Technical Description of the Project

Utilization of sunflower seed husks for steam and

power production at the oil extraction plant
OJSC ‘Kirovogradoliya’
1. General description

The project lies in the reconstruction and modernization of heat and power supply at OJSC
“Kirovogradoliya”. After the reconstruction heat and power supply at OJSC “Kirovogradoliya” will
be based mostly on biomass – sunflower husk. Thus there will be very little consumption of
fossil fuel (natural gas) and no purchase of electricity from power grid for own needs of CHP
unit.

Presently the Enterprise has three old husk fired boilers (with consumption of mazut as
additional fuel) and purchases electricity from power grid. All the boilers have exceeded their
operational lifetime though they are in operating condition due to regular investments of the
Enterprise into their repairs and modernisation. Presently the Enterprise is almost doubling its
production capacity and its heat and power needs will increase.

Within the project boundaries three old husk fired boilers will be dismantled and three new
boilers (N 1, N2, N3) for combustion of sunflower husk will be installed at the Enterprise. Two of
them (N2 and N3) will be operational and consume almost twice as much sunflower seed husk
than it was before the extension of the Enterprise and reconstruction of its energy supply
system. The third boiler (N 1) is a reserve one. It will be used in case when amount of generated
husk exceeds capacity of operational boilers and during maintenance period of one of
operational boilers. Two operational boilers (N2 and N3) can also use natural gas as reserve
fuel, third boiler (N 1) is designed only for combustion of sunflower seeds husk. Natural gas in
operational boilers (N2 and N3) is only reserve fuel for the case of unforeseen or unexpected
situation (emergency at the Enterprise that leads to unexpected absence or luck of sunflower
seed husk for the period more than 12 hours). The Enterprise has a 900 m 3 storage bin (6×150
m3 bins) for sunflower husk that ensures uninterrupted operation of two boilers up to 12 hours.
Plan of the territory of OJSC “Kirovogradoliya” (total area is 8.8 hectares) with indication of the
site of the project is presented on fig. 1.1

Also CHP equipment (turbo-unit) for two operational boilers (N2 and N3) will be installed for
CHP production purposes. CHP unit will produce power which totally covers its own needs in
electricity.

The project also includes installation of a gas fired boiler. It will be reserve boiler for the case of
emergency (breakdown of two or three husk fired boiler; emergency at the Enterprise that leads
to unexpected absence or luck of sunflower seed husk for the period more than 12 hours).
Besides the boiler will be used during about 1-month period of annual capital repairs of all husk
fired boilers and other equipment of the Enterprise (no generation of husk during that period).
Summary of the equipment to be installed in the project is presented in Table 1.1
Table 1.1. Equipment to be installed within the project boundaries
Name Type Technical parameters
Boiler for sunflower husk E-16-3,9-360D Steam production: 16 t/h, P=3.9 MPa
combustion Fuel consumption: 21399.5 t/yr
Boiler for sunflower husk E-16-3,9-360D Steam production: 16 t/h, P=3.9 MPa
combustion Fuel consumption: 21399.5 t/yr
Boiler for sunflower husk E-16-3,9-360D Reserve boiler*)
combustion (Nominal steam production: 16 t/h,
P=3.9 MPa)
Fuel consumption: 9106 t/yr
Gas fired boiler DE-25-1,4-225 Reserve boiler**)
GMO (Nominal steam production: 25 t/h,
P=1.4 MPa)
Gas consumption: 1145.4 thous. m3/yr
Turbo-unit P-2,5-3,4/1,0 Installed capacity 2.5 MW
(turbine)
*) The boiler operates in case when amount of generated husk exceeds capacity of operational
boilers and during maintenance period of one of operational boilers.
**) The boiler operates only in case of emergency at the Enterprise and during 1-month period
of annual capital repairs of all husk fired boilers and other equipment of the Enterprise.

