DBR of Boiler For Ambuja Cement

TECPRO SYSTEM LIMITED
AMBUJA CEMENT LTD
DESIGN BASIS REPORT FOR

BOILER
Revised as per HOLTEC

comments dated 26-62012
Revised as per HOLTEC
comments dated 13-62012
28.06.20
12
22.06.20
12
04.06.20
12
For Approval
REVISION
DATE
DESCRIPTION OF REVISION
NK
NK
AG
S
NK
NK
AG
S
VSM
/NTK
NK
AG
S
INL
PROJECT
INL
SIGN
INL
CHECKED
SIGN
APPROVED
WASTE HEAT RECOVERY BASED POWER PLANT

AT RABRIYAWAS, RAS DISTRICT, RAJASTHAN.
AMBUJA CEMENT LTD.
OWNER
OWNERS CONSULTANT
SIGN
PREPARED
HOLTEC CONSULTING PRIVATE LTD.,

Holtec Centre, A-Block, Sushantlok, Gurgaon.
TECPRO SYSTEMS LIMITED

CHENNAI.
EPC CONTRACTOR
SYSTEM DESIGNER &

SUPPLIER
NANJING TRIUMPH KAINENG ENVIRONMENT

& ENERGY Co., Ltd. NANGJING,CHINA
HIQ POWER ASSOCIATES PRIVATE LIMITED
CHENNAI
EPC CONTRACTOR
CONSULTANT
TECPRO DOC.NUMBER
TSL-1057/03/A/D/003
Total No of Pages : 21
TECPRO SYSTEMS LTD, CHENNAI Page 1
HIQ DOC.NUMBER
Rev.02

AMBUJA CEMENT LTD
Project No.
: 1057
Client Name
: Ambuja Cement Ltd,
Rabriyawas.
Consultant Name
: Holtec Consulting Pvt.
Ltd.
Source of Heat
: Cement Kiln Exhaust Gases
Boiler Capacity
AQC Boiler
HP Section
/cm
(a)
AQC Boiler
/cm
: 15870 kg/hr, 11.50 kg
LP Section
0
1
: 3500 kg/hr, 2.80 kg
(a)
Preheater 1 Boiler HP
/cm
: 10180 kg/hr, 11.50 kg
(a)
Preheater 1 Boiler LP
: 1750 kg/hr, 2.80 kg /cm
(a)
Preheater 2 Boiler HP
/cm
: 10180 kg/hr, 11.50 kg
(a)
Preheater 2 Boiler LP
: 1750 kg/hr, 2.80 kg /cm
(a)
o
Superheated Steam Temp. (HP): 335 C (for AQC Boiler)
o
: 305 C (for PH Boilers)
o
Superheated Steam Temp. (LP): 180 C (for PH Boilers)

AMBUJA CEMENT LTD
No. of Boilers
: 3 Nos
Reference: HEAT MASS BALANCE DIAGRAM (FA00791C-J010401) REV 01
1. INTRODUCTION:
M/s Ambuja Cement Ltd. is having 1 no. of Kilns with Clinker production capacity
of 6560 TPD with two strings of 06-stage preheater. Kiln has one Clinker cooler.
Exhaust gases from given sources are presently rejected to atmosphere.
Objective is to utilize the waste heat of gases to generate steam and generate
power for captive use by driving steam generator.
M/s Holtec Consulting Private Limited has
carryout PMC Services for this project. The
presently being wasted will be utilized to
temperatures at outlet of all preheater boiler
process heating requirement.
been appointed as consultant to

Exhaust gas heat of Kiln which is
produce steam. The exhaust gas
to be maintained so as to fulfill the
AMBIENT CONDITIONS
Ambient temperature
Max. 45
Average.27
Min. 5
Relative humidity (Min/Max/Average)
3/99/80
Relative humidity for performance
80
Ambient for ACC design
42 deg C
Ambient for Electrical design
50 deg C

