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“Preparation of general arrangements engineering drawings of energy efficient typical top fired
pusher hearth re-heating furnace with pulverized coal firing”
for the project
“Upscaling energy efficient production in small scale steel industry in India”
Submitted to:
United Nations Development Programme
55, Lodhi Estate, New Delhi 110003
Submitted by:
Mr. V.K. Sharma,
Chief Executive
Refined Structures & Heat Control Unit, Jaipur
Submission on:
10th May, 2014
1
ABBREVIATIONS:
mm millimeter
tph tonne per hour
kg/t kilogram per tonne
m meter
OC degree celsius
m3/h cubic meter per hour
kWh/t kilo watt hour per tonne
2
TABLE OF CONTENTS
EXECUTIVE SUMMARY…………………..…………………………………………………………………………..3
1. INTRODUCTION……………………………………………………………………………………………………..5
2. FURNACE DESIGN PARAMETERS……………………………...…………………………………………….5
3. ENERGY EFFICIENT MEASURES IN RE-HEATING FURNACE…………...………………………..7
4. INSULATION & REFRACTORIES………………………………………………………………………………9
5. HEAT RECOVERY SYSTEM…………………………………………………………………………………….10
6. PULVERIZER………………………………………………………………………………………………………..11
7. AUTOMATION AND CONTROL SYSTEM…………………………………………………………………11
8. COST BENEFIT ANALYSIS ……………………………………………………………………………………..12
9. GENERAL ARRANGEMENT DRAWING: LAYOUT & AUXILIARY………………………………13
10. GENERAL ARRANGEMENT DRAWING: STRUCTURAL………………………………………….14
11. GENERAL ARRANGEMENT DRAWING: REFRACTORY………………………………………….15
12. GENERAL ARRANGEMENT DRAWING: PIPING…………………………………………………….16
13. GENERAL ARRANGEMENT DRAWING: P & I DIAGRAM………………………………………..17
14. GENERAL ARRANGEMENT DRAWING: SINGLE LINE POWER DIAGRAM……………….18
15. GENERAL ARRANGEMENT DRAWING: CHIMNEY………………………………………………..19
16. GENERAL ARRANGEMENT DRAWING: RECUPERATOR………………………………………..20
17. GENERAL ARRANGEMENT DRAWING: PULVERIZER …………………………………………..21
LIST OF TABLES
Table 1: Basic design data........................................................................................................................... 6
Table 2 : Broad dimensions of the furnace........................................................................................... 6
Table 3 : Comparison between conventional & new burner ......................................................... 7
Table 4 : Details of refractory & insulation .......................................................................................... 9
Table 5 : Cost break up for energy efficient re-heating furnace ................................................ 12
Table 6 : Benefits of energy efficient re-heating furnace .............................................................. 12
3
EXECUTIVE SUMMARY
UNDP in association with Australian Aid Programme & Ministry of Steel, Government of
India is implementing a project titled “Upscaling energy efficient production in small
scale steel industry in India”. The objective of this project, which was launched in July
2013, is to scale-up adoption of energy efficient technologies in small scale steel
industry in India. In line with project’s continuous endeavor to provide inputs on energy
conservation, a typical design of re-heating furnace, based on pulverized coal as fuel,
was developed.
Re-heating furnace was designed based on most commonly prevailing operational
practices in small scale steel industry in India. The basic design has been carried out
considering “state of the art” technology and accessories. The capacity for design was
considered as 10 tph as it was the mean average of varying capacity of re-heating
furnaces operating on pulverized coal in small scale steel industry in India and to
provide inputs to larger section of the sector on ideal scenario. The overall designing
and development of general arrangement drawings were done by aiming the best
possible specific coal consumption of 50 to 55 kg/t (with coal CV of 7,000 kcal/kg). Coal
feeding system consists of separate hoppers with a dual cyclone and air filter system for
each of the two zones i.e., heating zone and soaking zone. In comparison to conventional
furnace, these hoppers are located just above the burners. Further considerations on
design of various systems of re-heating furnace are depicted in below table.
