ENVRO DV8ON.

PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.

CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX


OPERATION


And


MAINTENANCE

8Y8TEM :
GA8 COOLER FOR 100 TPD 8PONGE
RON KLN.


DESIGNED , SUPPLIED & COMMISSIONED BY
ENVRO DV8ON ,
THERMAX LTD

OC NO. :

Date:


ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX


INDEX
1. Introduction.
2. Subject.
3. System description.
4. System safeties.
5. Operation.
a. Start-up.
b. Normal operation.
c. Shutdown.
d. Dos & Donts
6. Recommended spares
7. Annexure.

















ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX


INTRODUCTION

We congratulate you for buying state of art gas cooling system from Thermax Ltd,
(Enviro division), Pune, India.
Thermax ltd is leading engineering company in various fields like, heat transfer
equipments, boilers, pollution control equipments, water treatment, waste management
systems etc.
Thermax ltd ensures the need of customer and designs equipment to suit needs. This
gas cooler cools waste gas of Sponge Iron (I.R.) processes. Cooler is designed to have
minimum running cost and efficient gas cooling. Design has ensured the fluctuating input
of gas & its impact on safety and performance of equipment.
This document gives guidelines for effective operation and maintenance of the
equipment to active desired performance, safety for desired period of life. We always
ensure to document our field experience and share with you through this document. We
would appreciate your feed-backs for further improvement of this document.

















ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX


SUBJECT
It is expected that user should read this document thoroughly before first time
gas cooler is put into operation and follow recommendations/ guidelines in
regular operation. In case of any doubt, user should write to Thermax Ltd (Enviro
Division) Pune, and seek confirmation.

Any performance degradation or life degradation of equipment due to non-
conformance of guidelines indicated in this document, Thermax Ltd. will not be
held responsible.




















ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX


SYSTEM DESCRIPTION.

The intention of this equipment is to cool down sponge iron (IR) process off
gases coming from kiln, before entering into gas cleaning system. The
temperature at outlet of gas cooler is controlled to suit the desired temperature
limits of gas cleaning system. The gases are cooled by indirect cooling, by air
blowing through the tubes over which hot gases are passing.

Process parameters.
1. Gas flow 24000 nm3/hr.
2. Gas inlet temp deg c 1000 +/- 50 deg c.
3. Gas outlet temp deg c 180 +/- 20 deg c.
4. Gas dust content 30-35 gm/nm3.
5. Ambient temp 40 deg c.
6. Gas side pressure drop 60 mm WC.

The off waste gases coming out of ABC (after burning chamber), is taken
from gas duct into gas cooler. The gas is entered into gas cooler from top inlet
duct and diverted into first module from bottom side. The gas cooler is
constructed with four modules. Modules are of horizontal tubular construction. Air
moves inside the tubes and gas flows outside the tubes. Air moves horizontally
and gases move from bottom to top, i.e. vertically. The materials of construction
for modules are selected based on individual metal temperature. First module
tubes are of SS 304 construction and casing of module 1 & 2 are lined with high
temperature refractory lining. Tubes are secured in tube sheets on both side and
firmly constructed in the casing. One end of tube is fixed to tube sheet by welding
and other end is encased in sleeve for free expansion.

ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX

On one side of tube sheet, cooling air is passed and from other end it is
escaped in to ambient. While air moves through the tubes, heat is picked up from
gas and in turn gas is cooled down. To achieve required gas outlet temperature,
cooling is done in four stages.
Gas enters from bottom of first module and escapes from bottom of fourth
module. The gas leaving from bottom is taken to gas cleaning system. The
bottom face of first module is mounted on steel structure. The gas comes from
ABC through duct and turns by 180 deg through hopper in to module no 1. As the
gas turn by 180 deg, good amount of dust is removed before entering in to
module 1 which is collected in hopper 1.

Axial blowers generate the high pressure cooling air. The ambient air is
utilized for the cooling purpose. All blowers are driven by individual electrical
motors. This fan is directly mounted on the gas cooler structure and connected to
individual modules through canvas expansion joint. The canvas joint
compensates differential expansion between fan and modules and isolates
vibration forces from fan to cooler.