AMBUJA CEMENT LTD
SITE CONDITIONS
Seismic zone
II
Basic wind speed
m/s
Site Elevation Above sea level
50m/s
330
Codes and Standards
Sr.
No.
Details
Referred for
IBR 1950 With Latest Amendments
Pressure parts calculations
ASME Section II Part A - Edition 2010
Material Specifications
ASME Section II Part D - Edition 2010
Material Properties
Pressure Vessel Handbook,
Mechanical Calculations
2. Basis of Design
This design basis is intended to cover requirements for design of Waste Heat
Recovery Based Power plant at Rabriyawas, Rajasthan for M/s Ambuja Cement Ltd.
through M/s Tecpro Systems Ltd., Chennai.
The exhaust gases from each of Kiln will enter the respective connected WHRB.
The heat from high temperature exhaust gases will be recovered in WHRB and
after recovery of heat, gases at lower temperature will be exhausted to the ESP.
The system has following major sections:
1.
Super heater
2.
Evaporator
3.
Economizer
4.
Condensate Pre-heater
5.
Steam Drum
6. Damper
7. Boiler feed pump
8. De-aerator

AMBUJA CEMENT LTD
9. Blow down Tank

10. Chemical dosing system
11. Dust dislodging system
2.1
0
1
WASTE HEAT RECOVERY BOILER

The PH boiler shall be HP/ LP drum boiler, vertical configuration with
horizontal tubes. AQC boiler shall be HP/ LP drum boiler, vertical
configuration with horizontal tubes. The PH & AQC boilers are top
supported, outdoor Unit suitable for the specified Pre-heater and
Clinker Cooler exhaust of cement plant. The boilers designed for fully
automated operation from DCS. The tube thickness shall be 3.2mm
2.2
Steam Drum
The Steam drum is of welded construction and placed on structure
over the evaporator sections. The material of construction is made of
SA 516 Gr.70. Necessary nozzles and connections for piping and
fittings are provided with supports. Hinged manholes are provided in
both heads of the drum. The drum is provided with suitable two stage
internals to effectively separate saturated steam and to maintain the
required steam purity. Minimum dia. Of steam drum shall be 1372mm.
Type of steam separator is Demister.
2.3
Duct Enclosure
Necessary flue gas ducting from PH outlet to PH boiler and downstream
to fan along with the dampers specified elsewhere in the contract. Inlet
and outlet dampers of PH boiler shall be guillotine sealed motorized
isolation dampers. Damper provided in the bypass duct (PH down
comer) shall be motorized regulating (Multi-Louver) type. PH boiler
casing and ducting thickness for PH boiler shall be minimum of 8 mm
with adequate stiffeners.
For AQC, flue gas duct from mid tap point to De-duster and further to
AQC boiler to the existing bag filer along with dampers specified
elsewhere in the contract. Inlet and outlet dampers of AQC boiler shall
be guillotine sealed motorized isolation dampers. Damper provided in
the cooler exhaust shall be motorized regulating (Multi-Louvrer) type.
One No fresh air damper shall be provided in the air bleed line to
regulate the hot air temperature. Ducting thickness for AQC boiler shall
be minimum 6 mm with adequate stiffeners.
0
2

AMBUJA CEMENT LTD
MOC of PH & AQC dampers:

Considering the temperature of flue gas/ air vent, the AQC boiler and
PH boiler are enclosed with carbon steel casing (of specified thickness)
with outside insulation. Necessary access doors for ease of operation
and maintenance shall be considered.
2.4.1 Evaporator
PH boiler Evaporator section is of horizontal, inline tubes and cross-flow
arrangement with headers considering high dust content in the flue
gas. This design feature to be considered shall take into account
minimum accumulation of dust on heating surface.
The AQC boiler evaporator
arrangement with headers.
section
is
horizontal
inline
tube
It shall be connected to the steam drum through adequately sized