Parameter Design consideration
Input cross section &
composition
Billet of 100x100x1,500 mm size & mild steel
Discharge temperature &
temperature gradient
1,100 0C & < 30 0C
Burners Swirl flame motion with provision for secondary air
for efficient combustion
Waste heat recovery system To achieve combustion air temperature upto 350 OC
after waste heat recovery system
Refractory & insulation To attain
- skin temperature of furnace close to ambient temperature
- enhanced life of lining and - targeted specific fuel consumption
4
As compared to conventional pulverized coal furnace, this energy efficient furnace
would ensure saving of atleast 20 kg/t in specific coal consumption. And such saving is
projected by incorporating various energy conservation measures in re-heating furnace
viz. installation of PID controller system (taking feedback from flue gas analysis & zonal
temperature) to obtain high flame & low flame characteristics based on zonal
temperature, efficient burners, waste heating recovery system, optimum refractory &
insulation etc. Overall investment for installing energy efficient furnace is arrived at by
considering prevailing market rates for various equipment, structural steel & civil
works. It is estimated that the investment for re-heating furnace can be recovered in 9
months and such calculation is done by considering difference in specific fuel
consumption of conventional furnace & energy efficient furnace.
5
1. INTRODUCTION
The Steel Re-rolling Mill (SRRM) sector to a large extent uses coal as a fuel for the
re-heating furnace. Most of the units earlier were run by grate firing/ lump coal firing
system. In these systems, there was no control of furnace temperature, as lump-coal is
fired in a fire box attached at the end of furnace. The consumption of coal in these
furnaces therefore, ranged from 150-180 kg/t.
Lump coal fired furnaces have been converted in SRRM sector to pulverized coal
firing system in recent past, to increase combustion efficiency and reduce fuel
consumption. The present practice for burning pulverized coal is that the coal powder is
first stored in a hopper at the ground level. From this hopper, coal is carried to the
burner with the help of air, supplied by a blower.
This practice of pulverized coal firing system is based on outdated concept and
this has following limitations.
Poor furnace design.
Use of cold air for combustion (recuperator gets choked and removed).
Size of pulverized coal is very coarse (90% above 200 mesh).
Poor combustion efficiency.
Simple pipe is used as a burner. The following section provides details of a technological development in
pulverized coal fired units, which can result in reduction in specific coal consumption by
25% to 30% and burning loss by 50%, increase productivity by 25-30%, also leading to
cleaner environment in the factory premises.
2. FURNACE DESIGN PARAMETERS
2.1 Design criteria:
A capacity of 10 tph has been considered for designing the furnace. Nominal
capacity of the furnace is related to (i) Size of the billets, (ii) Discharge temperature, (iii)
Permitted temperature gradient across the billet height, (iv) Type of material (thermal
conductivity) and (v) Heating regime. Therefore, the furnace has been designed taking
6
into consideration, certain typical operational practices prevailing in the SRRM sector.
The basic design data considered are as below:
Table 1: Basic design data
Sl. No. Parameter Unit Dimension
a. Design capacity of the furnace tph 10
b. Biller cross-section mm 100X100X1,500
c. Material - Mild steel
d. Discharge temperature OC 1,100.
e. Permissible temperature gradient from top to bottom
OC < 30
f. Fuel - Pulverized coal
(calorific value: 6500-7000 kcal/kg)
2.2 Broad dimensions of the furnace:
The broad dimensions of the furnace are given below:
Table 2 : Broad dimensions of the furnace
Sl. No. Parameter Unit Dimension
1. Overall length of the furnace m 17.00
2. Effective length of the furnace m 13.80
3. Length of the soaking zone m 7.00
4. Length of the heating zone m 5.50
5. Length of the pre-heating zone m 4.50
6. Overall width of the furnace m 4.97
7. Inside width of the furnace m 3.3
8. Height of the roof above the hearth
At soaking zone
At heating zone
At pre-heating zone (unfired zone)
mm
mm
mm
1,200
1,800
875 / 675
7
3. ENERGY EFFICIENT MEASURES IN RE-HEATING FURNACE
The new technology being used in this furnace design has been successfully
tested in many furnaces and following are the prominent features:
3.1 Pre-heated air:
The technological innovation makes use of 100% pre-heated combustion air. The
air is supplied by a single blower connected to a recuperator. By the use of 100% pre-
heated air (temperature upto 350 0C) for burning coal, the flame temperature rises
substantially, thus providing temperature rise in the furnace equivalent to furnace oil.