Platforms with ladders are provided for easy approaches to various
locations for operation and maintenance of various components. For safety
purpose no approach is provided in front of hot air discharge. For regular
discharge of dust from hopper, dead weight operated lever type valve is
provided. The dust is discharged in to water filled tank. The hot dust cools down
after discharging in to water. Client to make provision for regular shifting of
cooled down dust. System should be in place to maintain tank with sufficient
water level continuously.




ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX


Material of construction.
1. Tubes Module 1 SS 304
Module 1/2/3 Carbon steel

2. Tube sheets- Module 1,2,3,4 IS 2062
3. Tube sheet sleeves- Module 1 SS 310
Module 2 SS 304
Module 3 & 4 carbon steel.

4. Anchors for: Module 1 SS 310
Module 2 SS 304
Inlet duct SS 310
Hopper SS 310

5. Casing for: Modules 1,2,3,4 IS 2062
Gas Inlet duct IS 2062
Hopper IS 2062
Gas Out duct IS 2062
Air in/out duct IS 2062

7. Refractory-
Gas inlet duct First layer Whytheat C
Second layer Insulite 11
Hopper First layer Whytheat C
Second layer Insulite 11
Module1, 2 Casing layer Insulite 11

8. Insulation Mineral wool 120 kg/m3 (LRB type).

ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX


SYSTEM SAFETIES
1. For protection of over all gas cooler system, If gas in-let temp and outlet temp
are beyond expected level, the gases are directly bypassed to atmosphere
through ABC top duct damper before entering into gas cooler system

2. To protect over heating of tubes and subsequent damage to tubes,
temperature at inlet of gas cooler is measured continuously. As the
temperature increases beyond the set point, signal will be transferred to ABC
duct damper actuator. The damper will bypass the gas till the time gas
temperature reaches to acceptable set point.

3. To protect down stream dust removal system, temperature at outlet of gas
cooler is measured continuously. As the temperature increases beyond the
set point signal will be transferred to ABC duct damper actuator. The damper
will bypass the gas till the time gas temperature reaches to acceptable set
point.

4. To protect overloading of ID fan due to obstructions in gas side of gas cooler,
DP switch is provided across module 1&4. If pressure drop is more than set
point, alarm signal will be generated.

For more detailed control system information refer P&I diagram, control logic and
respective component manuals.






ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX

OPERATION
a. Start-up.
Following pre-commissioning and checking activities to be carried out
before taking gas cooler first time in to operation. These activities to be
documented prior to take hot gases in to system.
1. Ensure that all assemblies are in line with approved drawings.
2. All expansion provisions are in line with drawing.
3. All temporary support used during construction are removed.
4. Ensure no restriction remain in the system for expansion.
5. All instruments are calibrated.
6. Trouble free no-load trails for fans are checked for at least 12
hours.
7. Ensure that heating surfaces are clean from both sides. No foreign
material like wool, sand etc is on tube inside and outside surfaces.

Refractory dry out - Procedure
Before taking high temperature gas in to system, refractory needs to
be cured to form proper refractory bond and avoid damages due to steaming
of moisture in it. Following procedure to be followed for refractory curing.
Take hot gases (from kiln / other source) at low temp in to system.
Measure refractory temp continuously. The refractory temp should be raised
slowly from ambient to 100-110 deg C in 4 to 5 hours time. Hold gas
temperature so that refractory temp remains at 100-110 deg temp for at least
5 hours. Then raise temp of refractory to 300-325 deg C slowly at rate of 25
deg C per hour. Hold refractory temp for 5 hours at 300-325 deg C. Again
refractory temp be raised to 500 deg C slowly at rate of 50 deg C per hour
and hold it for 5 hours. Finally refractory temp be raised to 700 deg C at rate
of 50 deg C per hour and hold for 5 hours.
Cool down refractory once it is cured at 700 deg c. Cooling rate should
be very slow. The rate of cooling should be less than 15-20 deg c per hour.
ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX

Once the temp of refractory is cooled to ambient temp, refractory to be
observed for its status. In case refractory produces cracks beyond
acceptance limit, local repair to be done as per refractory manufacturers
recommended procedure.

Important- In any case tube metal temp of module 1 tubes should not cross
450 deg c and module 4 tubes should not cross 375 deg c.

Once the refractory is cured and all steps indicated above completed,
equipment is ready for first startup.