down comers and risers, to ensure adequate circulation under all
operating conditions.
2.5
Superheater
Super heater shall be minimum two stage design with primary and
secondary sections. (For AQC Boiler Only)An inter stage de-super
heater of variable multi nozzle orifice with external control valve type
to be provided in between the super heaters to control the final steam
temperature. The de-superheating system shall be provided with all
required isolating valves, piping, insulation, supports, regulating
valves, etc. Supplier shall furnish detailed P&I diagram with line sizes
and instruments. The spray water shall be tapped off from the feed line
at a point, upstream of the feed control station. PH Boiler Superheater
is of Single stage only.
2.6
Economiser
The economizer is considered as the heat recovery unit for raising the
feed water temperature before entering the steam drum of respective
boilers. The economizer shall be Horizontal for AQC boiler and PH
boiler.
2.7
Condensate Preheater System in AQC boiler

AMBUJA CEMENT LTD
Condensate pre-heater (CPH) shall be considered as the additional heat

recovery unit to raise the condensate temperature before entering into
de-aerator to reduce the steam consumption in de-aerator.
2.8
Gas / Air Circuit

Exhaust gas from Pre-heater being at higher elevation, the gas ducting
to PH boiler will have a top entry. Hot air from Clinker Cooler being at
lower elevation, the air ducting to AQC boiler will be provided with
bottom entry in pre dust collector. Prior to AQC boiler entry, pre dust
collector shall be provided to reduce the dust concentration before
entering into the boilers. The exhaust from respective sources shall
flows through the various heat transfer sections of each boiler. This
shall be further connected to the existing downstream equipments.
Damper with expansion joints as specified elsewhere in the contract
shall be provided for isolating the boiler during emergency conditions.
The dampers to be considered shall be 99.95% sealing dampers.
2.9
Dust Dislodging System

The dust accumulated on the heat transfer surface of PH boiler shall be
removed and dropped into the bottom hoppers by rapping mechanism.
Hammers mounted on a rotating shaft drop (by gravity) and strike anvils
(solid shaft) that are attached to the pressure part inside the boiler
casing. Rapping intensity shall be controlled by the weight of hammers
and the length of hammer mounting arm. The frequency is changed by
adjusting the speed of the shaft. The design of the dust disposal system
shall be proven.
The collected dust in the hoppers below the PH boiler and other dust
collection points in the system shall be transported through the mass
flow type conveyor to the existing dust conveying system of the cement
plant. Each dust collecting hoppers shall be provided with plate gate,
Rotary air lock valve. These rotary air lock shall discharge the dust to
the mass flow type conveyor below the full length of the boilers. The
discharge of this mass flow type conveyor shall be connected to the
final mass flow type conveyor to transport the dust to the existing
conveying system.
For AQC Boiler:

Due to the abrasive nature of the clinker grains, pre dust collector at the
inlet of AQC boiler to be considered. This shall ease the erosion and

AMBUJA CEMENT LTD
abrasion tendency of the heating surfaces and also to collect dust. In

addition to the above, bottom entry/ vertical flow of Hot air in to the
boiler, so that any partial grains that got carried away also settles at the
bottom hopper of the WHRB due to gravity. The collected dust in the
hoppers below the AQC boilers and other dust collection points in the
system shall be transported through the mass flow type conveyor to the
existing dust conveying system of the cement plant. Each dust
collecting hoppers shall be provided with plate gate, Rotary air lock
valve. These rotary air lock shall discharge the dust to the mass flow
type conveyor below the full length of the boilers.
2.10 Method of Flue Gas / Hot Air Isolation
PH Boiler:
Flue gas tapping shall be taken at a higher elevation of the existing PH
exit flue gas duct so as to match with the gas entry point of the WHRB.
The exit of the WHRB is again to be connected to the PH fans inlet duct
at a lower elevation.
The type of dampers and their positioning shall be clearly specified
considering no dust accumulation on the dampers.
AQC Boiler:
The air above the inlet section of the Clinker cooler after mixing with
the ambient air from the cooler fan will be at a very high temperature.
The hot air mixture tapped above the cooler grate in this section will
then be recycled as secondary and tertiary air to the kiln for clinker
production. The section after the secondary and tertiary air tapping is
the location identified for tapping the hot air required for heat recovery.
2.11 Common Blow Down Tank