3.2 Burner: New burner design having provision of both primary as well as secondary air,
has been used. Hot primary air is used for carrying coal and hot secondary air for
complete combustion of powder coal. The new burner has been developed on the basis
of three 'T' principle.
Time : Sufficient time for burning.
Temperature : Ignition temperature must be achieved.
Turbulence : Proper mixing of fuel and air. This has been
achieved by swirlers.
Comparison between conventional pulverized coal burners and the new burners
is tabulated below:
Table 3 : Comparison between conventional & new burner
Sl.
No. Conventional burner New burner
1. 4 inches hollow pipe is used as a
burner
Swirl flame motion
2. No provision for secondary air Provision for secondary air
3. Flue gas analysis
O2 : 6-10%
CO2 : 10-14%
Excess air : 90-100%
Primary air (m3/h) : 1,600-
2,200
Secondary air
(m3/h) : NIL
Pressure at burner : WC 4-7"
O2 : 2-4%
CO2 : 16-18%
Excess air : 20%
Primary air (m3/h) : 1,000-
1,100
Secondary air (m3/h) : 1,600-
1,700
Pressure at burner : WC 25"
8
3.3 Coal feeding arrangement:
The system makes provision of separate hoppers with a dual cyclone and air
filter system for each of the two zones i.e., heating zone and soaking zone, where coal
will be transferred pneumatically, directly from the pulverizer. Dual cyclones are
provided, so that coal drops at two places in the coal hopper, thereby ensuring even
filling of the hopper and also to fully separate powder coal and the carrier air. These
hoppers are located just above the burners. Each hopper have a capacity holding of coal
for 2-3 hours operation and the feed of the coal is controlled through screw feeder
driven by an A.C. motor coupled with a gear box. Instead of using cold air, hot air from
the recuperator is used for ensuring optimum combustion.
Coal hoppers are made of outer shell of mild steel plate and inner shell of
stainless steel lining, in order to ensure that hopper does not get rusted from the
moisture present in pulverized coal. In addition, an agitator is connected to A.C. motor
drive to make sure that coal powder falls freely from the hopper into the burner.
3.4 Other energy efficient measures:
3.4.1 Both the heating zone and soaking zone are lined with high temperature dense
refractories so that the lining in heating zone is also able to tolerate higher temperature
desired in the new design.
3.4.2 Metallic skids can cause the problem of ingest/billets sticking to the skids because
of the higher temperature in the heating zone. To achieve the purpose of operating both
the zones at almost the same temperature and to reduce the overall furnace
temperature, instead of skids, the top layer of soaking and heating zone hearth is lined
with magnasite bricks. The furnace hearth has been lined with different type of brick
lining in the hearth area. The reasons for this are as follows:-
(a) From burner wall to just before the discharge door, the top layer is lined
will 60% alumina brick, because this area has to tolerate heat only, as there is no
movement of billets here. But strong insulation is provided at the bottom so that
heat loss is avoided.
9
(b) The top layer of the hearth upto some distance in the heating zone is lined
with magnasite bricks as a replacement for skids. Good quality magnasite bricks
are used because these bricks can tolerate high temperature as well as abrasion
at high temperature.
(c) The insulation bricks at the bottom have been replaced by dense bricks.
That is because if strong insulation is provided here, magnasite brick will get
over heated all over and the expensive brick might get damaged in a short
period. So, therefore, in order to get a long hearth life and to avoid expensive
furnace breakdown, some heat loss is allowed in this critical hearth area. There
after strong insulation is provided again.
4. INSULATION & REFRACTORIES
The refractories & insulation lining used in the furnace has been tabulated
below:
Table 4 : Details of refractory & insulation
Sl.
No.
Area Lining details
1. Furnace hearth
Burner wall to
beginning of
discharge door
115mm 60% alumina backed by 115 mm 50% alumina
backed by 75mm IS-8 bricks backed by 115mm IS-6
bricks backed by 115 mm hot-face insulation backed by
5mm asbestos sheet
From here to
straight portion of
soaking zone.
