Factory Name: Ajara Shetkari Sahakari Sakhar Karkhana Ltd.

, Ajara,
Maharashtra
Operational Status: WorkingPlant
Plant Name: Ajara
Code: 38401
Factory Nature: PVT
Nearest Railway Station: Sawantwadi 70 Km.
Nearest Airport: Kolhapur.
Nearest Hotels: 1) Minerva, Ajra 10 Km., 2) JRD, Amboli 24 Km.
Holiday: Sunday
Courier Service: Prithvi, Palande
Bank Details: Bank of Maharashtra, Gavase, A/c.No.-20238000080,
A/c.Type- Current, NEFT/IFS Code- MAHB0001066.
GST Number: 27AAAAA0496R1ZB
Plant Make: NHEC, WIL, BELLISS, KAY IRON
Milling Plants: 4 mill Tandem, Fibrizor, 12 Rollers, Roller size 930 x
1700mm with UFR
 Table of content
1 Introduction...

1.1 general overview of internship...

1.1.1 objective of internship...

1.1.2 Challenges...

1.1.3 Benefit gained from internship...

1.2 Company Background....

1.2.1 main product..

1.2.2 main customer...

2. Steam and power generator..

2.1 introduction

2.2 Steam generator (Boiler)...

2.3 classification and type of Boilers..

3. Boiler Auxiliaries....

4. Boiler Mounting.....

5. Water/Steam Flow in boiler auxiliaries..........

6. Bagasse Flow......

7. Feed and Boiler Water Treatment...

7.1 Controlling corrosion....

 1. INTRODUCTION

1. General overview of internship

1. Objective of internship

The main objective of this internship is to evaluate our theoretical knowledge and make us
develop practical skills that have a huge progress for our future professional experience and
career. This internship program has the following major advantages:

 It helps us to take a challenging position that allows us to utilize our currents skills.
 It helps us to think about the future and review our goals.
 It helps us to develop several business ideas that we will be able to delve when we
graduate.
 Helps us to work in a real life engineering environment for problem solving skills.

The two month we spent in wonji/shoa sugar factory has been the most successful month of our
internship period. We will use this experience as an asset for our next summer internship.

2. Challenges
There are many challenges that we have been through during performing our intern tasks,
although we manage to accomplish all tasks and duties assigned to us by the host supervisor.
These challenges were personal, organizational, work group, community and other and they
include: -

 Adapting to the working environment

 Due to the fact that we were new to the organization, it took some time to get used
to and cope with the working environment. In the first day of internship we did not
have much to do and had to be vigilant and sit all day without having much to do.
This was a challenge because it made us so idle and bored for the first weeks in the
factory. But this problem was solved by our immediate supervisor by giving us a
schedule of duties.
 Get confused on the first week of the internship program.
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  This was due to the lack of confidence to ask question, but solved after our
supervisor gave us an opportunity to ask anything that wasn’t clear and helped us
understand what to do.
 Noise pollution at the boiler house
 This was due to the function of boiler and monotony of the work being carried out
and there was little to learn under this condition.
 No training manual for intern student
 The factory is under the contract of Indian company called UTAM group. They
keep most of their information on boiler as a top secret and they don’t want to give
manual to the factories employee. But our supervisor tried his best to give us a
manual on boiler that he could find.
 Location of the factory from the main city
 The factory is found in rural area of Oromia region and far from the main road.
 There is no transportation service for intern students.

3. Benefits gained from internship

Throughout our internship term, we develop the following fundamental skills: -

1. Upgrading Theoretical Knowledge

 further knowledge on boiler auxiliaries and mounting,

 operations and calculating boiler efficiency

2. Improving Practical Skills

 hand skill on maintenances

 coupling and de-coupling pumps from there motors

 de-attach bolts and nuts from boiler auxiliaries

 operating crane to lift heavy load

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  cleaning ash from economizer and boiler wall tube

3. Improving problem solving capacities

4. Level of accomplishment of duties and responsibilities assigned.

5. Exposure to the working environment

 This boosted the understanding which was mainly theoretical to be practical.

6. Improving team work skills

7. Improving leadership skills

8. Develop Entrepreneurship skills

9. Develop basic Work ethics rules

 Punctuality

 Reliability

 Responsibility, etc

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1.2Company Background

The factory is found at Oromiya Regional State near Adama City at 110 Kilo Meters from
Addis Ababa. Commencing production in 1954 it is the oldest and the pioneer in the
history of Ethiopia’s sugar industry. And Shoa Sugar Factory constructed in 1962 is the
second oldest and both, being obsolete, have stopped production since July, 2012 and July,
2013 respectively. The two factories constructed by the Holland Company known as
H.V.A had a capacity of producing 750,000 quintals of sugar a year. The Sugarcane
plantation land of these two factories was 7,000 hectares out of which 1,000 had been
planted by out growers.