One no. blow down tank to be considered for each to which the boiler
Blow down, boiler drain lines from various system will be connected.
2.12
Water and Steam Circuit

AMBUJA CEMENT LTD
Feed water enters the common condensate pre-heater, de-aerator,

from de-aerator outlet to economizer from BFP/ feed control station,
from economizer outlet it is fed to the Steam drum. From the drum the
water enters to the evaporator inlet header. After absorbing heat from
the heat sources, steam-water mixture formed and moved to the
respective steam drum through natural circulation. Separated
saturated steam from steam drum shall be heated in respective superheater.
2.13 Common De-aerator cum storage tank
Pressurized de-aerator shall be provided by the supplier along with LP
dosing system. The location of de-aerator along with BFP shall be
provided in the TG hall .This system shall consists of De-aerator in
which the oxygen content in the feed water is reduced to the required
level by spraying water as droplets in the presence of steam. Storage
tank below the De-aerator to store de-aerated water.
2.14
Chemical Dosing System

LP Dosing System
Since feed water contains traces of oxygen due to the incomplete
mechanical / thermal deaeration. Traces of oxygen shall be scavenged
by chemical deaeration. Chemicals like sodium sulphite or hydrazine
shall be dosed in the suction pipe of feed pump by LP dosing. LP dosing
with sodium sulphite is to be considered to reacts with oxygen and to
form sodium sulphate or in case of hydrazine, it reacts with O 2 and
forms water and nitrogen.
HP dosing system
Scale formation is limited by converting hardness salts to a free flowing
sludge. HP dosing is done by carbonate control and phosphate control
by addition of sodium carbonate or trisodium phosphate respectively.
Other chemicals such as sodium hydroxide carbonate or calcium
oxyphosphate can also be added. Best result of calcium carbonate or
magnesium hydroxide or calcium silicate, magnesium silicate will be
available as free flowing sludge where caustic alkalinity is 10 to 15% of
the dissolved solids. OH alkalinity leads to prevention of magnesium
phosphate as bad scale by converting magnesium to magnesium
hydroxide. The HP dosing system shall add the chemical to the boiler
water to take care of the ingress of the hardness salt and to increase
the boiler water pH.

AMBUJA CEMENT LTD
2.15 Water quality index of circulation cooling water

N0.
Item
Make-up water quality
pH
7.0-9.2
Suspended
solid(SS)
10mg/L
Oil & grease
Cl
300 mg/L
methyl orange
alkalinity
500 mg/L
Ca2+
30-200 mg/L
Fe2+
0.5 mg/L
SO42-
1500 mg/L
SiO2
175 mg/L
10
Free chlorine
0.5-1.0 mg/L
Remark
0
2
Demineralization water quality requirement:
2.16
No.
Item
Make-up water quality
pH
8.0-9.5
Hardness
0.03mmol/L
Turbidity(FTU)
oil
2.0 mg/L
Total ferrum
0.3 mg/L
Conductivity
110 S/cm
Remark
Boiler steam drum feed water, boiler water standards
The quality control standards of drum feed water GB1576-2008 are as

follows:
0
2

AMBUJA CEMENT LTD
S/N
Item
Unit
Control standards
SS
PH
value25Deg
C
mg/L
non
dimension
mmol/L
0.03
Total hardness
dissolved
oxygen
mg/L
0.05
Oil content
mg/L
Iron content
mg/L
0.3
2
3
The quality control standards of steam drum waterGB1576-2008are as

follows:
S/N
Item
Unit
Control standards
Total alkalinity
14
1012
pH25
dissolved
solid
mmol/L
non
dimension
mg/L
100
PO43-
mg/L
1030
SO32Relative
alkalinity
mg/L
non
dimension
1030
0.2
2.17 Boiler Feed Pumps

