DESIGN REVIEW

04/DE/4825
UPGRADATION OF ESPs IN SINTER
PLANT - 2, DSP

FEASIBILTY REPORT
Presenter:
Dr. Somraj Chakravarty, Date of Acceptance : 08.03.2021
AGM (Utilities) Sch Date of Submission: 05.06.2021
TASK FORCE
Activity Schedule
 BACKGROUND
 SP-II, DSP was commissioned in Feb’ 1995. It has 1
no. Sinter machine of 180 m2 sintering area with rated
capacity of 1.71 Mtpa gross sinter
 Sinter Plant (SP) -2 of DSP has 2 nos.Electrostatic
Precipitators (ESPs)T1 A& T1B for Process gas
cleaning and 2 nos. of ESPs (B1 & B2) for area de-
dusting. Both Process gas cleaning and area de-dusting
ESPs were designed forstack emission of 150 mg/Nm3
 Present stack emission during normal running of the
Sinter Plant is in the range of 60-80mg/Nm3 for Process
gas cleaning ESPs and in the range of 80-120 mg/Nm3
for area de-dusting
 BACKGROUND Contd…
 Existing system details
 BACKGROUND Contd…
 As per one of the specific conditions mentioned in the
ToR of EC from MoEFCC during Environment
clearance application for the upcoming modernization
cum expansion projects at DSP - Particulate matter
emissions shall be less than 30 mg/Nm3 in new units
and in all old units, it shall be achieved by Dec 2023
except for Coke oven stacks which shall be less than
50 mg/Nm3
 Accordingly, DSP has assigned CET to study and
prepare FR for Upgradation of ESPs in SP-2 for
achieving <30 mg/Nm3 stack emission in all four
ESPs
SELECTION OF ALTERNATIVES
 Keeping in view the constraint of space and time required for
increasing the ESP size in order to enhance the collection
efficiency as well as the longer shutdown requirement, the
possibility of installation of additional fields in the existing
ESPs have been not considered.
 The only alternative by replacement of collecting and
discharge electrode, rapping mechanisms and electrical up
gradation with the deployment of HFTR/Pulse technology for
up gradation of ESPs to achieve stack emission level of <30
mg/Nm3 has been considered. Similar system has been
implemented in Tata Steel and JSW also
 SELECTION OF ALTERNATIVES Contd…

 Benefits to ESP with HFTR/Pulse technology : Dust

reduction, Power reduction, Fine particle reduction
 Considering the small shutdown, no new space requirement and
minimum hindrance to existing operation for installation, the
only alternative of replacement of internals and TR sets with
HFTR and related electrical system has been considered
PRINCIPLE OF OPERATION OF TR SET WITH PULSE TECHNOLOGY
 The new Pulse technology energizes the ESP with narrow pulses,
superimposed on a pure DC base voltage. These narrow pulses make it also
possible to raise the peak voltage considerably over the normal sparking limit
in the ESP. This gives a better current distribution inside the ESP, a minimized
"back-corona" effect on the collecting plates and a better charging of the
dust particles. This is particularly important when treating fine particulate
PRINCIPLE OF OPERATION OF TR SET WITH PULSE TECHNOLOGY Contd..