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In a bid to replace these two oldest factories with a new and modern one, an expansion
project had been carried out both in the cane cultivation field and the factory since 2010.
And, the factory plant expansion project has come into its completion in July, 2013.
Accordingly, the newly built and modern Wonji/Shoa Sugar Factory is constructed by the
Indian Company known as UTAM GROUP, has currently a design capacity of crushing
6,250 tons of cane a day and producing over 174,000 tons of sugar per annum which with
further expansion will reach up to 12,500 TCD maximizing its production to 220,700 tons
of sugar a year. The new ethanol plant planned to be built, will have a capacity of
producing 12,800 meter cube. The Factory is currently contributing 20 mega watt electric
powers to the national grid in addition to satisfying its own demand which is a round 11
mega watt.

Its agricultural expansion project is currently being carried out around the areas known as
Wakie Tiyo, Welenchiti and North Dodota areas. The factory, with the help of this
agricultural expansion project, will have 16,000 hectares of sugarcane plantation field in
total. The total cane cultivation field of the factory has currently reached 12,800 hectares.
And, the 7,000 hectares of the factory’s sugarcane field cultivated with the agricultural
expansion project is owned by out grower farmers of the surrounding area. There are 32
Sugarcane out Growers associations which in total have 9,100 member farmers. The
Factory, beyond supplying the farmers with selected seeds, and rendering professional as
well as technical support to them, has made irrigable land available to all.

Mission: Creating modern technology and capable human resource so as to develop the
nation’s potential to the sector produce sugar, sugar bi-products and co-products and take
remarkable foreign market share and support the nation’s economy beyond satisfying
domestic demand.

Vision: Stand as one among ten leading countries of the world in sugar industry in 2023
based on a sustainable growth.

Core Values wonji shoa sugar Factory

 Sustainable change and competitiveness;

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  Virtuous work ethics;
 Productivity is crucial to our existence;
 Popularity is our typical feature;
 We never stop learning;
 We encourage creativity and best performance;
 Working in team spirit is our unique feature;
 Environment protection is fundamental to our development;
 Development of human resource is vital to our success.

AIMS OF THE INDUSTRY

 To satisfy the country need in technological development in sugar.

 In order to maximize the export market.
 In order to satisfy the market demand of customer.
 To maximize profitability of the industry.

1. Main products of wonji/shoa sugar factory

 White sugar
 Brown sugar
 Ethanol
 Molasses
2. Main Customers
 Most of Brewing and wine-making industry
 Different type of food complex company
 Different baking company for different types of bakery product

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 2. Steam and Power Generation

Introduction: - A power plant may be defined as a machine or assembly of equipment that

generates and delivers a flow of mechanical or electrical energy. The main equipment for the
generation of electric power is generator. When coupling it to a prime mover runs the generator,
the electricity is generated. The type of prime move determines the type of power plants. The
major power plants, which are known all over the world, are the following: -
1. Steam power plant
2. Diesel power plant
3. Gas turbine power plant
4. Nuclear power plant
5. Hydro electric power plant
The Steam Power Plant is called THERMAL POWER PLANT, because it converts heat into
electric energy. The simplest steam cycle of practical value is called the Rankine cycle, which
originated around the performance of the steam engine. The steam cycle is important because it
connects processes that allow heat to be converted to work on a continuous basis. This simple
cycle was based on dry saturated steam being supplied by a boiler to a power unit such as a
turbine that drives an electric generator.

2.2 Steam Generator (Boiler)

In wonji/shoa sugar factory Steam is generated in boiler plant. Water requires heat energy to be
boiled in to the boiler pressure parts and then the generated saturated steam is then sent to the
supper heater for further temperature increment. The use of steam mainly to generate electric city
and then is used in other plants for various purposes.

Boiler is any closed vessel that produces energy by the combustion of either fuel or bagasse,
having water holding capacity of 22.75 L and pressure 3.5 Kg/Cm2 and above be used for steam
generation under high pressure.

Boiler is considered as the heart of a sugar factory. If any breakdown occurred at boiler plant, the
whole sugar factory is shut down.

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3. Classification and Types of Boilers
There are many types of boilers but basically they fall under two categories:

1. Fire Tube Boiler

2. Water Tube Boiler

Fire Tube Boiler

Fire Tube or "Fire in tube" Boilers: - Long steel tubes through which the hot gasses from a
furnace pass and around which the water to be converted in to steam.