Plan of the territory of OJSC “Kirovogradoliya”

1 - entrance checkpoint, 2 – laboratory of raw material, 3, 5 – garage, 4 – fire protection tank
(V=300 m3), 6 – laundry, 7, 22 - cooling tower, 8 – waste water treatment unit, 9 – the main
petrol storage, 10 – elevator for grist, 11 – granulator of grist, 12 – preparatory division, 13 –
refining workshop, 14 – construction site for the project, 15 – extraction workshop, 16 –
working petrol storage, 17 – pumphouse (fire protection by foam), 17a - 2×250 m3, 18 – club, 19
– canteen, 20 – administrative building, 21, 48 – auto -weighing machine, 23 – air-compressor
unit, 24 – unit for collection, cleaning and pumping of condensate, 27 – steam boiler house, 28
– shop for packing, 29 – railway acceptance unit, 30 – mazut division, 31 – dryer -furnace
division, 32 – storehouse for raw material, 33 – storage -shed, 34 – storage of oil tanks, 35 –
laboratory of control-measuring devices and automatics, 36 – power shop, 37 - forge shop, 38 –
repair-mechanical shop, 39 – warehouse, 40 – repair -building shop, 41 – pumphouse with fire
protection tanks, 42 – auto transport unit, 43 - silo bin, 44 – work building, 45 – TP -5, 46 –
auxiliary building, 47 - fire-station, 49 – bunkers-collectors of husk

2. Specification of boiler equipment

Within the bounds of the project there will be installed three boilers E-16-3,9-360D at the
Enterprise. The boilers E-16-3,9-360D are intended to burn organic waste – sunflower husk with
the purpose to produce superheated steam for power generation. Quality of superheated steam
meets GOST 20995-75 (State Standard). Evaporation is two-stage.
The composition of sunflower husk to be burnt is the following: S – 0.2%, C – 42.5%, H – 4.9%,
N – 0.4%, O – 34.6% (at that deviation of each parameter is not more than ± 10%). Moisture
content W is 9-11%. Ash content (A) is not more than 2.4%. Low heat value Q = 3685 kcal/kg
(15.4 MJ/kg). Volume of volatile (V r) is 78.4%.

Range for regulation of steam production is within 50-100%. Installation of the equipment, its
exploitation, maintenance, lightning and thermal isolation is made according to DNAOP 0.00-
1.08-94 (State Regulations for Labour Protection).

Pipes of the boilers correspond to GOST 108.031.08-85 – 108.031.10 -85. The boilers will be
fitted out with control equipment, devices for disaster protection and signalling. Automation
devices correspond to GOST 12.1.005-88, GOST 12.2.003-91 and DNAOP 0.00-1.08-94.
Parameters of noise and vibration meet requirements of GOST 12.1.012-90, GOST 12.2.007-75
and DNAOP 0.00-1.08-94. Electrical safety meets requirements of GOST 12.1.019-79, GOST
12.1.010-76, GOST 12.2.007-75 and DNAOP 0.00-1.08-94.

Table 2.1. Technical characteristics of husk fired boilers E-16-3,9-360D

Parameter Numerical value
Manufacturer OJSC “Sater”
(Ukraine)
Design temperature superheated steam, ºC 360
Design pressure of superheated steam 3.9
(absolute), MPa
Steam production, t/h 16
Feed water temperature, ºC 104
Temperature of flue gases, ºC 170
Efficiency, % up to 86
Type of fuel combustion flare-layer
Emission of NO x, mg/m3 meets the
standards
Emission of flying ash, g/m3 meets the
standards
3
Emission of SOx, mg/m meets the
standards

Table 2.2. Technical characteristics of gas fired boiler DE-25-1,4-225 GMO

Parameter Numerical value
Manufacturer OJSC “TEKOM”
(Ukraine)
Design temperature superheated steam, ºC 225
Design pressure of superheated steam
(absolute), MPa 1.25
- after steam super-heater 1.4
- in boiler drum
Steam production, t/h 25
Feed water temperature, ºC 104
Temperature of flue gases, ºC 170
Efficiency, % up to 92
Type of fuel combustion flare
Emission of NO x, mg/m3 meets the standards
Emission of flying ash, g/m3 meets the standards
Emission of SOx, mg/m3 meets the standards
3. Specification of CHP equipment

CHP equipment consists of turbo-unit, condenser, evaporator, and deaeration unit.

