the sludge blanket, which is formed due to the impeller action on the sludge. Denser and bigger particles get settled in the bottom and the clear water then passes to the radial launders and come out through the outlet channel.

There is provision of bypassing either DM clarifier or Potable water clarifier or both for maintenance or if the turbidity of the influent raw water is within range of 20NTU

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COAGULATION: The coagulation-flocculation processes facilitate the removal of suspended solids, turbidity and colloids.

Suspended solids of sand and gravel of size greater than 1mm settle rapidly in water. Clay -like material of the size of a few microns take time to settle. While colloids which refer to particle size in the submicron range cannot settle naturally and so the process of coagulation - flocculation brings about the settling of these substances to effect their removal. Trivalent aluminium and iron salts are widely used in all water coagulation treatment. The hydrolysis of inorganic coagulants results in the formation of insoluble metallic hydroxide causing the production of a substantial amount of sludge. This sludge is removed in the final solid-liquid separation process.

The basic reaction when Al+3 ions are added to water is the formation of a precipitate of aluminium hydroxide with the release of some acidity. Al+3 + 3H2O Al(OH)3 + 3H+

This acidity reacts with the bicarbonate ions in water. HCO3 - + H+ H2O + CO2

The acidity can be neutralized also by adding the coagulant with a base (caustic soda, lime, sodium carbonate).

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Al+3 + 3OH

Al(OH)3

IRON SALTS: Fe2 (SO4)3. 9H2O The reaction principle is the same as for aluminium salt Fe+3 + 3 H2O Ferric Sulphate: Fe2 (SO4)3 + 6HCO3 - Fe (OH)3 + 3SO-2 + 6CO2 Fe (OH)3 + 3H+

GRAVITY FILTERS: There are two gravity filters (in twins) for each potable water and DM water. The filter box are of water tight RCC structure. Each filter is divided into the two parts and there are two collecting header. Each Header is connected to the nos. of pipes which have the small holes to enter the filtered water. The same distribution/ collection system is used for the air scrubbing and back purpose. The clear water from the clarifier enters into the inlet channel. From the inlet channel it overflow into the filter bed which is made up of six layers of sand/ gravels size ranging from 0.68mm to 60mm.While going down the bed it get cleaned by entrapping the suspended particle in the voids in the bed and clear water having turbidity 2 NTU comes out into the clarified storage tank from where it goes to clarified water sump. FILTER BACKWASHING: The inlet distribution and under drain collecting system shall be so designed as to give uniform distribution and flow without channelling and obstruction. The water used for backwashing is the filtered water supplied from the overhead tank over chemical house. The capacity of the overhead tank is 300m 3 minimum/ or 1.5 times of water required for complete backwash of one filter (both sections). The water rushes into the gravity filter from the bottom of the filter through the gravels and sand bed. It makes the bed loose and fluidized and removes the mud and silt accumulated in the gravity filter making it ready for the service. FILTER WATER SUMP CUM PUMP AREA:

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PT-DM SYSTEM Filtered water from the two section of the filtered water reservoir shall enter the sump through two numbers of isolation valves. Filtered water from the sump shall be pumped by Filtered water pumps to DM plant. PT POTABLE SYSTEM Filtered water from two sections of filtered water reservoir shall enter the sump through two numbers of isolation valves. Filtered water from the sump shall be pumped by means of Potable water pumps to Colony and plant and for filling the overhead filtered water tank. OVERFLOW AND DRAIN DISPOSAL SYSTEM: The overflow and drains from the various chemical tanks and floor water drain from chemical house building (except overflow from O/H filtered water storage tank) be led to the PT Plant clarifier sludge sump. The overflow and drains from structures and piping handling clear raw water clarified water and filtered water in the pre-treatment plant such as stilling chamber, Filtered water reservoir, filtered water sumps etc shall be led to the backwash sump.

PT-PLANT CLARIFIER SLUDGE DISPOSAL SYSTEM: One number of sludge pits, in twin section shall be provided to collect the sludge from all the clarifiers periodically. The sludge shall be transferred to the Ash Slurry sump by means of sludge transfer pump. Each section of the pit shall be provided with agitation by recirculation from sludge pump discharge system and air agitation system. The gravity blowers are used for the air agitation system of the sludge. COOLING WATER SYSTEM: At Sipat, cooling water is the clarified water. Cooling water system is the open recirculation type with COC 5. The cooling towers are induced draft type. For cooling water system, a common cascade aerator is provided. The Raw water coming from the raw water pump house goes to aerator where dissolved gases like Ammonia, Hydrogen sulphide etc. get removed. It also helps to reduce the iron and manganese by precipitation as their hydroxides. In the stilling chamber, chlorine dosing is done for the disinfection of water and finally it goes to the clarifier through the inlet cum draft chamber. There are two SOLID CONTACT REACTOR CLARIFIER of 2400 m 3 Capacity. The cooling water is stored in the clarified water storage tank in two sections with clarified water sump of total capacity 600 m3.

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CLARIFIED WATER: The CW makeup is given in the cold-water trench. Water goes to the trench by gravity.

TECHNICAL SPECIFICATIONS OF PRE-TREATMENT PLANT:

(A) FOR AERATOR & CLARIFIER:

Sl. No.

Description

PT-CW System

PT-DM System

PT-Potable System

1.

AERATOR (i). Type (ii). Number (iii).Design flow Cascade Type 1 6180 m3/hr. Cascade Type 1 278 m3/hr. Cascade Type 1 370.8 m3/hr.

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2.

STILLING CHAMBER (i). Number (ii).Design flow (iii). Drain from stilling chamber to sludge sump 1 6180 m3/hr. By gravity 1 278 m3/hr. By gravity 1 370.8m3/hr. By gravity

3.

INLET CHANNEL (i). Number (ii). Design for each channel flow 2 3090 m3/hr. 1 278 m3/hr. 1 370.8 m3/hr.

4.

