Engineering for Excellence

ISGEC HEAVY ENGINEERING LIMITED

Welcome
All Delegates
Presentation Road Map
Engineering for Excellence

Overview : Company

Isgec Slop Fired Boilers

Insights of Isgec
 Engineering for Excellence

Isgec Heavy Engineering Limited

Overview
Who are we?
Corporate Data and Business
Founded & Incorporated
Group Turnover
Market Capitalization
Headquarter
International Offices
Manufacturing Facilities
Engineering Offices
Global Footprints
Engineering for Excellence
1933
INR 4200 Crore*
INR 4700 Crore *
Noida (Delhi NCR)
California, USA , Dusseldorf, Germany
Plant 1: Yamunanagar
Plant 2: Ratangarh
Plant 3: Dahej
Plant 4: Muzafarnagar
Plant 5: Bawal, Gurgaon
Noida (Delhi NCR)
Chennai
Pune
Yamunanagar
85 Countries
* As on 31st March, 2015
 Engineering for Excellence

ISGEC SLOP FIRED BOILERS

Next Generation Slop (Spent Wash)
Incineration Technology
What is Slop (Spent Wash) ?
Slop / Spent Wash Engineering for Excellence

An effluent (Process Waste) from molasses based Distillery.

Hazardous for direct disposal to environment.
Hence, there is a need for efficient disposal of this effluent.

Characteristics of Slop / Spent wash (Raw) Effect

Acidic in Nature
Acidic pH 4 - 4.5 Corrodes the surroundings and
contaminates the Soil.

BOD* 45000 60000 PPM It pollutes rivers and ground water.

Water becomes unfit for human
consumption and for sustaining
COD* 110000 135000 PPM aquatic life.

9 12 % w/w depending
High Moisture Difficult to handle and store
on plant configuration
Odour Pungent Unbearable

BOD - Biological Oxygen Demand

COD - Chemical Oxygen Demand
Effluent Treatment Method
Engineering for Excellence

Concentrated Slop/ Spent Wash is directly fired in the Boiler to meet

Zero Liquid Discharge

a. To Meet the Statutory Norm of Zero Discharge:

By Firing Concentrated Distillery Effluent spent wash (Slop) in a boiler.
b. By Product:
Steam Generation to meet the process requirement of Distillery.
c. Benefits:
Reduction in production cost per liter of alcohol.
Power Generation to meet captive requirement.
Potash rich ash is saleable, generates good revenue and also eliminates
disposal problem.
Solutions for Firing Slop
Engineering for Excellence

Travelling Grate Furnace with Slop Atomization

Solutions for Firing Slop
Engineering for Excellence

Travelling Grate Furnace with Slop Atomization

General Arrangement of Slop Fired Boiler

 Engineering for Excellence

ISGEC SLOP FIRED BOILERS

Spent Wash Boilers Executed
Spent Wash Fired Boilers Executed
Engineering for Excellence

32 TPH, 35 Kg/cm2, 380 Deg C at Dharani Sugars, Villupuram

Slop with Bagasse / Coal as supporting fuel
 Brief Report
Engineering for Excellence

DHARANI SUGARS & CHEMICALS LTD.

Site : Kalyanpur Village, Villupuram District, TN Commissioned Sep
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 32
Steam pressure at MSSV Outlet kg/cm2(g) 35
Steam temperature at MSSV Outlet C 380
Feed water temp. at economiser Inlet C 150
Main Fuel/s (Percentage on Heat Basis)
50% Slop + 50% Bagasse
50% Slop + 50% Coal (Indian / Imported) 100% MCR
100% Bagasse
100% Coal (Indian / Imported)
Slop quantity to be fired (55 65 Brix) Kg/hr 10000
Slop GCV (at 55 Brix) Kcal/kg 1750
Dust concentration at the ESP outlet mg/Nm3 100
Spent Wash Fired Boilers Executed
Engineering for Excellence

22 TPH, 45 Kg/cm2, 400 Deg C at Mumias Sugar, Kenya

Slop with Bagasse / Coal as supporting fuel
Commissioned in September- 2012
 Brief Report
Engineering for Excellence

MUMIAS SUGARS & CHEMICALS LTD.