Two (02) nos, (01 working+01 standby). each capable of meeting feed
water requirement at 110% BMCR capacity of each boiler (excluding
the pump margins), horizontal, multistage, barrel casing, centrifugal
type boiler feed pumps, driven by electric motor would be provided.
Each pump would be provided with forced lubricating oil system for
lubrication of the bearings, couplings etc. All necessary protective and
supervisory system would be provided to ensure safe and trouble-free
operation of the feed pumps.
3.1 Design Data
S No
Description

AMBUJA CEMENT LTD
A
Clinker production capacity-BDP
Source of exhaust
Clinker Cooler
Pre heater
(VI Stage)
Nature of exhaust
Hot Air
Flue Gas
HEATING SIDE
Ambient Temperature
6560 TPD
Unit
AQC boiler
Total Exhaust Flow available for

design
Nm3/hr
Flow rate
kg/hr
Exhaust tapping location
Density
Temperature
At tapping point
Inlet of WHR
Outlet of WHR
Composition
Max.45
Max.45
Average.27
Average.27
Min.5
Min.5
174,000
222720
Mid Tap Off
Kg/Nm
C
C
C
C
PH boiler 1 &
2. each
ILC -1 :
132,000
ILC - 2 :
132,000
188760
Pre heater Exit
1.28
360
355
1.43
ILC-1
ILC-2
ILC-1
ILC-2
:330
:330
:325
:325
100
179
CO2
Nil
26.7/24.2
CO
N2
79.00
65.2~6
8.3
H2O
0.10
3 3.5
O2
20.3
4 - 4.6
Dust concentration in exhaust

gas
10
Fouling factor
11
Pressure
% by
volume
3
gms/Nm
50
0.0001
ILC-1: 108
ILC-2: 108
0.0001

AMBUJA CEMENT LTD
a
At Inlet of WHRB
mmwc
Max. pressure drop across WHRB

boiler
Max. pressure drop across WHRB
system(taping to taping)
including inlet duct, outlet
duct,pre-duster(in case of AQC)
and boiler
mmwc
11
No. of WHRB
12
Condenser t
13
14
15
mmwc
Nos.
-50
ILC -1: -720

ILC -2: -720
<60
< 70
<90
<100
type
ACC
Condensing pressure
Kg/cm2(a)
Water Temperature
Power generation voltage
0.2 at 42 deg C
34
34
6600+10%
3.2. Output Specifications

a) Flue Gas Specifications
Sr. No.
Details
Ambient Temperature
Exhaust gas outlet

temperature
Pressure drop across
WHRS
Unit
O
mmWC
Clinker
Cooler
Pre Heater 1
Boiler
Pre Heater 2
Boiler
3
5
10
0
6
0
35
35
179
179
70
70
b) Steam Specifications
Sr.
No
Steam Data
Unit
Steam Generation HP/LP

1
TPH
Clinker
Cooler
15.87/
3.5
Pre Heater 1
Boiler
10.18/
1.75
Pre Heater 2
Boiler
10.18/
1.75

AMBUJA CEMENT LTD
Steam Pressure at HP/LP

Super heater main steam
stop valve outlet
Steam temperature at
HP/LP Super heater main
steam stop valve outlet
kg/cm2
(a)
O
11.5 /
2.8
11.5/
2.8
11.5/
2.8
335
180
305
180
305
180
4. Design Specifications
4.1
Super Heater
i. Material of Construction
a. Tubes
: SA 210 Gr. A1, Seamless
b. Headers
: SA 106 Gr. B
0
2
ii. Design
Header size: During detail engineering
a. Gas Side Specifications
Type of flow: Cross flow
Arrangement: Staggered
Sr.
No.
A
Details
0
2
Unit
Clinker
Cooler
Pre Heater 1
Boiler
Pre Heater 2
Boiler
174000
132000
132000
222355
189683
198683
355
325
325
195
213
213
222355
189683
189683
Inlet
Exhaust gas flow rate
Nm3/hr
Kg/hr
Exhaust gas inlet temperature