CLARIFIER (i). Number (ii). Design for each channel flow (iii). Type 2 3090 m3/hr. Circular reactor (RCC Type) 1 278 m3/hr. Circular reactor (RCC Type) 1 370.8 m3/hr. Circular reactor (RCC Type)

(B). FOR GRAVITY FILTERS:


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PT-DM System 1. 2. 3. 4. 5. 6. Type No. of filters Design flow per gravity filter Maximum flow per gravity filter Surface medium Back washing: (a). Quality water (b). Source 7. Air scour Blower (a). Number blower of 03 of Filtered water O/H Tank (On Chemical house) Duplex 3 135 m3/hr. 135 m3/hr.+ 3 % Sand

PT-Potable System Duplex 3 180 m3/hr. 180 m3/hr. + 3% Sand

Filtered water O/H Tank (On Chemical house)

(b). Capacity & head

1800 m3/hr. @ 0.4 ksc (each)

FILTER WATER RESERVOIR:

PT-DM System 1. 2. Number Effective capacity One (1) section 150 m 3 in three

PT-Potable System One (1) in three section 150 m 3

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[D]. OVERHEAD FILTERED WATER STORAGE TANK: (i). Number: 01 (ii). Capacity: 300 m3 (minimum)

[E]. BACKWASH WATER PIT & PUMPS: (PT-DM & Potable Water Back Wash Water Pit: (i). Number: One in two sections (ii). Effective capacity: 250 m3 (min) (Total of both section) System)

Backwash Sump: Number: One (1)

Backwash Water Pumps: Number: 3 (2W+1S) Capacity: 40 m3/hr. @ 12.5 mmwc

[F]. SLUDGE PIT & SUMP PUMP AREA: Common for all clarifiers. Sludge Pit: Number: 2

Sludge Sump: Number: One (1)

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Sludge Pump: Number: Three (2W+1S) capacity: 100 m3/hr. @ 19mmwc

[G]. CHEMICAL HOUSE: a) Lime Slaking Tanks: (i). Number: 2 (ii). Capacity: 30 m3 @ 10% w/v strength. b) Lime Solution Preparation Tanks: (i). Number: 4 (ii). Capacity: 20 m3 @ 6% w/v strength.(each) c) Lime Slurry Transfer Pumps: (i). Number: 2 (1W+1S) (ii). Capacity: 15 m3/hr. @ 10 mmwc d) Lime Dosing Pumps: Common to PT-DM, CW & potable. (i). Number: 2 (1W+1S) (ii). Capacity: 36 m3 /hr @ 15 mmwc e) Alum Solution Preparation Tanks: (i). Number: 4 (ii). Capacity: 30 m3 at 10% w/v strength. (each) f) Alum Dosing Pumps: (i). For PT-CW System: 3 (2W+1S) Capacity: 2900 lph @ 5 ksc (ii). Common for PT-DM & PT-Potable: 2x100% (1W+1S) Capacity : 600 lph @ 10 ksc (iii). Tube Settler/ Lamella Clarifier: 2x100% (1W+1S) Capacity: 300 lph @ 10 ksc

[H]. HORIZONTAL PUMPS: a) HVAC Makeup Pumps:


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(i). Type: Horizontal centrifugal (ii). Number: 2 (1W+1S) (iii). Capacity: 150 m3 /hr (iv). Head: 70 mmwc (v). Operation Speed: 1500 RPM (max.)

b) Service Water Pumps: (Service water pump area) (i). Type: Horizontal centrifugal (ii). Number: 3 (2W+1S) (iii). Capacity: 400 m3 /hr (iv). Head: 80 mmwc (v). Operation Speed: 1500 RPM (max.)

c) APH Wash Pumps: (Service water pump area) (i). Type: Horizontal centrifugal (ii). Number: 2 (1W+1S) (iii). Capacity: 400 m3 /hr (iv). Head: 80 mmwc (v). Operation Speed: 1500 RPM (max.)

d) Lubrication Water Pumps For Raw Water Pump: (i). Type: Horizontal centrifugal (ii). Number: 3x100% for each raw water pump
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(iii). Capacity: 18 m3/hr. @ 60 mmwc (iv). Operating Speed: 3000 RPM (max.)

(I) WASTE SERVICE WATER TREATMENT SYSTEM: Waste service water pump = 3 Nos. Capacity: 250 m3/hr @ 15mmwc (each) (a) Treated Service Water Transfer Pumps: (i). Type: Horizontal centrifugal (ii). Number: 3 (2W+1S) (iii). Capacity: 275 m3 /hr (iv). Head: 30 mmwc (v). Operation Speed: 1500 RPM (max.)

(b) Waste Service Water Collection Sump: (i). Number: One (1) in two sections (ii). Effective Capacity: 500 m3/hr. (Total of two sections)

(c) Treated Service Water Collection Tank (Over ground): (i). Number of Section: One (1) (ii). Effective Capacity: 150 m3 (min.) (Total of two sections)

(d) Lamella Clarifier/ Tube Settlers: (i). Number: One (1) in each section (ii). Capacity: 250 m3 /hr each
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(iii). Minimum Storage Capacity of Flash Mixer: For 1 min. at designed flow rate (iv). Tube settler Sludge: To be taken to common sludge sump of PT plant

[J]. CENTRAL MONITORING BASIN (CMB): (i). Number of Chambers: Two (twin compartment) (ii). Effective Capacity: 300 m3 (Total twin compartment & sump)

[K]. COAL HANDLING PLANT:


a)

Coal Handling Plant Run Off Water Treatment Scheme: Coal decanted water pump : 02

b) Coal Slurry Settling Plant : ( Twin compartment) (i). Size of each pond : 40m X 8m X 4.7m effective depth (ii.) Number of ponds : 02 c)

Coal Decanted Water Sump: (i). Capacity : 150 m3/hr (ii). Number of compartments : 01

d) Poly- Electrolyte Solution Preparation Tanks: (For CHP run off water treatment) (i). Quantity : 02 nos. (ii) Capacity : 1m3/min.

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De Mineralisation Plant (Sipat STPS Stage-I, 3x660 MW)


Equipment and systems in DM Plant DM Stream Section Filter Water Pumps Activated carbon Filters with all necessary equipments Strong Acid Cation Exchange units with all necessary equipments Weak Base Anion exchange units with all necessary equipments Strong Base Anion exchange units with all necessary equipments Mixed Bed exchange units with all necessary equipments Degasser units Blowers for each degasser units DM water storage tanks (With capacity of 2500m3 each) DM plant pump house section DM make-up pumps Boiler fill pumps DM water regeneration pumps DM Stream Regeneration section Acid storage tanks (common for Stage-I & Stage-II) Alkali storage tanks (common for Stage-I & Stage-II) Acid unloading pumps (common for Stage-I & Stage-II) Alkali unloading pumps (common for Stage-I & Stage-II) Alkali Preparation Tanks Alkali transfer pumps Alkali filter Alkali measuring tanks Hot water Tank Acid measuring tanks Safety Shower Effluent treatment section (Neutralisation Pit) Neutralisation pit Priming Tanks
DOJ Report of ACT Batch-2011

: 3 Nos. : 2 Nos. : 2 Nos. : 2 Nos. : 2 Nos. : 2 Nos. : 2 Nos. : 2 Nos. : 2 Nos.

: 4 Nos. : 2 Nos. : 2 Nos. : 4 Nos. : 2 Nos. : 2 Nos. : 2 Nos. : 2 Nos. : 2 Nos. : 1 No. : 2 Nos. : 1 No. : 2 Nos. : 1 No. : 2 Nos. : 2 Nos.
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Lime Tank Effluent transfer pump

: 1No. : 3 Nos

MCC Room Stage -I

Control Room, Lab, Office.