115mm magnasite bricks backed by 115mm 50%
alumina backed by 75mm IS-8 bricks backed by
115mm IS-6 bricks backed by 5mm asbestos sheet
From here to end of
heating zone straight
portion
115mm magnasite bricks backed by 115mm 50%
alumina backed by 75mm
IS-8 bricks backed by 115mm IS-6 bricks backed
115mm hot-face insulation bricks backed by 5mm
asbestos sheet
Note: Metallic SKIDS start from here upto charging door
From here upto
heating zone end
115mm 60% alumina backed by 115mm 50% alumina
backed by 75mm IS-8 bricks backed by 115mm IS-6
bricks backed by 115mm hot-face insulation bricks
backed by 5mm asbestos sheet
10
From here to end of
the furnace i.e. upto
the charging door
115mm IS-8 bricks backed by 115 mm IS-8 backed by
75mm IS-6 bricks backed by 115mm Hot face insulation
bricks backed by 115mm hot-face insulation bricks
backed by 5mm asbestos sheet
2. Soaking & heating
zone sidewall
230mm 60% alumina backed by 115mm hot-face
insulation bricks backed by 115mm cold-face insulation
bricks backed by 75mm ceramic fibre backed by 5 mm
asbestos sheet.
3. Burners walls Same as above
4. Pre-heating zone
sidewall
230mm IS-8 bricks backed by 115mm hot-face
insulation bricks backed by 115mm cold-face insulation
bricks backed by 100mm ceramic fibre backed by 5 mm
asbestos sheet.
5. Soaking & heating
zone Roof
60% alumina hanger & shoulder bricks backed by
50mm
castable insulation bricks backed by 75mm hot-face
insulation bricks backed by 50mm ceramic fibre blanket
6. Pre-heating zone
roof
200mm thick ceramic fibre blankets
5. HEAT RECOVERY SYSTEM
In the present practice in pulverized coal fired re-heating furnace used in SRRM
sector, a recuperator is generally not used for recovery of sensible heat from the flue
gas, mainly because of maintenance problem associated due to choking of tubes and
also due to absence of proper burner to use the pre-heated air. A radiation cum
convention type recuperator is used in the present design. The fact that ash does not
stick to stainless steel is used in this design to provide all surfaces in contact with gases
to be made of stainless steel. Moreover the recuperator is designed to be installed
vertically above the ground, thus ensuring longer life and gravity is used to make ash
drop downwards. The radiation heat transfer section which is at the bottom has a
double drum design with inner drum, which is in contact with flue gas, made of stainless
steel. The convective heat transfer section has only stainless steel pipes in contact will
flue gases. The air pre-heat temperature for such recuperator is expected to be around
350-400 0C depending on the flue gas temperature. But at least 50% recovery of the flue
gas temperature is achieved.
11
6. PULVERIZER
Pulverizer should be capable of delivering, (-) 200 mesh of coal. General
recommendations for the pulverizer are as follows:
Hammer : High manganese alloy
Liner : En-31 steel
Classifier blades : Stainless steel
Fan blades : Stainless steel
RPM : 2,200
7. AUTOMATION AND CONTROL SYSTEM
For automation, the concept of high and low flame is used. High flame is set for
100% air supply from the air blower and matching coal supply.
Combustion air pipelines are provided with motorized butterfly valves, which
are pre-set for high and low flame air supply.
Low flame is set for reduced air supply (around 40% of the total air available)
with matching coal powder supply. Coal supply should be regulated with the help of flue
gas analyzer.
Furnace maximum temperature and allowed temperature drop can be set to any
desired level. For example if 1,130 0C temperature is desired for rolling, the burners will
operate at high flame setting till this temperature is achieved. After attaining this
temperature, burners will shift to low flame setting. If we allow a temperature drop of 5
0C, the burners will shift to high flame setting at 1125 0C and the process will go on.
Signal from furnace thermocouple is received by digital temperature controller,
which upon getting the signal, controls the air and coal supply to the desired flame
condition.
A.C. variable frequency drives are used to control speed of coal feeder motors.
12
8. COST BENEFIT ANALYSIS
The additional investment towards energy efficient measures as compared to a
conventional furnace has been tabulated below:
Table 5 : Cost break up for energy efficient re-heating furnace
Sl. No.