Example - Locomotive Boiler, Cochran Boiler, Cornish Boiler

Water Tube Boiler (the one used in wonji/shoa sugar factory)

The water passing through the tubes and the hot gasses passing outside the tubes, These
boilers can be of Single or multiple drum type and can be built to any steam capacity and
pressure, have higher efficiency than fire tube boilers.

3.Boiler Auxiliaries
Boiler auxiliaries are in the boiler circuit to increase the boiler efficiency
1. Heat-Recovery Equipment
a) Economizer
b) Air Pre - Heater
c) Super Heater
2. Water Tanks
a) Condensate storage water tank
b) DM (Demineralizing) tank
c) Hot-well tank
d) De-aerator tank
e) Deaerated feed water storage tank
f) Blow down tank
g) Main and day oil tank
h) High pressure(HP) heater tank
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 3. Fans
a) P.S fan
b) S.A fan
c) F.D fan
d) I.D fan
e) Burner fan
4. Pumps
a) Make-up water pump
b) Feed Water Transfer pump
c) Boiler Feed water pump
d) Chemical dosing pump
e) Start-up feed water pump
5. The drums
a) Steam drum
b) Lower(water) drum

6. Temperature and pressure controlling equipment

a) PRDS
b) Attemprator
7. Soot blowers
8. Wall Tube and Convection Bank
9. Super heater headers
10. Furnace

11. Boiler Grate

12. Mechanical separators
 ESP (Electrostatic precipitator)
13. Ash Handling System
14. Boiler stack

Economizer: - is a heat recovery system, usually installed near and at the back side of boiler.
In boilers, economizers are heat exchange devices that heat fluids, usually water, up to but
not
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normally beyond the boiling point of that fluid. Economizers are so named because they can
make use of the enthalpy in fluid streams that are hot, but not hot enough to be used in a boiler,
thereby recovering more useful enthalpy and improving the boiler's efficiency. They are a device
fitted to a boiler which saves energy by using the exhaust gases from the boiler to preheat the
cold water used to fill it (the feed water).
Economizer shall be installed before the air heater and after boiler bank. Heating surface of the
economizer shall be adequately designed to give the water outlet temperature of 250 to 260 0C.
The economizer shall have facility to bypass gas and water in order to raise air temperature at the
cost of feed water temperature, during abnormal conditions. The Economizer header material
shall be SA-106, seamless and the material of tubes shall be grade 360 of BS 3059/ part II having
4.06 mm thickness. Economizer tubes shall be seamless. The economizer should have ash
removal/handling system to dispose the ash into the ash Silo’s. Also soot blowers shall be
provided at suitable locations.
The internal structure of economizer is must be cleaned from ash that result when flue gas pass
through the tube and also must be maintained properly. The burn-out tube must be removed and
replaced by new tube.

Figure 3.1 Structure of Economizer used in Wonji/Shoa sugar factory.

Air Pre – Heater: - An air pre-heater or air heater is a general term to describe any device
designed to heat air before another process (for example, combustion in a boiler) with the
primary objective of increasing the thermal efficiency of the process. They may be used alone or
to replace a recuperative heat system or to replace a steam coil. In particular, this article describes
the combustion air preheaters used in large boilers found in thermal power stations producing
electric power from bagasse.

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 Figure 3.2 External Structure of Air Pre-heater used in Wonji/Shoa sugar factory

The purpose of the air pre-heater is to recover the heat from the boiler flue gas which increases
the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas. As a
consequence, the flue gases are also sent to the flue gas stack (or chimney) at a lower
temperature, allowing simplified design of the ducting and the flue gas stack. It also allows
control over the temperature of gases leaving the stack to emissions regulations. Air heater shall
be tubular type located downstream of the economizer. The air heater shall be of sufficient
heating surface area to get preheated air temperature not less than 175 0C and the flue gas at the
outlet of air heater shall not be more than 160 0C. The tube material, for first ten rows facing the
entry of cold air, shall be Corton steel ASTMA – 423, Grade – 1 having Chromium 0.5% to
1.2% minimum or of equivalent grade, as per BS/IS Standard, of 2.03 mm thickness. All other
tubes shall be ERW steel tubes having 2.03 mm thickness. The air heater should have ash
removal/handling system to dispose the ash into the ash Silo’s.

Super Heater: - The function of a super heater is to increase the temperature of the steam
above its saturation point. The super heater is very important accessory of a boiler and can be
used both on fire tube and water-tube boilers. Super heaters are located in the path of the furnace
gases so that heat is recovered by the superheated from the hot gases. It is used to reduce steam
consumption of the turbine and increase the efficiency of steam plant.