Site : KENYA Commissioned Sep
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 22
Steam pressure at MSSV Outlet kg/cm2(g) 45
Steam temperature at MSSV Outlet C 400
Feed water temp. at economiser Inlet C 150
Main Fuel/s (Percentage on Heat Basis)
50% Slop + 50% Bagasse
50% Slop + 50% Coal (Indian / Imported) 100% MCR
100% Bagasse
100% Coal (Indian / Imported)
Slop quantity to be fired (55 65 Brix) Kg/hr 6000
Slop GCV (at 55 Brix) Kcal/kg 1750
Dust concentration at the ESP outlet mg/Nm3 100
What Competitors Said
Engineering for Excellence

Total 8 Slides
Spent Wash Fired Boilers Executed
40 TPH, 45 Kg/cm2, 400 Deg C at Balrampur Chini Mills, U.P. Engineering for Excellence

Slop with Bagasse as supporting fuel

Engineering for Excellence
 Brief Report
Engineering for Excellence

BALRAMPUR CHINI MILLS LIMITED

Site : BALRAMPUR, UTTAR PRADESH Commissioned Nove ber
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 40
Steam pressure at MSSV Outlet kg/cm2(g) 45
Steam temperature at MSSV Outlet C 400
Feed water temp. at economiser Inlet C 140
Main Fuel/s
Slop + Bagasse MCR 100%
Bagasse

Slop quantity to be fired (55 65 Brix) Kg/hr 13000

Slop GCV (at 55 Brix) Kcal/kg 1700
Dust concentration at the ESP outlet mg/Nm3 50
 Brief Report
Engineering for Excellence

BALRAMPUR CHINI MILLS LIMITED

Site : BALRAMPUR, UTTAR PRADESH Commissioned Nove ber
SITE PARAMETERS UNIT VALUES
Steam flow at MCR TPH 39 - 42
Steam pressure at MSSV Outlet kg/cm2(g) 43 - 45
Steam temperature at MSSV Outlet C 395 - 402
Feed water temp. at economiser Inlet C 130 - 140
Fuel Fired
MCR 100%
Slop + Bagasse
Fuel Parameters Avg. (TPH) TPD
Slop quantity fired (52 62 Brix) 13.00 300 315
Bagasse fired 7.00 170 175
Dust concentration at the ESP outlet mg/nm3 29 - 42
Brief Report
Engineering for Excellence
Spent Wash Fired Boilers Executed
Engineering for Excellence

18 TPH, 45 Kg/cm2, 400 Deg C at Dalmia Sugars, Kolhapur

Slop with Coal as supporting fuel
 Brief Report
Engineering for Excellence

DALMIA SUGARS LIMITED

Site : KOLHAPUR, MAHARASHTRA Commissioned Nove ber
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 18
Steam pressure at MSSV Outlet kg/cm2(g) 45
Steam temperature at MSSV Outlet C 400
Feed water temp. at economiser Inlet C 150
Main Fuel/s
Slop + Indian / Imported Coal MCR 100%
100% Imported Coal
100% Indian Coal MCR 80%
Slop quantity to be fired (55 65 Brix) Kg/hr 5500
Slop GCV (at 55 Brix) Kcal/kg 1750
Dust concentration at the ESP outlet mg/Nm3 50
Spent Wash Fired Boilers Executed
Engineering for Excellence

24 TPH, 45 Kg/cm2(a), 390 C at Madhucon Sugar & Power, Telangana

Slop with Coal as supporting fuel
 Brief Report
Engineering for Excellence

MADHUCON SUGAR & POWER LIMITED

Site : TELANGANA Commissioned Ja uary
DESIGN PARAMETERS UNIT VALUES
Steam flow at MCR TPH 24
Steam pressure at MSSV Outlet kg/cm2(a) 45
Steam temperature at MSSV Outlet C 390
Feed water temp. at economizer Inlet C 150
Main Fuel/s
Slop + Bagasse MCR 100%
100% Bagasse
Slop + Coal (Indian / Imported)
MCR 100%
100% Coal (Indian / Imported)
Slop quantity to be fired (55 65 Brix) Kg/hr 6500
Slop GCV (at 55 Brix) Kcal/kg 1750
Dust concentration at the ESP outlet mg/Nm3 50
 Reference Installations for Slop Fired Boilers
Engineering for Excellence