Parameters Amount (in Rs)
1. Recuperator 5,00,000.00 2. Burners with accessories 1,20,000.00 3. Coal hoppers with motors, gear boxes, dual cyclone & bag filters
etc. 6,00,000.00
4. Auto control system 3,50.000.00 5. Pulverizer size 36" 3,80,000.00 6. Pipelines 2,50,000.00 7. Insulation and refractories 10,00,000.00 8. Steel structure 10,00,000.00
Total 42,00,000.00 The benefits of improvement in efficient with the new furnace has been
tabulated below:
Table 6 : Benefits of energy efficient re-heating furnace
Sl. No.
Parameter Conventional furnace of
similar dimensions
Energy efficient furnace
Benefits (Rs. in lakhs
per year)
1. Productivity (tph)
9 10 15.00
2. Fuel consumption (kg/t)
75 to 80 50 to 55 50.00
3. Power consumption (kWh/t)
75 70 10.00
4. Burning loss % 2.5 1.5 75.00
Total 150.00
In addition there are other benefits like improvement in mill yield & mill
utilization. The cost of new efficient furnace of 10 tph capacity will be approximately
Rs. 1, 10, 00,000 and pay-back period will be 9 months.
MAN HOLE
Ø1000
RECUPERATOR
TROUBLE DOOR
TROUBLE DOOR
TROUBLE DOORTROUBLE DOOR
DISCHARGE
DOOR
750
150
675
150
750
150
3300
DAMPER
DAMPER
1600
EXTRACTOR
AIR PIPE LINE
500
SKIDS
1000
2500
PUSHER
PULVERIZER UNIT
MOTOR
25 HP
960 RPM
GEAR BOX
40:1
1000
1000
ROLLER
BLOWER
40" WG PRESSURE
2800 CFM
MOTOR
40HP
2880RPM
BILLETS
100 SQX1500
MOTORISED
BUTTERFLY
VALVE
350
MAN HOLE
BY PASS
BUTTERFLY
VALVE
MOTORISED
BUTTERFLY
VALVE
200
2750
SKIDS
1595
17000
Ø1900
1613
CHIMNEY
2500
438
Ø800
350
3735
675 16503150
9000
450 350 4100
4370
350
4970
INSULATION
Ø100Ø500
MOTOR
75 HP
1440 RPM
AIR INLET
COLD AIR INLET
COVER FOR TUBE
CLEANING
DAMPER
HOT AIR
FLUE DUCT
1000 W
600 H
300
INSULATION
(75 THICK)
3035
530
350
DISCHARGE DOOR
CHANNEL
150X75
300
THERMO
COUPLE
R-TYPE
THERMO
COUPLE
K-TYPE
450
I-BEAM 150X75
I-BEAM
250X125
675
875 1250 1850 1075 425
1040 1075 425 875 1000 885 915
400 12001200 1200 12001200 12001200 1200 1200
200
(TOTAL LENGTH) 17000
2435
450
825
1500
550
60
0
150
1500
30
0
50
0
18
00
60
03
00
90
0
30
0
650
18
00
Ø350
1000
BLOWER
1000 959
1200 12001200 1000 1000
1000
250
600
350
1900
1500
2500
1700
4500
(SOAKING ZONE) 7000 (HEATING ZONE) 5500 (PREHEATING ZONE) 4500
33000
4370
4686
2935
600
1173
800
963
1535
593 600 600 600 600600
8
593
8
150150
685
300
4686
100
4386
750
150
750
150
675
150
3250
INSIDE WIDTH = 3300 mm
EFFECTIVE WIDTH = 3000 mm.
TOTAL LENGTH = 17000 mm
EFFECTIVE LENGTH = 15000 mm
SOAKING ZONE LENGTH = 7000 mm.
HEATING ZONE LENGTH = 5500 mm.