AC F Degassed water pumps Degas ser Blower s SA C

Alkali (NaOH) Storage tanks Acid (HCl) Storage tanks

Alkali Unloadin g pumps

Degasser towers

Acid Unloadin g pumps

WB A SB A MB MB Blowers 7 8 1 2 3 4 5 6 9 1 0 1 Acid Measuring tank (for SAC) 2 Acid measuring tank (for MB) 3 Hot water tank 4 Alkali measuring tank (for SBA) 5 Alkali measuring tank (for MB) 6 Alkali filter 7 Alkali preparation tank 8 Alkali preparation tank 9 Alkali transfer CPU pump 10 Alkali transfer pump

Primin g tanks Effluent transfer Pumps

Neutralisati on Pit

DM stream Regeneration House (Stage-I) Lim e Tan k

Stage-I

DM Plant pump house (Stage-i)

To Unit # 1, 2 &3 (Stage-I)

Boiler Fill Pumps DM make-up pumps

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of ACT Batch-2011

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DM regeneration pumps

Activated Carbon Filter :( ACF) There are two ACFs in Stage-I DM Plant with anthracite fills which remove chlorine, odour and organic substances by adsorption phenomenon. Specifications: Fill activated carbon (Bed depth not less than 1200 mm excluding supporting material). Net output between two backwashes Total surface area (min) Particle density Iodine number Particle length For needle/ cylindrical type For granular type : 202-2.4 mm : 4-16 mesh : 3240 m3 : 850 m2 : 1.3-1.4 : 1000

Parameter at the outlet of ACF Residual (Free) chlorine Organic matter Turbidity : Nil : Below detectable limit : <0.5 NTU

Ion Exchange: Ion exchange is reversible exchange of ions between a solid and a liquid phase. In DM plant solid phase used for demineralising is ion exchange resins. These resins are made of porous hydrocarbon solid phase (mostly cross linked poly styrene) with an ionic charge
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either positive or negative in conjugation with free oppositely charged ions that can be displaced by similar ions. Solid phase must have robust structure and should be chemically insoluble and inert.

Demineralisation: Demineralisation (also known as deionisation) of water results in removal of all minerals in water. The process uses cation resin In H+ form for the removal of cations and anion resin in OH- form to remove anions. There are two basic types of demineralisation. a. Two bed b. Mixed bed Also there are several extensions depending on the chemistry of raw water. Here in Stage-I combination is:

SAC-Degasser-WBA-SBA-MB

This combination is chosen by analysing the quality of raw water used here. Strong Acid Cation exchanger: (SAC) In SAC resins are with sulphonic acid (SO3H) group which provides H+ ion for exchange when influent water comes in contact with resin. The reactions occur as shown below:
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Ca (HCO3)2 (l) +
Temporary hardness

2ZH(s)

CaZ2(s) +
Exhausted Resin

2H2CO3 (l)
Carbonic Acid

Regenerated Resin

MgCl2 (l)
Permanent

+ 2ZH (s)
Regenerated Resin

Mg Z2 (s) +
Exhausted Resin

2HCl (l)
Free mineral Acid

Na2SO4 (l)
Neutral

+ 2ZH (s)
Regenerated Resin

2NaZ(s) +
Exhausted Resin

H2SO4 (l)
Free mineral Acid

Carbonic acid dissociates into CO2. H2CO3 (l) H2O (l) + CO2 (g)

Specifications: o Number of stream o No. of unit per stream o Designed flow per stream : 2 : 1 : 135 m3/Hr

o Net output between two successive regeneration: o Designed surface flow rate at designed flow: 35m3/m2/Hr (max) o Resin Type : Polystyrene resin in bead form with sulphonic acid (SO3H) group o Regeneration reagent o Resin bed depth : 4% Hydrochloric acid (HCL) : 1500 mm

Degasser System: Degasser system comprises of degasser tower, degassed water storage tank, degasser blowers and degassed water pumps. In degasser, water carbon dioxide is removed by blowing air (water and air in counter flow with each other) through blowers. Carbon dioxide is produced from carbonic acid generated in SAC exchange unit. Thus degasser unit reduces the load on strong base anion exchange (SBA) unit.
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Specification: i. ii. iii. iv. v. Number Type Normal flow rate Fill Material CO2 content in effluent :2 : Forced draft type : 135m3/Hr : Polypropylene or equivalent : max. 5ppm

Degassed water storage tank: i. ii. iii. Type ends Number Capacity : Horizontal atmospheric type with dished :2 : 50 m3

Degasser blowers: i. ii. iii. Number for each degasser tower Capacity (each) Speed :2 : 100% requirement of one tower : max 1500 rpm

Weak Base Anion exchanger: (WBA) Weak base anion exchange resin contains tertiary amine groups. It removes free mineral acidity such as HCl and H2SO4, but does not remove weakly ionized acids such as silicic acid and carbonic acid. A main advantage of WBA exchanger is that they can be regenerated with small amount and, therefore, it is much more efficient. These have a higher capacity for removal of chlorides and sulphates. These are used in conjugation with SBA in demineralization system to reduce regeneration cost and to attract organics, thereby protecting the more susceptible SBA resins.
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H2SO4 (l) HCl (l)


Free mineral acid

+ ROH (s) + 2ROH (s)


Regenerated resin

R2SO4 (s) + H2O (l) R2SO4 (s) + 2 H2O (l)


Exhausted resin Decentralized Water

SPECIFICATIONS: Number of Stream No of unit per stream Design flow per stream : Two : One : 135m3/HR : max 35m3/m2/Hr

Design surface flow rate at design flow Resin bed depth: 850mm

Resin type: Weak base, high capacity polystyrene resin in bead form

STRONG BASE ANION EXCHANGER: (SBA) SBA resins derived their functionality from quaternary ammonium exchange sites. These are capable of exchanging anions like Cl-, HCO32- & silica. Two types of SBA resins are commercially available and commonly referred as Type-I & Type-II. H2SO4 (l) HCl (l) Free mineral acid CO2 (l) + + + ROH (s) 2ROH (s) Regenerated resin ROH (s) Regenerated resin ROH (s) R2SO4 (s) + R2SO4 (s) + H2O (l) 2 H2O (l)

Exhausted resin Decentralized Water RHCO3 (s) exhausted resin RHSiO3 (s)
Page 31

Carbon dioxide SiO2 (l) +

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Silica SPECIFICATIONS:

Regenerated resin

exhausted resin

Number of Stream No of unit per stream Design flow per stream

: Two : One : 135m3/HR

Net output between two consecutive regeneration and period : 3000 m3 Design surface flow rate at design flow : max 35m3/m2/Hr Resin type: Strong Base, Type-I, high capacity polystyrene resin in bead form. Resin bed depth : 1000mm

MIXED BED UNIT: Mixed bed unit consist of SAC and SBA resins intimately mixed in the same unit to bring about demineralization. In effect it is multiple two bed decentralizing pairs resulting in very high quality of DM water. The SAC resin is in hydrogen form and the SBA resin is in the hydroxide form. The reactions of the SAC & SBA resins in service are the same as for two- bed demineralization process. The multiple contact of water with SAC & SBA provides a polishing action yielding extremely pure DM water of conductivity less than 1S/cm and silica 0.02mg/ml.