for HP Super heater

for LP Super heater
B
1
0
1
Outlet
kg/hr

AMBUJA CEMENT LTD
331
311
311
193
207
207
Exhaust Gas Velocity at HP

super heater
m/s
4.9
5.6
5.6
Exhaust Gas Velocity at HP

super heater
m/s
4.2
5.1
5.1
Exhaust gas outlet temperature

for HP Super heater

for LP Super heater
4
5
b. Fluid Side Specifications
Sr.
No.
A
Detail
s
Inlet
Flow rate HP /LP
Steam inlet
Temperature HP/LP
Unit
kg/hr
O
C
2
Clinker
Cooler
Pre Heater 1
Boiler
Pre Heater 2
Boiler
15870/
3300
188/
132
13.5/
3.8
10180/
1750
188/
132
13.5/
3.8
10180/
1750
188/
132
13.5/
3.8
Design pressure
HP/LP
kg/cm (a)
Working pressure
HP/LP
kg/cm (a)
12.5/
3.2
12.5/
3.2
12.5/
3.2
Design temperature
HP/LP
425/
250
350/
250
350/
250
Working temperature
HP/LP
335/
180
305/
180
305/
180
Type of fin
Bottom two
rows of bare
tube type,
Balance rows is
finned tube
type
Bare type
Bare type
Fins per Inch
Fin materials
CS
0
1

AMBUJA CEMENT LTD
10
B
1
2
Type of fin weld
Resistant
welded
15870/
3500
10180/
1750
10180/
1750
335/
180
305/
180
305/
180
1382/
377
561/
78
561/
78
12.5/
2.8
12.5/
2.8
12.5/
2.8
Outlet
Flow rate HP/LP
kg/hr
Superheated
steam outlet
temperature
Heating surface area

HP/LP
Safety valve set

pressure HP/LP
kg/cm (g)
4.2 HP Evaporator
a. Tubes
: SA 210 Gr. A1, Seamless
b. Headers
: SA 106 Gr. B
0
2
Inner Casing material : IS 2062 GB or equivalent

Outer Casing material: GI/Colour sheet 0.5mm thick
0
2
ii. Design Specifications

a. Gas Side Specifications
b. Header size : 219.1
Sr.
No.
A
Details
0
1
Unit
Clinker
Cooler
Pre Heater 1
Boiler
Pre Heater 2
Boiler
Inlet
Kg/hr
222355
189683
189683
Nm3/hr
174000
132000
132000

HP/LP
331/
177
311/
198
311/
198

AMBUJA CEMENT LTD
Outlet
Flow rate

HP/LP
Exhaust Gas Velocity HP/LP
222355
189683
189683
195/
142
213/
179
213/
179
m/s
4.4/
4.2
5.4/
4.9
5.4/
4.9
kg/hr
O
Sr.
No.
A
D
et
Inlet
Water inlet
temperature HP/LP
Design pressure
HP/LP
Working pressure
HP/LP
3
4
5
Design temperature
HP/LP
Working temperature
HP/LP
Type of fin
Fins per Inch
Fin materials
10
Type of fin weld
Outlet
Water & steam

mixture outlet
temperature
HP/LP
Unit
C
2
kg/cm (a)
2
kg/cm (a)
O
Clinker
Cooler
Pre Heater 1
Boiler
Pre Heater 2
Boiler
188/
133
188/
133
188/
133
14.5/
4
13.5/
3.5
15/
4
14/
3.5
15/
4
14/
3.5
197/
144
199/
144
199/
144
194/
139
194/
139
194/
139
Fin type
Bare type
Bare type
CS
Resistant welded
189/
135
189/
138
189/
138
0
1