PRE-HEATING ZONE LENGTH = 4500 mm
10TPH RE - HEATING FURNACE WITH PULVERIZED COAL FIRING
GENERAL ARRANGEMENT.. LAYOUT & AUXILIARIES
DRAWING NO. VKS /UNDP/RHF/PC/01
BACK PANELFRONT PANEL
13
SKIDS
1200 1200 2280 1127 968 1150 2950 1250 1175 750 1250 1325
581
600
600
600
600
600
600
506
SKIDS
9000
300
1885
3035
530
350
DISCHARGE DOOR
CHANNEL
150X75
300
THERMO
COUPLE
R-TYPE
THERMO
COUPLE
K-TYPE
TROUBLE DOOR
SIZE 350X300
450
I-BEAM 150X75
I-BEAM
250X125
675
875 1250 18501075 425
1040 1075 425 875 1000 885 915
400 12001200 1200 12001200 12001200 1200 1200
200
(TOTAL LENGTH) 17000
450
825
300
525
600
350
1000 1000 959
1200 12001200 1000 1000
(SOAKING ZONE) 7000 (HEATING ZONE) 5500 (PREHEATING ZONE) 4500
3270
685
300
4686
100
4386
750
150
750
150
675
150
3250
150
750
750
4370
4686
500
3270
2935
600
1173
800
963
1535
593 600 600 600 600600
8
593
8
150150
75
150
130
250
125
150
150
150
75 75
300
3035
530
350
DISCHARGE DOOR
CHANNEL
150X75
300
THERMO
COUPLE
R-TYPE
THERMO
COUPLE
K-TYPE
450
I-BEAM 150X75
I-BEAM
250X125
675
875 1250 18501075 425
1040 1075 425 875 1000 885 915
400 12001200 1200 12001200 12001200 1200 1200
200
2435
450
TROUBLE DOOR
SIZE 350X300
8251000 1000 959
1200 12001200 1000 1000
(SOAKING ZONE) 7000 (HEATING ZONE) 5500 (PREHEATING ZONE) 4500
CHARGING DOOR SIDE PANEL
ROD PIPE
FLAP
100x200
SKID
150x150
I-BEAM
250X125
I-BEAM
125X75
FRONT BURNER SIDE PANEL
8mm Thick
M.S. Sheet
P
Q
R
S
DETAIL AT 'P'
DETAIL AT 'Q'
DETAIL AT 'R'
DETAIL AT 'S'
VIEW 'A'
VIEW 'B'
'B'
'A'
100
200
10TPH RE - HEATING FURNACE WITH PULVERIZED COAL FIRING
GENERAL ARRANGEMENT.. STRUCTURAL.