SPECIFICATIONS:

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Number of Stream No of unit per stream Design flow per stream

: Two : One : 135m3/HR

Net output between two consecutive regeneration : 14580m3/108Hrs Design surface flow rate at design flow : max 40m3/m2/Hr Resin type : Strongly acidic & strongly basic type-I, both the resin shall be of high capacity polystyrene resin in bead form. Total resin bead depth : (500+500= 1000)mm

DM WATER TANK: DM water tank is used for DM water storage. There are Two DM tanks (1& 2) for Stage-I, having interconnection with each other and also with tanks 3 & 4 of Stage-II.

SPECIFICATION: Height Capacity Inside protection : 12.28m : 2476 m3 : Solvent free epoxy coating

Vent with CO2 absorber: At Ground level.

PARAMETERS OF DM WATER: Silica pH : 0.01ppm (maximum) : 6.8 - 7.2

Conductivity : < 0.1 S/cm Iron : Nil

Total Hardness : Nil Dissolved Oxygen : Maximum 7ppm

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MAIN PLANT CHEMISTRY


Continuous monitoring of water-steam cycle is very important for 660 MW units as the parameters for these units are more stringent than for 500 MW units. Analysis of different parameters of condensate, feed water, boiler water and steam is done to take corrective actions if required. Beside it hydrogen gas purity and its dew point analysis, testing of stator cooling water of

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generator, pH analysis of equipment cooling water & flue gas analysis are also done. The boilers in 660 MW units are supercritical drum-less boilers.
Feed Steam-water Water

cycle in

Economiser these I/Lunits is different

Economis Economis er from that of subcritical units. er Hanger

The steam-water cycle for supercritical 660MW unit is given below: evaporators Hanger O/L Lower
(water walls) Header Header

Spiral

Furnace

Economiser

Vertical evaporators (water walls)

Separat or

Furnace roof I/L Header

BWRP

Storag e Tank

Furnace roof

Back pass wall Feed Water Heater System

Divisional panel Super heater

CEP s Platen Super heater Condenser -1 LP Turbine 1 Condense r-2 LP Turbine 2

Final Super heater

IP Turbine Hot Reheat Steam (HRH) 5680C, 47 Final KSC RH

Main Steam 5400C, 255 KSC Cold DOJ Report of ACT Batch-2011 Page 35 Reheat Steam Low Temp. HP (CRH) Reheater

KSC

Samples are taken from various locations like Economiser I/L (for feed water), Separator storage tank, Separator O/L, Main Steam, HRH, CEP discharge i.e. condensate to check boiler steam-water parameters for possible corrective measures. Chemical control limits of various parameters of different systems in 660 MW units are given below:

WATER-STEAM CYCLE: In supercritical 660 MW units the limits of different parameters are given below:

During Start-up
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During Oxygenated Treatment

Sample Name

pH

Sp. Conductivity (S/cm)

ACC (S/cm)

Silica (ppb)

Hydrazine (ppb)

Sodium (ppb)

Iron (ppb)

DO (ppb)

Feed Water

9-9.2

4-4.5

<0.3

<20

<40

<10

<20

<7

Main steam

9-9.2

4-4.5

<0.2

<20

--

<10

<10

--

HRH

9-9.2

4-4.5

<0.2

<20

--

<10

<10

--

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Beside these chemical monitoring is also done for Generator stator cooling
Sample Name pH Sp. Conductivity (S/cm) ACC (S/cm) Silica (ppb) Hydrazine (ppb) Sodium (ppb) Iron (ppb) Chlor ide (ppb) DO (ppb)

Feed Water

8-8.5 8-8.5

1-2 1-2

0.15 <0.15

20 <20

---

-<2

-5

-<2

30150 --

Main steam

CEP Discharge

8-8.5

1-2

<0.15

20

--

--

--

--

30150

water (Primary water) and generator hydrogen system.

Generator system: Primary Water (Stator Cooling Water): Parameters 660 MW

pH at 250C Sp.Conductivity at 250C, S/cm Dissolved Oxygen (DO), ppm

6.5- 8.5 < 3S/cm > 2ppm

Generator Hydrogen System: Parameters H2Purity (%) Dew Point (0C) at frame pressure 660MW >98 Not less than -11C

IMPORTANT TESTS IN MAIN PLANT:

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1.

LOW SILICA ANALYSIS (CONDENSATE, FEED WATER, STEAM): Take 100 ml of the sample + 2 ml of acidified ammonium molybdate, wait for 5

minutes and then add 4 ml of oxalic acid. Wait for 5 minutes and then add 1 ml of ANSA (1-Amino Naphthol Sulphonic Acid) and wait for again 5 minutes. Solution becomes of blue colour. Now record its absorbance in spectrophotometer at 815 nm, which indirectly gives the value of its concentration.

2.

HIGH SILICA ANALYSIS (BOILER WATER): Take 50 ml of the sample + 2 ml of acidified ammonium molybdate, wait for 5

minutes and then add 4 ml of oxalic acid. Wait for 5 minutes and then add 1 ml of ANSA (amino naphthol sulphonic acid) and wait for again 5 minutes. Solution becomes of blue colour. Now record its absorbance in spectrophotometer at 815 nm, which indirectly gives the value of its concentration. 3. PHOSPHATE ANALYSIS (BOILER WATER): Take 25 ml of sample + 25 ml DM water + 2 ml sulpho ammonium molybdate and wait for 5 minutes. Then add 0.2 ml SnCl2 and wait for 5 minutes. Solution becomes of blue colour. Now record its absorbance in spectrophotometer at 690 nm, which indirectly gives the value of its concentration.

4.

RESIDUAL HYDRAZINE ANALYSIS (FEED WATER): Take 50 ml of sample + 4 ml of PDAB (para dimethyal amino benzaldehyde) &

wait for 5 minutes. . Solution becomes of yellow colour. Now record its absorbance in spectrophotometer at 455 nm, which indirectly gives the value of its concentration.

5.

