Sorbent Handling Plant by NHI-Design & Equipment Specifications Ibtisam Mahyyuddin Management Associate (Machinery CPP)

Objective “To provide complete overview of Sorbent (limestone) Handling Plant and description of its main equipment supplied by NHI.”

Contents Sorbent Handling Plant (SHP) Battery Limits Mechanical Conveying Section Sorbent Unloading & Storage Building Crushing House Limestone Storage Silo (450T) Pneumatic Conveying Section Compressor House Dense Phase Pumps Pneumatic Conveying Piping Summary

Sorbent Handling Plant Designed to convey Sorbent (limestone) of required size to the CFB boiler limestone bins in Coal Power Plant Limestone as desulphurization agent Sorbent Handling Plant Mechanical Conveying Section Pneumatic Conveying Section

Mechanical Conveying Section Pneumatic Conveying Section Battery Limits Start Point: Limestone Unloading Station End Point: Outlet Flange of limestone storage silo (450T) Mechanical Conveying Section Start Point: Outlet Flange of limestone storage silo (450T) ` End Point: Inlet Flange of boiler limestone bins Pneumatic Conveying Section

Mechanical Conveying Section Sorbent Unloading & Storage Building Belt Conveyor Limestone Storage Silo 450t Crushing House Column Mill Air Classifier Double Cyclone Separator Mill Feeding Silo

Mechanical Conveying Section Sorbent Unloading & Storage Building Purpose To receive limestone from trucks & keep it as storage Specifications Type: Shed & three sides covered (Only South Side Open) Capacity: 1000MT Pile Dimensions: 30x11x3 m (LxWxH) Main Equipment Unloading hopper Rod gate Belt Conveyor

Belt Conveyor & Selection Options For Raw Limestone Conveying From Unloading Hoppers Belt Conveyor & Bucket Elevator Chain Conveyor Belt Conveyor FPCL Selection Parameters Reliable Operation Easy Maintenance Safe Working

Belt Conveyor Specifications Title Description Horizontal Length (Pulley center to center) 148.5 m Width 650 mm Rated Capacity 100 t/h Troughing Angle 30° Belt Speed 1.25 m/s Belt conveyor Inclination 10° Belt Construction Type EP belt (fire resistant) No. Of Plies 3 Belt cover material grade DIN class F Total Thickness of Belt 14.1 mm

Mechanical Conveying Section Limestone Crushing House FPCL Requirements Facility: Covered Building Milling Type: Single Stage Milling No. of Mills: 2 Capacity of each Mill: 50 t/h Inlet Granulometry: 20 ~ 30 mm (nominal size) 5% above 30 mm up to max. 35mm Outlet Granulometry: <1mm Grinded Powder (Particle Size Distribution as per graph 1.1)

Graph 1.1

Mechanical Conveying Section Limestone Crushing House Main Equipment Mill Feeding Silo Weighing Belt Feeder Column Mill Air Classifier & Separator Belt Feeder (Enclosed) Bucket Elevator Chain Conveyor Bag Filter Mill Feeding Silo Weighing Belt Feeder Column Mill Air Classifier Belt Feeder (Enclosed) + Bucket Elevator Cyclone Separator

Mill Feeding Silo Purpose Specifications Title Description Receiving limestone from unloading hoppers Maintaining continuous supply to column mill Store raw limestone for emergency Specifications Title Description Capacity 100 ton Shape Cylindrical Material of Construction Steel Liner Hardox 400 Diameter 5 m

Weighing Belt Feeder Purpose Specifications Title Description Two weighing belt feeders to feed limestone to column mills from mill feeding silo (100t) and air classifier (recycled oversize). To weigh limestone received from mill feeding silo (100t) only. Specifications Title Description Horizontal Length (Pulley center to center) 7.5 m Width 1000 mm Capacity 150 t/h Location Before column mills

Column Mill & Selection Options For Milling of Raw Limestone Option 1 70 mm < 1 mm Option 2 35-30 mm < 1 mm Crusher Column Mill 30 mm Column Mill

Column Mill Purpose Specification Title Description Carrying out milling of limestone Specification Inlet Chute Main Shaft Title Description Type Conical Grinding Mill No. of column mills 2 (1 Operational + 1 Standby) Capacity 45-50 t/h Input Material Size Range ≤35mm Output Material Size Range <1mm Rollers Outlet Chute

Air Classifier & Cyclone Separator Purpose Separation of particles for following motives: Re-cycling of oversized material Conveying desired material to 450t Silo Specifications Double Cyclone Separator Title Description Type PL Waterfall-type Powder Separator Desired Material Output Size <1 mm Capacity 50 t/h Location Limestone Crusher House Operating pressure 2.903 kPa Air Classifier