DRAWING NO. VKS /UNDP/RHF/PC/02
14
12
00
65
0
18
00
1000
20
00
30
0
1200
1000
67
5
17000
4500 1500 10004000 1500 4500
120014251025105010001950
82
5
250
125
1000 1000 959
1025 1475 1050 950 1000 1000
7000 5500
130
350 mm
TROUBLE DOOR
TROUBLE DOOR
TROUBLE DOORTROUBLE DOOR
DISCHARGE
DOOR
750
150
675
150
750
150
3300
DAMPER
1600
AIR PIPE LINE
500
SKIDS
1000
2500
1000
1000
BILLETS
100 SQX1500
SKIDS
1613 438 350675 16503150
9000
450 350 4100
43
70
350
49
70
300
200
190
140
200
115
115300
400
200
65
265
465
40
35
LEGEND
1 60% ALUMINA
2 RED BRICK
3 I.S. 6
4 END ARCH (60%)
5 END ARCH (40%)
6 R.C.C.
7 I.S. 8 (40% ALUMINA)
8 MAGNASITE
9 COLD FACE INSULATION BRICK
10 HOT FACE INSULATION BRICK
11 ASBESTOS SHEET (5mm THICK)
12 INSULATING CASTABLE
13 50% ALUMINA
14 CERAMIC FIBRE
15 STEEL PLATE (6mm THICK)
7
3
3
10
10
115
115
75
115
115
S
Enlarged View 'S'
Enlarged View 'Q'
8
13
3
11
10
12
1
14
9
10
7
265
50
75
230
115
115
75
Q
8
13
7
10
Enlarged View 'R'
R
3
13
8
50
3
7
10
14
10TPH RE - HEATING FURNACE WITH PULVERIZED COAL FIRING
GENERAL ARRANGEMENT.. REFRACTORY
DRAWING NO. VKS /UNDP/RHF/PC/03
HANGER BRICK DETAIL
BURNER DETAIL
BUTTERFLY
VALVE 50mm
BUTTERFLY
VALVE 75mm
BURNER
COAL
3
115
115
75
115
115
50
75
50
HANGER
SHOULDER
11
15
15
MAN HOLE
Ø1000
RECUPERATOR
TROUBLE DOOR
TROUBLE DOOR
TROUBLE DOORTROUBLE DOOR
DISCHARGE
DOOR
750
150
675
150
750
150
3300
BURNERS
DAMPER
DAMPER
1600
EXTRACTOR
AIR PIPE LINE
500
SKIDS
1000
2500
PUSHER
PULVERIZER UNIT
MOTOR
25 HP
960 RPM
GEAR BOX
40:1
4370
1000
1000
ROLLER
BLOWER
40" WG PRESSURE
2800 CFM
MOTOR
40HP
2880RPM
BILLETS
100 SQX1500
MOTORISED
BUTTERFLY
VALVE
350
MAN HOLE
BY PASS
BUTTERFLY
VALVE
MOTORISED
BUTTERFLY
VALVE
3625
200
2750
SKIDS
1595
17000
Ø1900
1613
CHIMNEY
2500
438
Ø800
350
3735
675 16503150
9000
450 350 4100
4370
350
4970
Ø100
INSULATION
1613 450438
675
350
2175
3501675
350
11071950
Ø100Ø500
Ø500
MOTOR
75 HP
1440 RPM
300
3035
530
350
DISCHARGE DOOR
CHANNEL
150X75
300
THERMO
COUPLE
R-TYPE
THERMO
COUPLE
K-TYPE
450
I-BEAM 150X75
I-BEAM
250X125
675
875 1250 1850 1075 425
1040 1075 425 875 1000 885 915
400 12001200 1200 12001200 12001200 1200 1200
200
(TOTAL LENGTH) 17000
2435
450
825
1500
550
60
0
150
1500
30
0
50
0
18
00
60
03
00
90
0
30
0
650
18
00
1000 1000 959
1200 12001200 1000 1000
(SOAKING ZONE) 7000 (HEATING ZONE) 5500 (PREHEATING ZONE) 4500
10TPH RE - HEATING FURNACE WITH PULVERIZED COAL FIRING
GENERAL ARRANGEMENT.. PIPING
DRAWING NO. VKS /UNDP/RHF/PC/04 16
300
3035
530
350
DISCHARGE DOOR
CHANNEL
150X75
300
THERMO
COUPLE
R-TYPE
THERMO
COUPLE
K-TYPE
450
I-BEAM 150X75
I-BEAM
250X125
675
875 1250 1850 1075 425
1040 1075 425 875 1000 885 915
400 12001200 1200 12001200 12001200 1200 1200
200
A
(TOTAL LENGTH) 17000
1
2
0
TEMP
1050° C
% RPM
35
BA
% RPM
45
1
2
0
B
TEMP
1047° C
2435
450
25
0
125
825
1500
550
600
150
1500
300
500
1800
600
300
900
300
650
1800
1000 1000 959
1200 12001200 1000 1000
(SOAKING ZONE) 7000 (HEATING ZONE) 5500 (PREHEATING ZONE) 4500
A
1
2
0
TEMP
1050° C% RPM
35
BA
% RPM
45
1
2
0
B
TEMP
1047° C2435
1 = AUTO
0 = MANUAL SLOW
2 = MANUAL FULL
A= HIGH FLAME RPM
B = LOW FLAME RPM
BUTTERFLY
VALVE 50mm
BUTTERFLY
VALVE 75mm
GEARBOX
30:1
MOTOR
2HP
1440 RPM
GEARBOX
30:1
MOTOR
2HP
1440 RPM
10TPH RE - HEATING FURNACE WITH PULVERIZED COAL FIRING