DISSOLVED OXYGEN ANALYSIS (CONDENSATE, FEED) Range: (0-100ppb)

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Take 20 ml of Indigo carmine solution +5 ml of KOH which gives yellow Colour. It is filled fully in a small tube present within a large tube and covered by a round glass ball .Sample is inserted in larger tube very slowly without disturbing smaller tube containing alkaline indigo carmine solution. When it is completely filled, it is immediately stoppered. Then larger tube is inverted for proper mixing with alkaline indigo carmine solution. Colour developed in the sample give the value of dissolved O2 present in the sample. Colour Yellow Orange Orange-pink Pink Pink-red Red-purple Purple Blue CONCENTRATION (PPM) O2 0.0 0.005 0.010 0.015 0.025 0.050 0.100 >0.100

6.

HIGH DISSOLVED O2: (WINKLER METHOD) (>1 ppm) Take 300ml sample + 2 ml MnSO4 + 1 ml KI-NaN3 solution + 1 ml of 1:1

H2SO4. Take 100 ml of it, add 1-2 drops of starch which gives blackish colour. Titrate it with N/80 sodium thio sulphate till the end point appears (black to colorless).Consumed amount of sodium thio sulphate gives the value of the dissolved oxygen.

7.

TOTAL IRON AS Fe:

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Soluble iron is complexed with ferrozine [3-{2-pyridyl}-5, 6 bis (4 phenyl sulphonic acid)-1, 2, 7 triazine disodium salt at pH 4.4 & its concentration is determined calorimetrically at wavelength of 562 nm. 8. TOTAL COPPER AS Cu: Cu is reduced with NH2OH.HCl. The pH of aqueous phase is adjusted to 4-6 with sodium acetate buffer. Cu ions are reacted with neocuproine & the yellow complex is extracted with chloroform and its intensity of colour is measured at 457 nm, which gives concentration of Cu in the sample. 9. TOTAL SODIUM AS Na: Sodium in a sample is determined by making use of Flame photometer.

10.

CHLORIDE ANALYSIS: Chloride is estimated in boiler water by making use of high performance liquid

chromatography (HPLC). 11. AMMONIA ANALYSIS: Take 50 ml of sample + 1 ml Nesseler reagent, wait for 5 minutes Solution becomes of amber colour. Now record its absorbance in Spectrophotometer at 425 nm, which indirectly gives the value of its concentration.

12.

pH DETERMINATION: pH is a term which tells us about acidic and basic character of a solution.

Mathematically it is given as, pH = -log [H+] {Where, [H+] = concentration of H+ ions in the given solution} It means, higher the concentration of H+ ions lower the value of p H. It is determined by pH meter which makes use of pH sensitive glass electrode. 13. SPECIFIC CONDUCTIVITY:
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Ability of a solution to conduct electric current is called its conductivity. More the amount of dissolved ions in a solution more will be its conductivity. So it indicates the amount of total dissolved solids present in the solution. It is determined by conductivity meter.

14.

AFTER CATION CONDUCTIVITY: It is determined just like specific conductivity but first the sample is passed through

a strong cation resin. It is very important parameter for deciding condenser leakage. 15. H2 PURITY & FLUE GAS ANALYSIS: Both of these analyses are done by Orsat apparatus. In this apparatus a sample gas is drawn by use of a hand pump. It consists of a water cooled measuring cylinder and three absorption bottles containing chemicals. Bottle 1: KOH solution to absorb CO2 Bottle 2: alkaline pyrogallol solution to absorb O2 Bottle 3: alkaline Cu2Cl2 solution to absorb CO After passing the sample through the individual bottles, the sample is brought to measuring jar which shows the amount of gas component absorbed by the chemicals and thus determining the volume % of CO2, O2 & CO. H2 purity % = 100- (5 x O2 + CO2) 16. DEW POINT ANALYSIS OF H2 GAS: Dew point of a gas is the temperature at which the gas is fully saturated with water vapour and if the temperature falls below this liquid water will form on any available surface. Dew point apparatus consists of a shining surface tube enclosed in a sealed glass vessel. Inlet & outlet connection are provided to introduce gas.H 2 gas is passed at definite rate at atmospheric pressure through dew point apparatus. Crushed ice, 2 ml alcohol and alcohol thermometer are inserted in the capacitor of the apparatus. Monitor the temperature at which dew is formed on the capacitor. Allow H 2 gas to pass through apparatus for another 2-3 minutes without addition of ice/alcohol. Note the temperature at
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which dew disappears from the polished surface. Take the average temperature as dew point temperature & convert it from atmospheric pressure to system pressure which is the real dew point temperature of H2 gas at system pressure.

Condensate Polishing Unit (CPU)


CPU is very important part in the steam water cycle of 660 MW units, because unlike the subcritical units here the total condensate passes through CPU. Here each 660 MW unit contains CPU plant with four sets of vessels. Each vessel is capable to take 33% of total flow. Specifications No. Of vessels per unit: 4 Nos. Material Size Collecting system : Carbon steel with 4.5 mm rubber lined : 2800 mm diameter, spherical : Nozzle on bed plate.

Materials of nozzles : 316 stainless steel Flow in each vessel Designed pressure Resin Data Type of Resin: Cation Bed Anion Bed : Lewatit SP 112H : Lewatit MP 500 : 500 m3/Hr : 40 Kg/cm2

Differential pressure for each vessel: 2.0 kg/cm2

Quantity of Resin: Cation Bed Anion Bed : 3.90 m3 : 2.60 m3

Regeneration level: Cation Bed Anion Bed : 300 g/l of 100% HCl : 400 g/l of 100% NaOH

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The polishing units are designed for typical condensate quality as: pH Ammonia Total Solids Silica Copper Iron Sodium Chloride Crud 8-8.5 100 ppb as NH3 100 ppb 30 ppb as SiO2 10 ppb as Cu 50 ppb as Fe 10 ppb as Na 10 ppb as Cl 50 ppb (max.)

The condensate quality at plant outlet is Ammonia TDS -25 ppb


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Silica Copper Iron Sodium Chloride Conductivity crud

-3 ppb as Cu 5 ppb as Fe 2 ppb as Na 2 ppb as Cl <0.1 S/cm at 250C after removal of ammonia & amines. 5 ppb

ANALYSIS OF COAL
Introduction

Coal is a fossil fuel formed from the decomposition of organic bodies of vegetal origin that have been subjected to a series of complex natural transformation due to geological heat and pressure over millions of years. It can be considered as non-renewable resource of energy because it cannot be replenished on a human time scale. Coal has a highly heterogeneous organic matrix, which is invariably associated with mineral matter and moisture. The matter becomes more complicated for Indian coals, which are of drift origin. Hence, evaluation and efficient utilization of such a substance, requires an in depth knowledge of its character after which it can be put to various industrial uses. As majority of our coal resources are utilized for power generation, identification and subsequent optimal utilization of it can only be achieved if we know the character or quality of coal suitable for the purpose. For selecting a coal for power generation some essential analysis and tests are necessary viz. Proximate Analysis, Ultimate Analysis, CV, HGI, different forms of moisture, ash analysis, Ash Fusion tests, and Coal Maceral analysis etc. Amongst all these test and analyses, Proximate Analysis is perhaps the simplest and important as it throws light on the nature of coal as well as its industrial utilization aspects.
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The coal sample we have to carry out proximate and ultimate analysis. Besides this we determine calorific value, hard grove grindability index of coal and mill fines etc. These analyses are of great importance, as we decide the price of coal on the basis of useful heat value (UHV) taking into consideration ash & moisture content of the coal. The boilers are designed based on characteristics of fuel (coal). Also by regular analysis we can monitor the efficiency of mills etc.