Commissioned /
Customer TPH Ata Deg C Fuels
Commissioning

Shri Sai Priya Sugars Ltd., Karnataka 52 45 400 Slop + Bagasse February 2017

Balrampur Chini Mills, Uttar Pradesh 40 45 400 Slop + Bagasse November 2015

Dharani Sugars & Chemicals, Tamil Slop + Bagasse

35 35 380 2012
Nadu / Coal

Slop + Bagasse
Madhucon Sugar & Power, Telangana 24 45 390 January 2016
/ Coal

Indreswar Sugar Mills, Maharashtra 23.5 40 400 Slop + Bagasse February 2016

Slop + Bagasse
Mumias Sugars, Kenya 22 45 400 2012
/ Wood Chips

Dalmia Sugar, Kolhapur 18 45 400 Slop + Coal November 2015

 Engineering for Excellence

ISGEC SLOP FIRED BOILERS

Advantages of Isgec Design
Advantages of Isgec Design

Proven Travelling Grate technology Engineering for Excellence

Flexibility fuels :: Wide variety of support fuels such as Bagasse / Rice

Flexibility of Fuels
husk / Wood Chips / Coal etc.
Minimum
Minimum Maintenance
Maintenance : : Familiar, proven and easy to operate technology
Enhanced Up Time:
Enhanced Uptime : Online removal of clinkers with continuous ash
discharge ensuring no stoppage of Boiler.
3 pass design
Efficient Combustion : in tall furnace due to adequate time availability
for mixing of slop and support fuel.
Ash
Ash bridging Eliminated in third pass due to wide transverse pitch of
bridging eliminated
heating surfaces.
Better
Better
BetterCombustion
Combustion through Tall Furnace. Lower flue gas temperature at
Combustion
superheater inlet to avoid fouling due to alkalies in ash (Na2O + K2O)
and corrosion of SH due to chlorides in ash.
Advantages of Isgec Design
Online Cleaning System Engineering for Excellence

Easy
Easyremoval
removalof
ofgun
gunfor
forcleaning.
Cleaning
Reliable
Reliable & Efficient
Efficient On-Load
On-LoadCleaning
Cleaning:
Steam operated soot blowers for super
heater and other convective heating
surfaces in horizontal pass to ensure
cleaning without any stoppage.
 Advantages of Isgec Design
Engineering for Excellence

Slop firing system

Complete
Complete combustion
Combustion : high pressure
atomization (spray) of slop thru
Specially designed Nozzles.
Slop
Slop nozzles
nozzles : located at Strategic
height on furnace water wall to ensure
complete combustion and minimum
carry over.

Slop
SlopPumps
Pumps: high pressure
pumps are provided to ensure
adequate pressure of slop for
atomization.
Advantages of Isgec Design

Specially Designed Air Pollution Control Equipment Engineering for Excellence

Combination of Pre-Dust Collector and Electrostatic Precipitator / Bag

Filter.
Higher Spacing between Electrodes of ESP
Special Type TR Set Controllers of ESP.
Shorter Length of Electrodes for Effective rapping in ESP.

Bag filters with optimum air to cloth ratio.

Special material of filter bags to withstand corrosive flue gas.
Cleaning of filter bags with reverse air pulses.
Proper Gas distribution in Bag filter to promote better release of Dust.
Advantages of Isgec Design

Engineering for Excellence

100% Steam Generation possible with support fuels

Even if slop is not available, Power & Steam demand can be met at all
times.
Low Gas Velocity in Furnace, hence eliminates tube erosion.
Cost effective due to lower power consumption and negligible
maintenance.
Eliminates requirement of additional consumables like bed material.
Avoids manual poking due to self sustained and efficient combustion.
 Engineering for Excellence

ISGEC SLOP FIRED BOILERS

Improvement in Design
 Improvements in Design
Special Designed I-Grate Engineering for Excellence

Specially Designed-I Grate for Slop Fired Boiler

No Gaps B/w Grate Bars to avoid
Jamming due to entrapment of Foreign
Material
Minimum Gaps between Adjacent bars

No gap between Grate bars in new TG.

 Improvements in Design
Engineering for Excellence

Specially Designed-I Grate for Slop Fired Boiler

The Uniform distribution of air across the Grate take place to
avoid local combustion due to ash accumulation.

Practically no Gap between Grate bar &

partition plate in new TG
 Improvements in Design
Specially Designed-I Grate for Slop Fired Boiler Engineering for Excellence

MINIMUM GAPS BETWEEN ADJACENT BARS

WIDER GRATE BARS AND SHOTER IN LENGTH
SELF LUBRICATING SHAFT BEARINGS
ONLINE REPLACEMENT OF LAST ROW GRATE BAR BY SIMPLY REMOVING
ONE BOLT EASY MAINTAINANCE. LESS DOWN TIME

Grate Bar is wider and shorter in length. Grate bar consists of number of orifice shaped inline holes
through which air passes and Fuel burns over the grate bar.
 Improvements in Design
Low Dust Loading Engineering for Excellence

Economizer and APH are constructed in Vertical arrangement instead of

Horizontal in order to reduce the dust load in economizer and APH. It also leads to
easy cleaning of Economizer and APH.
 Improvements in Design
Effective Soot Blowing Engineering for Excellence