AMBUJA CEMENT LTD
9230/
5259
2911/
728
2911/
728
4.3 HP Economizer
a. Tubes
: SA 210 Gr. A1
b. Headers
: SA 106 Gr. B

a.
b.
c.
d.
e.
Sr.
No.
A
Gas Side Specifications

Type: Staggered
Header Size :219.1
Inner Casing Material :IS 2062 or equivalent
Outer casing : GI/Coloured sheet 0.5mm thick
Details
Unit
Clinker
Cooler
0
1
0
2
Pre Heater 1
Boiler
Pre Heater 2
Boiler
Inlet

HP/LP
Oulet
Flow rate

HP/LP
Exhaust Gas Velocity HP/LP
Kg/hr
222355
189683
189683
174000
132000
132000
213/--
213/--
222355
189683
189683
177/124
196/--
196/--
m/s
4/3.6
Nm3/hr
O
kg/hr
O
193/142
Sr.
No.
Details
Unit
Clinker Pre Heater 1

Cooler
Boiler
Pre Heater 2
Boiler

AMBUJA CEMENT LTD
Inlet
Flow rate HP/LP
Water inlet temperature HP/LP
Design pressure HP/LP
kg/cm (a)
Working pressure HP/LP
kg/cm (a)
Design temperature HP/LP
Max Working temperature

HP/LP
Type of fin
Fins per Inch
Fin materials
10
Type of fin weld
kg/hr
O
C
2
2
C
C
15870/
43230
10180/--
10180/--
124/
100
15/
30
13.5/
20
120
120
16/--
16/--
14/--
14/--
194
194
194
194
194
Fin type
Bare type
Bare type
CS
Resistant
welded
194
Outlet
Flow rate HP/LP
kg/hr
Water outlet temperature HP/LP
Heating surface area HP/LP
C
2
15870/
43230
10180/--
10180/--
176/
124
180
180
1639/
2458
479
479
4.4 Condensate Pre Heater (CPH Non IBR)

a.
Tubes
: SA 210 Gr. A1
c.
Headers
: SA 106 Gr. B

a. Flue Gas Specifications
0
1

AMBUJA CEMENT LTD
Sr.
No.
A
Details
Exhaust gas inlet

temperature
Outlet
Flow rate
Clinker
Cooler
Pre Heater 1
Boiler
Pre Heater 2
Boiler
kg/hr
222355
---
---
126
---
---
222355
---
---
100
---
---
m/s
3.4
---
---
Inlet
Unit
Exhaust gas outlet

temperature
Exhaust Gas Velocity
kg/hr
O
Sr.
No.
A
1
Detail
s
Inlet
Flow rate
Unit
Clinker
Cooler
Pre Heater 1
Boiler
Pre Heater 2
Boiler
42510
---
---
62
---
---
10
---
---
10
---
---
kg/hr
Water inlet temperature
Design pressure
Max Working pressure
Design temperature
150
---
---
Working temperature
95
---
---
Type of fin
Fin type
Bare type
Bare type
Fins per Inch
Fin materials
CS
1
0
Type of fin weld
Resistant
welded
C
kg/cm2
(a)
kg/cm2
(a)
C
C
0
1

AMBUJA CEMENT LTD
Outlet
Flow rate
Water outlet
temperature
kg/hr
42510
---
---
95
---
---
2458
---
---
C
2
4.5 Steam Drum

i. Material Of Construction
a. Shell
: SA 516 Gr 70
b. Dished Head
: SA 516 Gr 70
c. Nozzles
: SA 106 Gr B
d. Flanges
: SA 105
Sr.
No.
Pre Heater 1
Boiler
12.5/
3.2
13.5/
3.8
Pre Heater 2
Boiler
12.5/
3.2
13.5/
3.8
190/
136
190/
136
190/
136
194/
142
----
194/
142
----
194/
142
----
mm
1800/
1500
1500/
1500
1500/
1500
mm
26/
16
16/
16
16/
16
Ite
m
Working Pressure HP/LP
Unit
kg/cm (a)
Design Pressure HP/LP
kg/cm (a)
Working Temperature HP/LP
Design Temperature HP/LP
Shell
Shell Internal Diameter HP/LP
Shell Thickness HP/LP
C
C
----
Clinker
Cooler
12.5/
3.2
13.5/
3.8