PROXIMATE ANALYSIS:
The proximate analysis of coal determines the distribution of products obtained on heating with or without oxidation of coals under strictly standardized conditions. It is the simplest means of characterization of coal. The analysis is done on air-dry sample of coal size 212 and it involves determination of moisture, ash, volatile matter and fixed carbon percentages. The test procedure of proximate analysis is stipulated by I.S.1350 (Part-1) 1984.

1. MOISTURE:
The moisture in coal may be divided into free moisture and moisture due to the hygroscopic properties of the coal. The distinction between these two is not definite but depends upon the condition of atmosphere. For moisture analysis following terms are involved, as defined below:

Total Moisture: The coal, which has been exposed to contact with water in the seam or
in a washery or wetted by rain, may carry free or visible water. This water plus the moisture within the material is referred to as total moisture. Total moisture = Inherent Moisture + Free Moisture

Air Dried Moisture: It is moisture in coal which has been air dried under laboratory
condition.

Moisture in Coal Equilibrated at 60% RH & 400C: As the moisture content of airdried coal varies and depends on the temperature and relative humidity of the air to which it is exposed. It is necessary to determine moisture content of coal samples under standard conditions. This moisture determined at 60% RH & 40 0C, and is taken as reference moisture.

Near Saturation Moisture or Bed Moisture: It is the moisture content in coal


determined after equilibrating the sample at 96% RH and 40 0C. This is a measure of the moisture holding capacity of a coal.

Free Water or Visible Water: Free water or visible water is total quantity of water which
is physically adhering to coal. This is that quantity of water which is in excess of moisture holding capacity of a coal.
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Determination of Total Moisture: The total moisture is determined in two stages1). Air Drying 2). Oven Drying

Firstly 1kg of coal is crushed to pass a square mesh screen conforming to designation 12.5mm coal of IS: 460-1978. This sample is air-dried till the change in mass during an hour is less than 0.1% of the sample. From this percentage loss in mass of the original sample is noted (X). After that, about 10gm of crushed air-dried material is passed through 2.90mm IS sieve. This sample is dried in oven at 108 2 0C until there is no further loss in mass. From this percentage loss in mass of the air-dried sample on oven-drying is noted ( Y).

Total Moisture = X + Y (1 X/100)

Determination of Moisture:
For this, 1gm of air-dried coal sample of 212 size is dried in oven for 1 hour at 108 2 0C. Loss in mass is the moisture content of coal.

2. ASH AND ITS DETERMINATION:


Coal contains inorganic substances that are converted into ash on combustion of coal. Weigh 1 gm of sample of 212 size in a silica dish, spread uniformly. Keep it in a muffle furnace at room temperature. Raise the temperature to 815 10 0 C. Maintain the temperature for 1 hour. Take out cool and weigh.

[Wt. of (Dish + Ash) - Empty dish] x 100 Ash = ------------------------------------------------------Wt. of sample taken

3. VOLATILE MATTER:
It contains mainly carbon dioxide (CO2), carbon monoxide (CO), methane (CH4), tar vapours etc. These are the pyrolysed product of coal. Heat an empty, clean V.M. crucible with lid at 900 10 0C for 7 min. remove and cool on a metal plate for 1 min and further cool it for 10 min in a desiccator, then take empty weight. Take 1 gm of coal in it. Keep on a silica stand in an electrically heated furnace maintained at 900 10 0C for 7 min. After 7 min. take out, cool for 1 min on a metal plate then in a desiccator for 10 min. and weigh.

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Calculation Wt. of crucible with coal - Wt. after heating ------------------------------------------------------ = a (say) Wt. of coal taken

V. M. % =

( a - Moisture ) x 100

4. FIXED CARBON:
Fixed carbon of coal is calculated as,

Fixed Carbon (%) = 100 (Ash % + VM % + Moisture %)

ULTIMATE ANALYSIS:
The ultimate analysis is carried out to determine the percentage of carbon, hydrogen, nitrogen, sulphur and oxygen of the coal to ascertain the composition of coal. For determination of carbon & hydrogen in coal, sample is burnt in an atmosphere of oxygen. The carbon & hydrogen are oxidized to carbon dioxide and water, which can be measured by absorbing them in suitable reagents, from the weight of carbon dioxide and water produced, corresponding quantity of carbon & hydrogen present in the sample is calculated. The sulphur & nitrogen are determined by suitable analytical method. Oxygen content is then calculated by difference. By ultimate analysis we can calculate the theoretical air for combustion. This also gives an idea of amount of SOx and NOx formation, both of which are pollutants.

CALORIFIC VALUE: Calorific value gives us the amount of heat evolved by the
complete combustion of one gram of fuel. It is one of the important parameter for characterizing power plant coal.

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Fig: AUTOMATIC BOMB CALORIMETER In the laboratory we determine the gross calorific value of coal by Bomb-Calorimeter. Coal powder is hardened to cylindrical specimen of about 1gm. This sample is fired under a pressure of 20-30 Kg/cm2 of oxygen in bomb calorimeter. The heat liberated by the coal is absorbed by the calorimeter and the total heat gained is calculated by conventional procedures. Gross calorific value is employed to find out: a) Thermal efficiency of a combustor b) Coal equivalent of any fuel c) Coal consumption per KWH d) Useful heat value of coal Useful heat value of coal is an index of price fixation of coal. We grade the coal on the basis of UHV.

UHV = 8900 138 (CA + CM)


Where, CA = Conditioned ash CM = Conditioned moisture Grade A B C D E F G BG UHV (KCal/Kg.) > 6201 5601- 6200 4941- 5600 4201- 4940 3361- 4200 2401- 3360 1301- 2400 < 1300

HARD GROVE GRIANDABILITY INDEX (HGI):


HGI of coal indicates its easiness towards pulverization of coal. Lower HGI means difficulty in coal pulverization. HGI of power coal is normally 45-55. It is related to the power consumption by mill for pulverization of coal. The life and efficiency of the coal mill depends on the HGI of coal. It measures the increase of surface produced by the application of standard amount of work.

HGI = 13 + 6.93 x W
Where, W = grams of coal passing through 200 mesh sieve after 50gm of coal of size 16- 30 mesh are ground in a standard mill for 60 revolution.