Pendant type super heater shall be designed to furnish stable superheated steam temperature from
50 % part load up to peak load. All Super heater headers material shall be seamless pipe
conforming to suitable grade as per ASME specification SA – 335, P 11, HFS. Super heater tubes
shall be seamless alloy steel conforming to suitable grade as per ASME specification SA 213 T-
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11 for primary super heater and SA 213 T-22 or equivalent for secondary super heater.
Thickness of both primary and secondary tubes shall not be less than 8 SWG or 4.06 mm
whichever is higher and thickness of headers shall be in accordance with BS/IS.

Condensate storage water tank (Quantity: 1 No.): - This is a storage tanker in

which steam is condensed to water and stored after hitting or rotating the turbine blade.

Demineralizing(DM) tank (Quantity: 2 Nos.):- is the tank that stores treated water that
comes from demineralizing plant. The tanks shall be fabricated from carbon steel plates. The
capacity of each tank up to overflow level shall be 800 m3. The tank shall be installed on RCC
foundation designed for total load. The thicknesses of the plates shall be appropriately selected.
The tank shall be with conical top. One drain connection and one overflow connection with
valves, for both, shall be provided.

Figure 3.3 DM Tanker used in Wonji/Shoa sugar factory.

Hot well tank (Quantity: 1 No.): - The hotter the water the better! However pump
cavitations can be a problem at higher temperatures. A hot well should be correctly designed to
mix returning hot condensate with cold 'make up ‘water. Some hot wells can be too cool, or if a
spurge has dropped off the water temperature can be stratified (hot at the top and cooler at the
bottom). This means that cooler water is entering the boiler which will require more heat energy
to bring the boiler water up to operating temperature. Depending on the amount of condensate
returning, steam injectors are used to raise the water temperature in the hot well, which also
means less anti- corrosion chemicals are required.

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 Figure 3.4 Hot Well Tank of Wonji/Shoa sugar Factory.

De-aerator (Quantity: 2 Nos.): - It is a device that is used for the removal of oxygen and
other dissolved gases from the feed water. Three vertical cylindrical de-aerators with individual
horizontal cylindrical feed water tank shall be provided. Oxygen % in de-aerated water shall be
within 0.007 ppm (7 ppb). Motive steam available for De-aeration shall be at 1.5 bar (g) pressure.
Each De-aerator shall have 225 m3/hr capacities to heat feed water to specified temperature. De-
aerators shall be designed to give 105 0C water temperatures, at de-aerator outlet.

Deaerated feed water storage tank (Quantity: 2 Nos.): - Temperature of condensate

from de- aerators shall be 105 0C. The tank with dished ends shall be designed to 2.0 bar (g)
pressure The de-aerated water storage tanks shall be horizontal cylindrical and of carbon steel
construction, minimum 120 m3 capacity up to overflow level with at least 300 mm space for vapor
above overflow level. Hot well and de-aerator tanks shall be installed on the independent
supporting steel

Figure3.5 De-aerator and de-aerated feed water storage Tank of Wonji Sugar Factory.
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High pressure (HP) heater (Quantity: 2 Nos.): - One HP heater shall be provided for
each boiler to heat the feed water to 160oC. HP heater shall be located in delivery side of the feed
water pumps. The type of heater shall be tubular and shell type heat exchanger. Heating medium
shall be steam at 8 bar pressure. The condensate shall be sent to hot-well tank. The HP heater
shall be complete with pressure and temperature transmitters with level controller.

P.S Fan (Quantity: 2 Nos.): - It is called pneumatic spreader fan in which the discharged air
serves as a motive force in spreading the bagasse from the spreader to the boiler furnace.

Figure 3.6 Pneumatic spreader fan used in Wonji/Shoa sugar factory.

FD Fan (Quantity: 2 Nos.): - In a mechanical draught system, the draught is produced by a
fan. In a
forced draught system, a blower or a fan is installed near or at the base of the boiler to force the
air through the boiler combustion bed and other passages through the furnace, flues, air preheated,
economizer etc.

Figure 3.7 F.D fan of Wonji/Shoa sugar factory.