GENERAL ARRANGEMENT.. P & I DIAGRAM
DRAWING NO. VKS /UNDP/RHF/PC/05
17
MAN HOLE
Ø1000
RECUPERATOR
TROUBLE DOOR
TROUBLE DOOR
TROUBLE DOORTROUBLE DOOR
DISCHARGE
DOOR
750
150
675
150
750
150
3300
BURNERS
DAMPER
DAMPER
1600
EXTRACTOR
AIR PIPE LINE
500
SKIDS
1000
2500
PUSHER
PULVERIZER UNIT
MOTOR
25 HP
960 RPM
GEAR BOX
40:1
4370
1000
1000
ROLLER
BLOWER
40" WG PRESSURE
2800 CFM
MOTOR
40HP
2880RPM
BILLETS
100 SQX1500
MOTORISED
BUTTERFLY
VALVE
35
0
MAN HOLE
BY PASS
2HP
MOTOR
2HP
MOTOR
2HP
MOTOR
2HP
MOTOR
2HP
MOTOR
R
Y
B
N
R
Y
B
N
CONTROL
UNIT
CONTROL
UNIT
R
Y
B
R
Y
B
R
Y
B
R
Y
B
R
Y
B
R
Y
B
R
Y
B
CO
NT
RO
L
UN
ITR
Y
B
R
N
Y
B
MOTORISED
BUTTERFLY
VALVE
3625
2750
SKIDS
15
95
Ø1900
1613
CHIMNEY
2500
438
Ø800
350
37
35
675 16503150
9000
450 350 4100
43
70
350
49
70
Ø100
INSULATION
1613 450438
675
350
2175
3501675
350
11071950
Ø100Ø500
Ø500
MOTOR
75 HP
1440 RPM
10TPH RE - HEATING FURNACE WITH PULVERIZED COAL FIRING
GENERAL ARRANGEMENT.. SINGLE LINE POWER DIAGRAM
DRAWING NO. VKS /UNDP/RHF/PC/06
18
Ø800
1500
33000
4500
�‘��������
�‘�������������3�&�'��
2500
2500
10TPH RE - HEATING FURNACE WITH PULVERIZED COAL FIRING
GENERAL ARRANGEMENT.. CHIMNEY
DRAWING NO. VKS /UNDP/RHF/PC/07 19
AIR INLET
FLUE GAS
COLD AIR INLET
Ø1000
Ø1200
1200
COVER FOR TUBE
CLEANING
DAMPER
FLUE DUCT
1000 W
600 H
S.S. PIPE
75 N.B.
(70 Nos.)
BLOWER
INSULATION
1050
1000
250
600
PIPE
350 mm
1500
350
1900
1500
2500
1700
4500
1500
5396
1500
500
2000
410
550
500
SS 304
3mm THK
HOT AIR OUTLET
10TPH RE - HEATING FURNACE WITH PULVERIZED COAL FIRING
GENERAL ARRANGEMENT.. RECUPERATOR
DRAWING NO. VKS /UNDP/RHF/PC/08
BY
PASS
DAMPER
SS 304
3mm THK
MS 5mm THK
MS 12mm THK
20
30
0
30
35
53
0
35
0
DISCHARGE DOOR
CHANNEL
150X75
300
THERMO
COUPLE
R-TYPE
THERMO
COUPLE
K-TYPE
450
I-BEAM 150X75
I-BEAM
250X125
675
875 1250 18501075 425
1040 1075 425 875 1000 885 915
400 12001200 1200 12001200 12001200 1200 1200
200
(TOTAL LENGTH) 17000
24
35
450
825
1500
550
60
0
150
1500
30
0
50
0
18
00
60
03
00
90
0
30
0
650
18
00
1000 1000 959
1200 12001200 1000 1000
(SOAKING ZONE) 7000 (HEATING ZONE) 5500 (PREHEATING ZONE) 4500
600
1500
300
1600
1500
300
600
1500
300
1000 1000
600
500
900
75
75
950 950
1900
600
500
900
150
550
300
240015002400
300
300
1800
300
650
300
550
300
1800
650
10TPH RE - HEATING FURNACE WITH PULVERIZED COAL FIRING
GENERAL ARRANGEMENT.. PULVERIZED COAL FEEDING SYSTEM
DRAWING NO. VKS /UNDP/RHF/PC/09
ELEVATION
FRONT VIEW HEATING ZONE HOPPERFRONT VIEW SOAKING ZONE HOPPER
21
Disclaimer: The information contained in these drawing is for general information purpose only. The information is provided by UNDP and while we endeavor to keep the information up to date and correct, we make no representations or performance guarantee of any kind, express or implied, about the completeness, accuracy, reliability, suitability or availability with respect to the information, products, services contained here. Any reliance you place on this information is therefore strictly at your own risk. In no event will we be liable for any loss or damage including without limitation, indirect or consequential loss or damage, or any loss or damage whatsoever arising from the use of this information.
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