Actual Startup
Follow the startup sequence as below.
It is expected before gas cooling system start up that hot gases are
vented through ABC top discharge port (by opening damper on it).
1. First start module 1 to 4 axial blowers. Ensure that all fans reached
to equilibrium, i.e. full airflow condition.
2. The bottom flap of ash discharge valve is closed.
3. ID fan down stream of dust cleaning system is started slowly by
opening suction damper slowly. (It is presumed that dust cleaning system is
ready for taking hot gases in to system.) Ensure that head of 5 mm is
established at inlet of module 1.
4. Start closing of top damper on ABC slowly. Simultaneously control
ID fan suction damper in such a way that gases from ABC will be diverted in
to gas cooler. The gas entry should be very slowly so that gas flow will reach
to full flow in 4-5 hours time linearly.
5. Ensure all control systems are operating at expected set point
temperatures in operating conditions.
6. Check the expansion behavior of the equipment as per expectation.
ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX

7. Adjust the weight location of ash discharge valve in way that valve
will be open as soon height of ash in hopper reaches between 250 to 300
mm.

b. Normal operation.

This equipment is very simple to operate and does not require very high
level of attention in normal operation. However regular observations and
precautions are required for its effective performance.
1. Record gas inlet and out let temp regularly in log table.
2. Measure current drawn by fan motors regularly and record in log table.
3. Ensure that ash is regularly removed from the hopper. In no case ash
storage in hopper is more than 300 mm in height.
4. Ensure that fans are not vibrating and its regular maintenance is done
as per recommendations of fan manufacturer. (Refer attached manual
of fan for more details.)
5. Ensure that canvas joint of fan is intact. In case it is torn off, replace
the cloth immediately.

Warning. In case cloth is torn off, sufficient air may not pass through fan
and remaining will be escaped to atmosphere. This case may lead to high
metal temp and may have serious impact on metallurgical properties of
tubes.

c. Shutdown.
Planned shut down
The gas cooler should be close sequentially.
1. ID fan should be closed slowly and in parallel ABC duct
damper should be open. This activity is to take place for at least 15-20
min.
ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX

2. The axial blowers on all modules should be kept in running
condition for at least 34 hours so that refractory temp is cooled down to
400 deg c below. Fan can be kept in running condition to cool down
system further.
3. Do not open any manholes till the refractory comer to
ambient temp.

Emergency shut down

1. In case emergency shut down is required, open ABC
damper full.
2. Keep axial blowers in running condition till refractory temp is
dropped to 400 deg c.


d. Dos & Donts

Dos
1. Regular maintenance of fan and its motor.
2. Regular inspection and maintenance of canvas joint.
3. Regular inspection and maintenance of refractory.
4. Regular inspection and maintenance of ash discharge valve.
5. Regular observations for dust accumulation on tube surfaces. (to
be cleaned regularly in shut down by air blowing.)
6. Take shutdown as earliest when pressure drop across gas cooler is
increased beyond set point.
7. Regular logging of gas temperatures in various zones.



ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX

Donts
1. Excess ash accumulation in hopper.
2. Unclean (fouled) tube external surfaces.
3. Fan running with torn canvas joints.
4. Fans in vibrating condition.
5. Operation of equipment when refractory on tube sheet and module
casing fallen down.
6. Operation of equipment with module 1 & 2 fans working with low
airflow.
7. By pass of any control system.
8. Running of system even after pressure switch (for pressure drop
across gas cooler) alarm is generated.


















ENVRO DV8ON.
PROJECT: GAS COOLER FOR 100 TPD SPONGE RON KLN.
CUSTOMER:

CONSER\/NG ENERG. PRESER\/NG THE EN\/RONMENT

THERMAX



Maintenance spares

1. Tubes SS 304 for module 1, Carbon steel for module 2,3,4 -
5% of total tubes.
2. Refractory.
3. Fan components refer fan manual.
4. Canvas joint cloth.


Annexure:

Sr.
no. Document
Document No.
1 P & I Diagram 70516 007 20
2 General Arrangement drawing for Gas cooler 7E501 245 10
3 Equipment Layout 7E501 254 10
4 Fan + Motor Manual
5 Instrument Manual
6 Control Logic 70516 052 00
7 Erection drawings 7E509 825 10