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OIL ANALYSIS
LUBRICATING OIL: In power plant various lubricating oils are used to minimize the friction between two surfaces and also as a heat carrier. The friction is minimized by introduction of oil film between surfaces moving relative to each other. Due to continual use the performance of the oil is affected due to change in its properties, under operating conditions. In order to reasonably sure the oil is being maintained in a satisfactory condition it is necessary to monitor the selected properties of the oil. The following tests are to be carried out for monitoring of the oil. VISCOSITY: Viscosity is a measure of resistance to flow. It is measured by Viscometer. The principle that follows in this measurement is to determine the time required to flow a fixed volume of oil through viscometer. If the viscosity decreases below specified limit, the film between the moving surfaces become so thin that the surfaces actually touch each other. This causes abrasion and overheating. VISCOSITY INDEX: Viscosity temperature relationship of oil is denoted as the viscosity index and this index is expressed by a number on an arbitrary scale. V.I = (L-U/L-H) * 100 Where, U = Kinematic viscosity at 37.8 0C of the oil whose viscosity index is to be calculated L = Kinematic viscosity at 37.8 0C of the oil having V.I. = 0 H = Kinematic viscosity at 37.8 0C of the oil having V.I. = 100 L, H, & U have same viscosity at 8.90C. The viscosity of all oil doesnt alter by the same amounts for the equivalent temperature change. If the viscosity of the oil remains fairly constant when its temperature is altered it

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is said to have high viscosity index. On the other hand, the viscosity of oil with low viscosity index changes appreciably as the temperature is altered. CONTAMINATION BY DIRT AND METALLIC PARTICLES: For this 100gm of the oil to be tested is diluted with 300 cm3 of reptane solvent and left for two hours. The mixture is filtered through a fine glass mesh, which is weighed before and after the filtration. The test carried out measures the total amount of insoluble organic or inorganic material in oil. The organic material is generally caused by degradation of the oil and the inorganic material comes from wearing or corrosion of the metal parts of the lubrication system. TOTAL ACIDITY: The total acidity of the oil is determined by extracting both organic and inorganic acid by alcohol and titrating with standard solution. It is expressed as mg of KOH consumed per gram of oil. Increase in total acidity indicates degrading of the oil by oxidation, contamination etc. during its long use. This oil can corrode the metal surface over which it is flowing. TOTAL ACIDITY AFTER OXIDATION: For this 100gm of oil sample is taken and is subjected to temperature of 110 0C for 90 hours in the presence of suitable catalyst. Then the sample is tested for total acidity. OXIDATION STABILITY: 5gms of the sample is oxidized at atmospheric pressure at 150oC and the time taken by the oil to absorb 15ml of oxygen is recorded. This is commonly referred to as T 300. Formation of sludge in oil depends upon the oxidation stability of the oil. The oxidation stability gradually decreases in service due to the catalytic effect of metals like Cu, Fe, and also due to the depletion of anti-oxidant added in the oil. DEMULSIBILITY: Demulsibility characteristic of oil is indicated by demulsification number. It is number of seconds required for an oil to separate when 20ml of oil is emulsified with steam at 90 0C. The time of separation of the emulsion is noted by
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allowing the oil to separate at a constant temperature of 94 0C. High degree of demulsibility is desirable in the lubricating oils. The exposure of warm oil to air and its added mixture with water tend to form an emulsion. Emulsification is accelerated by any agitation or churning action. Emulsification reduces the value of the oil as a lubricant. ANTI RUST PROPERTIES: For this, 300ml of oil with 30ml of salt water is stirred at 60 0C. A cylindrical steel test specimen is completely immersed in this solution. After 24 hours contact with this solution, the specimen is examined to determine whether it has rusted or not. FOAMING CHARACTERISTIC: The sample of oil at 93 0C is blown with air at a constant rate for 5min then allowed to settle for 10min. The volume of foam is measured at the end of this period. The test is repeated after collapsing the foam at 240C. The comparative study of volume of foam formed under these two sequences gives an idea of foaming characteristic of the oil. CONDITION MONITORING OF LUBRICATING OIL: Condition monitoring of equipments by lubricating oil analysis can be divided into two main categories: 1. Debris monitoring 2. Lubricant condition monitoring DEBRIS MONITORING: Fragment separated from the parent body is called wear debris particles (metallic wear particles). Tribology is the study of the interaction i.e. friction, lubrication and wear. By lubricant condition monitoring it is determined whether lubricant itself is fit for service or not based on physical and chemical tests. When applied to determine that a system is nearing or has reached a failure mode, further damage can be avoided through scheduled maintenance or immediate shutdown and repair.

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Spectroscopy, the most widely applied of these techniques, provides qualitative and quantities analyses of wear debris in lubricating. INSULATING OIL: In power plant bulk quantity of insulating oils are used in transformers, circuit breakers, switchgears etc. These oils perform a dual function acting as a coolant and insulator. For monitoring the quality of transformer insulating oils the following tests should be performed periodically: Total acidity Oxidation stability Viscosity Flash point Moisture content Dielectric strength Breakdown voltage Mechanical impurities etc. Viscosity: Viscosity is a property of resistance to flow and depends its resistance to shear. Flash Point: It is the temperature at which oil on heating ignites on the introduction of test flame. It indicates comparatively degree of safety of storage, transportation and its use. Moisture Content: Being good conductor of electricity and hence always better to keep the minimum possible ppm content. Dielectric Strength: Maximum voltage at which oil can stand. Higher the value betters the oil. FUEL OILS:

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In India fuel oil fired boilers are not being used because of acute storage of oil and for being very expensive. Totally oil fired boilers are generally employed where oil is available in abundance. Here oil is being used in boilers only at the time of starting or for stabilizing flame if the combustion of coal used is not proper. Fuel oils used in power plant are products of petroleum refining. Generally we use light diesel oil, high-speed diesel oil and furnace oil. Following characteristic of fuel oils are considered while selecting for boiler: Specific gravity Viscosity Calorific value Flash point Pour point Sulphur content Heavy metals Water content Acidity etc. Calorific Value: A weighed quantity of the sample is burned in oxygen in the bomb calorimeter under controlled condition. The calorific value is calculated from the weight of the sample and rise in temperature. Pour Point: Pour point is the temperature at which a cloud or haze of wax crystals appear at the bottom of the test jar when the oil is cooled under prescribed condition. It gives a rough idea of the temperature above which the oil can be safely handled without any fear of congealing of filter clogging.