AMBUJA CEMENT LTD
mm
Steam drum shell length

HP/LP
Normal water level HP/LP
Dished Head HP/LP
----
Type of Dished Head HP/LP
Dished Head Internal diameter

HP/LP
mm
Dished end thickness HP/LP
mm
Number of Manholes HP/LP
Location of Manhole HP/LP
~5000
----
~5000
100 mm Below 100 mm Below 100 mm Below

centerline/
centerline/
centerline/
50 mm Below 50 mm Below 50 mm Below
centerline
centerline
centerline
----
----
----
1800/
1500
Ellipsoidal
head
1500/
1500
Ellipsoidal
head
1500/
1500
26/
16
16/
16
16/
16
2/2
Ellipsoidal head
Nos
~5000
On dished end On dished end On dished end

DBR of Boiler For Ambuja Cement

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DBR of Boiler For Ambuja Cement

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TECPRO SYSTEM LIMITED

AMBUJA CEMENT LTD

DESIGN BASIS REPORT FOR

Revised as per HOLTEC

WASTE HEAT RECOVERY BASED POWER PLANT

AMBUJA CEMENT LTD.

HOLTEC CONSULTING PRIVATE LTD.,

TECPRO SYSTEMS LIMITED

SYSTEM DESIGNER &

NANJING TRIUMPH KAINENG ENVIRONMENT

TECPRO SYSTEM LIMITED

: Ambuja Cement Ltd,

: Holtec Consulting Pvt.

: Cement Kiln Exhaust Gases

: 15870 kg/hr, 11.50 kg

: 3500 kg/hr, 2.80 kg

: 10180 kg/hr, 11.50 kg

: 1750 kg/hr, 2.80 kg /cm

: 10180 kg/hr, 11.50 kg

: 1750 kg/hr, 2.80 kg /cm

TECPRO SYSTEM LIMITED

Reference: HEAT MASS BALANCE DIAGRAM (FA00791C-J010401) REV 01

been appointed as consultant to

Relative humidity (Min/Max/Average)

Relative humidity for performance

Ambient for ACC design

Ambient for Electrical design

TECPRO SYSTEMS LTD, CHENNAI Page 3

TECPRO SYSTEM LIMITED

Basic wind speed

Site Elevation Above sea level

Codes and Standards

IBR 1950 With Latest Amendments

Pressure parts calculations

ASME Section II Part A - Edition 2010

ASME Section II Part D - Edition 2010

Pressure Vessel Handbook,

TECPRO SYSTEM LIMITED

9. Blow down Tank

WASTE HEAT RECOVERY BOILER

TECPRO SYSTEMS LTD, CHENNAI Page 5

TECPRO SYSTEM LIMITED

MOC of PH & AQC dampers:

It shall be connected to the steam drum through adequately sized

Condensate Preheater System in AQC boiler

TECPRO SYSTEMS LTD, CHENNAI Page 6

TECPRO SYSTEM LIMITED

Condensate pre-heater (CPH) shall be considered as the additional heat

Gas / Air Circuit

Dust Dislodging System

For AQC Boiler:

TECPRO SYSTEM LIMITED

abrasion tendency of the heating surfaces and also to collect dust. In

2.11 Common Blow Down Tank

Water and Steam Circuit

TECPRO SYSTEMS LTD, CHENNAI Page 8

TECPRO SYSTEM LIMITED

Feed water enters the common condensate pre-heater, de-aerator,

Chemical Dosing System

TECPRO SYSTEMS LTD, CHENNAI Page 9

TECPRO SYSTEM LIMITED

2.15 Water quality index of circulation cooling water