Turbo-unit

Table 3.1. Characteristics of steam turbine and generator

Parameter Numerical value
Type of turbine* Condensation type
with technological
bleeding of steam
TG 3,1-3,8/0,9/0,15
Nominal capacity, kW • 3050
Nominal steam pressure, MPa 3.8
Nominal steam temperature, ºC 355
Nominal steam pressure at bleeding, MPa 0.9
Nominal steam temperature at bleeding, ºC 211
Nominal steam pressure at the inlet to 0,15
condenser, MPa
Temperature of steam, ºC 111
Voltage on clips of generator, kV 10
Frequency of current, Hz 50
* Type of turbine may be specified

Condenser

Air condenser is a part of turbo-unit and ensures condensation of steam after the turbine. The
system for steam condensation consists of:
- Air condenser of sectional type with heat-exchange surface made of bimetal ribbed
tubes.
- Axial fans.
- System for control and regulation of air condensers.
- Pump for condensate.

Table 3.2. Technical characteristics of air condenser

Parameter Numerical value
2
Heat-exchange surface, m 8541
Nominal steam pressure at the inlet to 0,15
condenser, MPa
Temperature of steam, ºC 111
Temperature of super-cooled condensate, ºC 104
Cooling medium air

Evaporator of surface type I-120-0,6-III

Evaporator is made in accordance with Rules for vessels issued by State Inspection for Labour
Protection and GOST 10731-85. It is intended for obtaining distillate to compensate steam loss
and condensate loss in steam-turbine cycle and for steam production. Manufacturer is plant
“Krasny kotelschik” (Taganrog city, Russia).

Evaporator is a vertical vessel consisting of a body, heating section and two-stage system for
steam washing. Heating section is fixed inside the body. The section consists of cylindrical ring,
two tube plates and tubes fixed on tube plates. Inside the body above heating section are
installed two washing devices and louver separator for decreasing steam moisture. Application
of two-stage washing system and louver separator allows to obtain high quality steam which
meets standards.
Table 3.4. Technical characteristics of evaporator I-120-0,6-III
Parameter Numerical value
Production of secondary steam, 9.0-12.6
t/h
Maximal working pressure, MPa
- in tube system 0.59
- in the body 0.59
Nominal pressure (absolute),
MPa 0.27-0.59
- in tube system 0.12-0.27
- in the body
Heat-exchange surface, m2 120
Height of evaporator, mm 10000
Diameter of the body, mm 2050
Mass (dry), t 16.0

Deaeration unit feed pumps

Maximal rate of feed water is 40 t/hr, nominal rate is 34.65 t/hr. There are two feed pumps PE-
65-53 of 65 m3/h capacity and 580 m water column head for husk fired boilers E-16-3,9-360D.
One pump is operational, the other pump is reserve. Working range of the pump let CHP unit
operate with 1-3 husk fired boilers in operation.

For gas fired boiler DE-25-1,4-225 GMO there are two feed pumps 2TSNg-50-180 of 50 m 3/h
capacity and 180 m water column head. One pump is operational, the other pump is reserve.

Evaporator I-120-0,6-III can have its own group of pumps or use feed pump of boiler DE-25-1,4-
225 GMO.

In case of breakdown of operational pump of boiler DE-25-1,4-225 GMO, reserve feed pump
2TSNg-50-180 ensures parallel operation of boiler DE-25-1,4-225 GMO and evaporator.

For the production of deaerated water two deaeration units are included in CHP installation.
Deaeration unit consists of the following parts.

Table 3.5. Parts of deaeration unit

Name Type
Deaeration column KDA-50
Deaeration tank volume V=20 m3
Cooler of evaporation OVA-2
Safety device 50/75

Quality and scope of the equipment to be installed corresponds to GOST 16860-88 and data
from registration certificate.