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POLLUTION
India has a large and ambitious power generation program extending in to the future decades to support the economic growth of the nation. Installed generation capacity is day by day increasing. Projected rate of growth and level of power generation and increasing concern about the consequent environmental impact, have compelled the planner and technologist to think a fresh and find ways to protect the environment. A number of new regulations have come in to force to check the degradation of environment and more will come in future. The stress is on ambient air quality monitoring by reducing the stack emission in thermal power plant and also on effluent water treatment. Thermal power constitutes 62% of the total installed capacity, mostly in the form of coal-fired power stations. Major shares of additional generation capacity in the future will also be contributed by installation of thermal power stations using coal as fuel. The major control measure adopted in recent times is installation of electrostatic precipitators (ESP) to reduce particulate concentration in the flue gas. AIR POLLUTION: Major air pollutants from fossil fuel fired power plants include particulate matter (SPM & RSPM), SOx, NOx, CO. Often the solution to air pollution sought by dilution of pollutants in atmosphere. Respirable Dust High Volume Sample is used for ambient SPM & RSPM monitoring. 1. PARTICULATE MATTER: Particulates are emitted in the stack at a rate of about 78g/M3 for the representative 210MW plant. The use of 99.9% efficient ESP reduces the particulate emission rate into

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the atmosphere to about 158 mg/ M3 which nearly satisfies the mandate limit of 150 mg/ M3. Techniques for controlling particulate emission, from a thermal power station, are utilizing control equipments, which remove the particulate emissions, released in to the atmosphere. The basic techniques of particulate collection equipments are: a. Mechanical collector b. Wet collector c. Fabric filter (bag house) d. ESP Data for ESPs applied to coal fired sources show fractional collection efficiencies greater than 99% for fine (less than 0.1) and coarser particles (greater than 10). 2. SULPHUR DIOXIDE (SOx): The second most important air pollutant emitted by the coal fired power plant is SOx. The S content on an average in Indian coal is less compared to the coal found elsewhere in the world. SOx emissions are not a problem in India and, however, concentration of SOx in ambient air can reach high levels only due to clustering of thermal power plants. Besides using fuels low in S content, the possible methods for reducing SOx emissions from coal/ fossil fuel combustion are: Use of tall stacks to increase atmosphere dispersion and dilution. Flue gas desulphurization/ flue gas treatment Desulphurization of fuel itself wealth. THE STACK DISPERSION: This control method is based on natural dispersion at high elevation so that ground level concentration is acceptable at all the times. The benefit of using tall stack for pollutant

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dispersion is that it does not clearly rely on SOx removal process and/or fuel desulphurization methods, which involve high operating costs.

FLUE GAS DESULPHURIZATION: This system is generally used alkali slurries as the SOx absorbent medium and can be designed to remove greater than 90% of the incoming SOx. Lime/ lime stone scrubbers, sodium scrubbers are among the commercially proven FGD system. The lime and stone wet scrubbing process uses a slurry of CaO or lime stone to absorb SOx. 3. OXIDES OF NITROGEN (NOx): Nitrogen oxides are formed from fuel nitrogen or from the molecular nitrogen of combustion air. Gas power stations are more prone to NOx formation because of high temperature. Several techniques are used to reduce NOx emissions from coal combustion. The primary techniques can be classified into one of two fundamentally different methods: combustion control and post combustion control. Combustion controls are the most widely used methods of controlling NOx formation in all types of boilers and include: Low excess air (LEA) Burners out of service (BOOS) Biased burning firing Over fire air (OFA) Low NOx burners Post combustion control methods are: Selective non-catalytic reduction (SCNR) Selective catalytic reduction (SCR)

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TESTING PROCEDURE FOR SOx & NOx IN AMBIENT AIR: A. PROCEDURE FOR TESTING OF SOx IN AMBIENT AIR: REAGENT BLANK: 20ml Absorbing solution + 1ml of 0.6% Sulphamic Acid + 2ml of HCHO (0.2%) + 2ml Acidified P-Rosaniline. SAMPLE: 20ml Sample solution + 1ml of 0.6% Sulphamic Acid + 2ml of HCHO (0.2%) + 2ml Acidified P-Rosaniline. Wait for 20 minutes. Take the absorbance at 560 nm by using spectrophotometer. CALCULATION:
SO2 in g/M
3
=

(Conc. of SO2 in g) / (Vol. of Air passed)

B. PROCEDURE FOR TESTING OF NOX IN AMBIENT AIR: REAGENT BLANK: 20ml Absorbing solution + 2ml H2O2 solution + 20ml Sulphanilamide + 2.8ml NEEDA. SAMPLE: 20ml Sample solution + 2ml H2O2 solution + 20ml Sulphanilamide + 2.8ml NEEDA. Wait for 10 minutes. Take the absorbance at 540 nm by using spectrophotometer.

CALCULATION:
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NOx in g/M3 =

Conc. in ppm x Vol. of Abs. soln used Vol. of Air passed x 0.82used

ISO-KINETIC METHOD FOR STACK EMISSION MONITORING: Iso-kinetic Sampling: The velocity of gas stream through the sampling nozzle should be equal to the velocity of gas stream in the stack. Sampling at other than iso-kinetic velocities includes error. The particles of size greater than 3 to 5 in size have sufficient inertia so that particle motion may deviate significantly from the gas flow stream line pattern. In that case particles are selectively drawn into the probe in a size distribution different from that existing in the duct or flue gas. It has been observed that if the sampling velocity is greater than isokinetic velocity, the sampling will have lower mass concentration of particulate matter than the main stream i.e. collecting greater % of fine particles. However, if the sampling velocity is less than iso-kinetic velocity, the particulate samples have a higher mass concentration than actually present with lower % of fine particles. Procedure: Iso-kinetic method is used for stack emission monitoring. The stack gas velocity is calculated from the pressure of the flue gas. The total volume of the gas, flow for one hour, is determined by multiplying time of sampling and velocity of gas. The value is normalize3d by converting into NTP.

SPM in mg/NM3:
SPM (mg/NM3) = (Final wt. of thimble initial wt. of thimble) in mg Volume of gas

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This SPM is at stack CO2 (%). For getting SPM at 12% CO2, it is to be multiplied by (12/Stack CO2%).

SO2 in mg/NM3 or in PPM: The absorbed solution is to be titrated against N/50 NaOH by using mixed indicator until the colour change from red to green. Reagent blank is titrated in the same manner & this result is subtracted from the titre value and the SO2 is calculated as bellow:

(Titer value for full vol. of absorbing sol. x 32 x 1000) SO2 (mg/NM ) =
3

Volume of gas

This is SO2 at stack CO2%. At 12% CO2 multiply it by (12/Stack % of CO2).

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CONCLUSION
During one year training we were given mostly the theoretical exposure of Power Plant Chemistry. In this respect, this DOJ training proved very much effective & helpful to give a cutting edge to our practical knowledge. As the Sipat project is in commissioning phase of Unit-III, we had a chance to familiarize ourselves with various commissioning activities of the plant. Hope this experience will pay us a lot in the future.

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