Providing the More effective Short Retractable Soot Blowers for On-line cleaning of
Evaporator, economizer and APH.
It provide more blowing radius and better cleaning action even against the flue gas
flow.
 With Above Design & Features,
Engineering for Excellence

minimum 60 days Continuous

Operation of this boiler
Delighted Customers : Cogeneration Boilers
Engineering for Excellence

1 x 220 TPH Travelling Grate Boiler for

Ingenio Magdalena, SA, Guatemala
Delighted Customers : Cogeneration Boilers
Engineering for Excellence

190 TPH Travelling Grate boiler for 40 MW Bagasse /

Coal based Power Plant for Kesar Enterprises, Baheri, U.P.
 Delighted Customers : Cogeneration Boilers
Engineering for Excellence

3 x 150 TPH Travelling Grate Boilers for

Kamphaengphet Bioenergy Company, Thailand
Delighted Customers : Cogeneration Boilers
Engineering for Excellence

130 TPH Travelling Grate Boiler at

Coregreen Sugars Limited, Karnataka, India
Delighted Customers : Cogeneration Boilers
Engineering for Excellence
 Delighted Customers : Cogeneration Boilers
Engineering for Excellence

36 MW Bagasse / Coal based Power Plant with 1 x 180 TPH

Travelling Grate Boiler for Shree Dutta SSK, Kolhapur, India
Delighted Customers
Engineering for Excellence
 Delighted Customers : Biomass Fired Boilers
Engineering for Excellence

28 TPH Biomass Fired Boiler for 8 MW Power

Plant for Aldebran, Spain
 Engineering for Excellence

Isgec Heavy Engineering Limited

MORE ABOUT ISGEC
Business Verticals
Engineering for Excellence

ISGEC HEAVY ENGINEERING LIMITED

Industrial Boilers EPC Others

Oil & Gas Fired Turnkey Power Plants Process Equipment:
HRSGs Pressure Vessels &
CFBC Heat Exchangers
AFBC Presses: Mechanical &
Traveling Grate Hydraulic
Reciprocating Grate Sugar Machinery
Castings: Steel & Iron
WHRB Turnkey Sugar Plants Contract Manufacturing
Waste to Energy Trading
Vinasse / Slop

Utility Boilers Air Pollution Control Special Products

Equipment
Pulverized coal O&M services
ESP Spares & R&M
fired boilers
Dust Collectors
Global Experience
Engineering for Excellence
Our Locations
Engineering for Excellence
Noida
International Offices:
California, USA
Dusseldorf, Germany
Yamunanagar 70 International Agents
Ratangarh

Noida HO
New
Delhi
Bawal
Dahej Muzaffarnagar
INDIA

Dahej Kolkata

Mumbai

Pune

Chennai

Ratangarh
Isgec Yamunanagar
Engineering for Excellence
Isgec Ratangarh
Engineering for Excellence

Automatic Plant
TUBES in PRODUCT out.
100 % Shot blasting
Online real time inspection.
Multihead SAW moving panel welding machines
PLC operated heat-treatment furnace
Hydro testing up to 600 Kg/ sq.cm g.
Isgec Dahej
Engineering for Excellence
Isgec Muzaffarnagar
Engineering for Excellence
Boilers
Engineering for Excellence

170 TPH TG Boiler for Mumias Sugar

100 TPH CFBC Boiler for Nirma, India.
Company Ltd., Kenya

105 TPH AFBC Boiler at Gujarat 140 TPH Oil Fired Boiler for Kochi
Flurochemicals Limited, India Refinery, India
Power Plants
Engineering for Excellence

1x30.4 MW Power PlantCore

25 MW for Zambia Sugar
Green, Mahrashtra 1x30 MW KPR Sugar Mills, Karnataka
( part of British Sugars)

2 x 20 MW Grasim Industries Ltd., Karnataka 1x25 MW Power Plant for

Core Green Pvt Ltd, Karnataka
Quality, Safety and Environment
Engineering for Excellence

ISO 9001:2008 Approval by Lloyds Register of Quality Assurance

ASME S U U-2 & U-3 Stamps

ASME N Stamp

R Stamp

NB Stamp

Approval by Lloyds as a Class I fabricator of Fusion Welded Pressure Vessels

up to 200 mm (8) thickness

China Safety Quality License

ISO 14001 : 2004

OHSAS 18001 : 1999

 Engineering for Excellence

Thank you
ISGEC HEAVY ENGINEERING LIMITED
A-5, Sector 63, Noida - 201 301 (U.P.) India
Tel.: +91 - 120 4085900 Fax: +91 - 120 4085999
Email: vluthra@isgec.co.in / nshastry@isgec.co.in