Water from deaeration unit goes to the inlet of feed pumps. Two feed pumps PE-65-53 are used
for water supply to boilers E-16-3,9-360D. One of the pumps is operational and the other is
stand-by. Type of electric drive is 4AMH280M2U3.

Table 3.5. Technical characteristics of feed pump PE-65-53

Parameter Numerical value
Discharge capacity, m3/h 65
Head, MPa 5.8
Capacity, kW 200
Rotation speed of motor, rpm 3000
Voltage, V 380/660

Quality of feed pumps meets standards, drawings, TU26-06-1157-78 of a manufacturer

(Technical Conditions) and is confirmed by quality certificate of the manufacturer.

4. Steam and power production and consumption

Two operational boilers produce 32 t steam/hr. All amount of steam (direct steam) goes to the
turbine for power production. After the turbine total amount of steam (waste steam) is divided
into two flows. The first flow – up to 25 t/h – is process steam which is used for technological
purposes. The second flow goes partly for heating and hot water supply and partly to evaporator
and condenser and is used for the production of distillate for boilers make-up.

Main part of produced power is used by CHP plant for own needs. The rest of produced power
is supplied to the Enterprise.
 5. Detailed project schedule

N Name of work 2005 2006 2007

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4
1 Development of work X X X X X X X X
documentation for 1st
and 2nd stage of CHP
plant construction
2 Development of design X X X
documentation for 1st
and 2nd stage of CHP
plant construction
3 Manufacture of metal X X X X X X X X
constructions for 1st and
2nd stage of CHP plant
construction
4 Delivering metal X X X X X X X
constructions for 1st and
2nd stage of CHP plant
construction to building
site
5 1st stage of construction X X X X X X X
of CHP plant building
6 2nd stage of construction X X X X X X X X X X X X
of CHP plant building
7 Chimney. Manufacture of X X X
metal constructions
8 Chimney. Mounting metal X X
constructions
9 Mounting metal X X X X X
constructions of CHP
plant building (1st stage)
10 Mounting metal X X X X X
constructions of CHP
plant building (2nd stage)
11 Construction of outside X X
networks
12 Completing boiler E-16- X X X X X X X X X X X
3,9-360D N1
13 Completing CHP plant X X X X X X X X X X X
(1st stage)
14 Mounting: 1st stage of X X X X X X X X X X
CHP plant construction
14.1 Mounting of boiler E-16- X X X X X
3,9-360D N1
15 Boiler N1: starting-up and X X X X
adjustment
16 Boiler N1: X
Commissioning. Putting
into operation
17 Boiler N1: Preparation of X
purchase-sale documents
for the equipment
18 Completing boiler E-16- X X X X X X X X X X X
3,9-360D N2
19 Completing CHP plant X X X X X X X X X X X X X
(2nd stage)
20 Mounting: 2nd stage of X X X X X X X X
CHP plant construction
20.1 Mounting of boiler E-16- X X X X X
3,9-360D N2
21 Boiler N2: starting-up and X X X X
adjustment
22 Boiler N2: X
Commissioning. Putting
into operation
23 Boiler N2: Preparation of X
purchase-sale documents
for the equipment
24 Completing boiler E-16- X X X X X X X X X X X X X
3,9-360D N3
25 Completing boiler DE-25- X X X X
1,4-225 GMO N4
26 Completing CHP plant X X X X X X X X X X X
(2nd stage)
27 Mounting: Boiler E-16- X X X X X X X X
3,9-360D N3
28 Mounting: Boiler DE-25- X X X
1,4-225 GMO N4
29 Mounting: turbo-unit X X
TSCTG E-3,1-
3,9/0,9/0,15
30 Mounting: general CHP X X X X X X X X X X
plant equipment
31 Boiler N3, Boiler N4, X X X X
turbo-unit: starting-up and
adjustment
32 Boiler N3, Boiler N4, X
turbo-unit:
Commissioning. Putting
into operation
33 Boiler N3, Boiler N4, X
turbo-unit: Preparation of
purchase-sale documents
for the equipment