“Preparation of general arrangements engineering drawings ... drawing... · The Steel Re-rolling Mill (SRRM) sector to a large extent uses coal as a fuel for the re-heating furnace

“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


450

825

300

525

600

350

1000 1000 959

1200 12001200 1000 1000


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


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


GENERAL ARRANGEMENT.. STRUCTURAL.


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


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


GENERAL ARRANGEMENT.. REFRACTORY


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


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


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



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


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


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


GENERAL ARRANGEMENT.. P & I DIAGRAM


17

MAN HOLE

Ø1000

RECUPERATOR

TROUBLE DOOR

TROUBLE 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


GENERAL ARRANGEMENT.. SINGLE LINE POWER DIAGRAM


18

Ø800

1500

33000

4500

�‘��

�‘��3�&�'��

2500

2500


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


GENERAL ARRANGEMENT.. RECUPERATOR


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


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


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


GENERAL ARRANGEMENT.. PULVERIZED COAL FEEDING SYSTEM


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.

Documents

“Preparation of general arrangements engineering drawings ... drawing... · The Steel Re-rolling Mill (SRRM) sector to a large extent uses coal as a fuel for the re-heating furnace