Circulation Blower Purpose Specifications Title Description Circulate air between PL Classifier and Double Cyclone Separator Convey limestone dust to bag filter Specifications Title Description No. of Blowers 1 Type Centrifugal Blower Operating Pressure 2.903 kPa

Belt Feeder Purpose Specifications Title Description Two belt feeders Safe transportation of powdered limestone Specifications Title Description Horizontal Length (Pulley center to center) 11.42 m Width 800 mm Capacity 150 t/h Location Between column mills and bucket elevator 1

Belt Feeder Specifications: Title Description Horizontal Length (Pulley center to center) 11.08 m Width 800 mm Capacity 100 t/h Location Between PL classifier and weighing belt feeder

Bucket Elevator Purpose Specifications: Title Description Two bucket elevators Transport powdered limestone to higher elevations safely Specifications: Title Description Type Chain Bucket Elevator Conveying Height 30.12 m (From el. -6.62 m - el. +23.5 m ) Capacity 150 t/h Location Between belt feeder 1 and PL classifier

Bucket Elevator Specifications: Title Description Type Chain Bucket Elevator Conveying Height 18.95 m (From el. +0.150 m to el. +19.1m) Capacity 60 t/h Location Between chain conveyor 1 and chain conveyor 2

Chain Conveyor Purpose Specifications: Title Description Two chain conveyors Safe transportation of powdered limestone Specifications: Title Description Horizontal Length (Pulley center to center) 7.03 m Capacity 60 t/h Conveying Speed 0.33 m/s Location Between cyclone separator and bucket elevator 2

Chain Conveyor Specifications: Title Description Horizontal Length (Pulley center to center) 4.2 m Capacity 60 t/h Conveying Speed 0.33 m/s Location Between bucket elevator 2 and storage silo (450)

Mechanical Conveying Section Limestone Storage Silo Purpose Milled Limestone Storage for 3.5 days Continuous supply to dense phase pumps Specifications Title Description Capacity 450 ton Shape Cylindrical Material of Construction Steel Liner Hardox 400 Diameter 9 m

Dust Extraction System Purpose To extract limestone dust from following locations in crusher house: Mill Feeding Silo Belt Feeder 2 Cyclone Separator Equipment Bag Filter or Dust Collector Exhaust Blower Screw Chain Conveyor

Pneumatic Conveying Section Compressor House Purpose To supply compressed air for pneumatic conveying of limestone To supply air for dust extraction system To supply air for fluidization of storage silo (450T)

Pneumatic Conveying Section Compressor House Equipment Compression Unit for Pneumatic Conveying Air Compressors Air Dryers Filters Service Air Receivers Instrument Air Receiver

Pneumatic Conveying Section Air Supply Unit for Dust Extraction System Air Compressor Air Dryer Filter Instrument Air Receiver Fluidization Unit for Storage Silo (450T) Blowers Electric Heater

Compression Unit for Pneumatic Conveying Purpose To supply compressed air to pneumatic conveying piping Specifications of Compressor Title Description Type Rotary Screw Air Compressor No. of Compressors 3 (2 Operational+1 Standby) Capacity 28 m³/min Pressure 0.75 MPa Cooling Method Water Cooling Air Oil Separator Screw Element Air Inlet Pipe Motor

Air Supply Unit for Bag Filter Purpose To provide compressed air for bag filter Specifications of Compressor Title Description Type Rotary Screw Air Compressor No. of Compressors 1 Capacity 3.6 m³/min Pressure 0.75 MPa Cooling Method Air Cooling Air Oil Separator Screw Element Air Inlet Pipe Motor

Fluidization Unit for 450 T Storage Silo Purpose To supply fluidized air to avoid lump formation of material in silo Specifications of Blowers Inlet Title Description No. of Blowers 2 Type Root Blower Capacity 3 m³/min Pressure 50 KPa Blower Motor Outlet

Pneumatic Conveying Section Powder Limestone Silo 450t Compressor Vent Valve Air Injectors Dense Phase Pump Pneumatic Conveying Piping

Pneumatic Conveying Section Dense Phase Pumps Purpose Receiving powder limestone Convey it to pneumatic lines Specifications Title Description No. of Dense Phase Pumps 2 Effective Volume 2.5 m³ Pressure < 1 MPa

Pneumatic Conveying Section Pneumatic Conveying Piping Purpose To transfer limestone from powder limestone storage silo through dense phase pumps to limestone surge bins of CFB boilers. Specifications Title Description Material Carbon Steel Size 219-273 mm Elevation 7.5-35.4 m Capacity 30 t/h Pneumatic Conveying Piping

Summary Equipment Compatibility and suitability for limestone conveying and processing Provision of standby equipment at critical point to avoid any hindrance in smooth operation of plant Provision of sufficient space for equipment maintenance Availability of limestone storage for emergency use Covered Buildings for material storage and processing are considered to Avoid Air pollution