 The TR set with pulse technology consist of capacitors storing energy to be

released into the ESP. Up to 16 MW of energy is released within 75
microsecond. This is repeated up to 100 times per second, whereby an
electrical field of maximum 140.000 volts is created. Particles entering this
field are accelerated to high migration velocity.
 The high voltage exceeds the dielectric strength of the gas and results in
ionization of the gas. Plasma phase of the gas, resulting in electric sparks, are
avoided due to the ultra short pulses – due to which the generated voltage
goes beyond the natural spark limit.
 The pulse technology gives advantages as reduced outlet emission, especially
at high Resistive dust, energy saving and reduced precipitator size.
PRINCIPLE OF HIGH FREQUENCY TR SET WITH CONTROLLER
 Works at much higher frequency 20-25 kHz
 Creates ripple to the tune of 3-5% on the output DC voltage allowing the
average voltage to be nearly equal to the peak voltage.
 High frequency controller has a higher power factor above 0.95 against 0.63
of conventional controller.
 High frequency Controller has faster control response and better intermittent
energisation due to rapid turn off ability, resulting over 250 times faster
response than the conventional controller.
 Due to high frequency operation the controller is more compact and lighter
in weight than a conventional unit and can be retrofitted with minor
modification in existing ESP.
 Reaction time is below 100 micro sec. Conventional 50 Hz supply reaction
time of 10 milli secs or more. Results in significant improvement of pre
performances in terms of energy saving and improving the collection
efficiency.
 PROJECT DESCRIPTION
Following work shall be carried out for up-gradation of existing ESPs to
achieve an emission guarantee of ≤ 30 mg/Nm3
ESP system - physically surveyed and health condition assessment

System design checked by modelling and CFD analysis - guide vanes in inlet

duct or splitter plates in inlet funnel as recommended shall be installed.

Existing collecting plates, rapping and support system shall be replaced.

Existing discharge electrodes, rapping and support system shall be replaced

Existing roof beams, structures shall be checked and reused if suitable.

Existing GD screen at Inlet and Outlet funnels shall be replaced

Plates shall be installed in-between all the fields to avoid gas sneakage.

New mechanical key interlocking system

New casing hot roof and cold roof (steel supported outer roof)

Existing casing, hopper, inlet & outlet funnel shall be reused - Patch work

Repair of dust handling arrangement shall be done

The existing ID fans and stack shall be reused.

Existing monorail structure & hoist shall be reused

 PROJECT DESCRIPTION Contd…
 The existing TR sets shall be replaced with combination of new
HFTR sets and Pulsar system as per new design in all existing fields.
 The existing controller and control panels shall be replaced in
existing MCC room for all fields. Hardwire communication is
considered.
 The existing support insulators with its heating system, shaft
insulators, etc. shall be replaced
 The rapping and heating system will be powered & controlled from
new controller.
 Existing cable/tray & grounding system, CEMS shall be reused.
 The existing heating element shall be reused.
 PROJECT DESCRIPTION Contd…
SHUTDOWN REQUIREMENT
 For replacement of internals, i.e. GD screen as per recommendation of CFD

analysis, Collecting and discharge electrodes, with supporting structure,

Rapper systems, roof modification, replacement of TR set with HFTR and
Pulsar system about 1 month (30 days) shutdown of ESP system will be
required, hence, shutdown of about 1 month of Sinter machine will be
required for replacement of internals and TR set with controllers as per new
design for Process gas ESP (2 nos.) i.e. T1A &T1B.
 Also, during this shutdown replacement of internals of De dusting ESPs B1

& B2 shall be taken up in parallel as no separate shutdown of Sinter

Machine will be given.
 The shutdown to be matched with Planned Sinter Plant 2 shutdown to
minimise the loss of sinter production and proper planning to be done to
store the sinter by increasing the production or by sourcing from another
SAIL plant so that Hot metal production of DSP is not hampered
MANPOWER REQUIREMENT
 No additional manpower has been planned as replacement job.
 PROJECT IMPLEMENTATION
Implementation
The project is envisaged to be implemented within a period of 10
months from the date of Stage-II approval.
Pre-ordering activities are envisaged to be completed within 4
months from the date of Stage-I approval
Shutdown Activities
 PROJECT IMPLEMENTATION
 Schedule of activities After Stage II Sanction
CAPITAL COST
 RECOMMENDATION
 The project is a technical necessity and statutory
requirement for controlling the stack emission to less
than 30 mg/Nm3in view of the TOR given to DSP.
 The Project is technically feasible and in view of
fulfilment to the new emission norm, recommended
for consideration by DSP