I.D Fan (Quantity: 2 Nos.): - In this system a fan or blower is located at or near the base of
the chimney. The pressure over the fuel bed is reduced below that of the atmosphere. By creating
a partial vacuum in the furnace and flues, the products of combustion are drawn from the main
flue
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and they pass up the chimney. Designed flue gas temperature for ID fan shall not be less than 170
0C for capacity but the material of fan shall be suitable to handle flue gas at 250 0C temperature.
ID fan capacity shall be designed for 30 % higher than the actual flue gas quantity required for
MCR steam generation at 170 0C flue gas temperature. Each fan shall be suitable for minimum
50% designed discharge capacity, considering 30 % excess capacity, required for MCR
generation. For calculating the drive power, overall efficiency of the fan, transmission, motor,
etc should not be considered more than 70%. Drive shall be AC VFD. Also pneumatically
operated dampers shall be provided for fine automatic control of draught.

Figure 3.8 I.D fan in Wonji/Shoa sugar factory.

S.A Fan (Quantity: 2 Nos.): - It is secondary air fan. In this system a fan is located at or
near the sides of the Furnaces. The discharge of this fan is connected to the body of the boiler
with multiple nozzles that direct air to the inside combustion chamber to create turbulence in
the flue gas. This insures perfect mixing of fuels which makes the combustion under suspension.
Secondary air system shall be suitable for using only bagasse or, only furnace oil (for 50 % MCR
generation) or, mixed fuel firing. High pressure secondary air/ over fire air shall be injected into
the furnace through heat resistant nozzles mounted in the front and rear walls of the furnace to
create turbulence for complete and efficient combustion of the volatiles.
Make-up water pump (Quantity: 3 Nos.): - Three horizontal , centrifugal pumps, two
operating one
standby, directly driven by an electric motor, mounted on a combination base plate, shall be
provided. Capacity of each pump shall be about 200 cum/h with suitable head.
Feed Water Transfer Pumps (Quantity: 2 Nos.): - is pump that installed below the
hot-well and Suitable to pump feed water into De-aerator and maintain requisite pressure at the
de-aerator nozzles. It has a pumping capacity of 250m3/h (minimum) each, at temperature of
90oc (average) and 1100c (maximum) with specific gravity of 0.92 - 1.

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Boiler Feed water pump (Quantity: 6 Nos.): - is a multistage centrifugal pump of
higher head and reasonable discharge capacity. As this pump is mainly designed to supply water
to the boiler during steam generating, its discharge head should be sufficient enough to feed the
boiler by overcoming the boiler internal pressure. Reserve feed water pump is a must in case of
any possible mechanical and electrical failure. In some cases where there is absence of alternative
power source need may arise to have turbo feed water pump for the plant to use it in case of
power failure.

The pumps shall draw feed water from de-aerated feed water storage tank and deliver the same to
the boiler top drums through economizer. The pumps should be capable of handling feed water at
a temperature of 105 oC averages and 110 oC maximum. The minimum delivery head of the pump
shall be 950 meters of liquid column. Feed water pumps shall be connected to different power
sources/MCC. Hence, turbo feed water pump is not considered. Maximum efficiency of the pump
shall be at operating capacity of 85t/h. The de-aerated water storage tank shall be located at
suitable height so that adequate NPSH is available at pump suction for feed water of 105 0C
average and 110 oC maximum temperatures. Inline strainer shall be provided in pump suction
line with in-situ cleaning facility. Boiler feed water pumps shall be provided with motorized
discharge valves suitable for operation from control room.

Start-up feed water pump (Quantity: 1 No.): - This pump shall be similar to
Electrically driven feed pumps except the capacity shall be 75 m3/hr. Suitable TEFC electrically
driven motor and other fittings to be supplied. The minimum delivery head of the pump shall be
950 meters of liquid column.

The drums: - are used to separate the saturated steam from the water. The steam and water
drums shall be in accordance with BS/IS Standard. The drums shall be radio-graphed stress
relieved and hydrostatically tested. Each drum shall be equipped with manholes and gaskets.
Drums shall be located in the boiler setting in such a way that welding seams are protected from
direct radiant heat of the furnace. Material of construction for drums shall conform to ASTM
specification SA - 515/516 Grade 70, or equivalent. Drum thickness shall be in accordance with
BS/IS. Minimum inside diameter of the drums shall be as follows.
a) Steam drum inside dia - 1400 +/-10mm minimum
b) Lower drum inside dia - 1050 mm minimum
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For top drum a continuous blow down connection with an internal pipe -and intermittent surface
blow down connection shall be provided. Nozzles with valves and fittings for HP chemical
dosing, safety valves, air vent, water level gauges and indicators, pressure gauges, level
controllers, feed water feeding, boiler water sampling etc. shall be provided. For uniform
distribution of feed water inside the drums, perforated feed water pipe is to be provided.

Figure 3.9 Steam and Water drums used in Wonji/Shoa sugar factory

PRDS: - The term PRDS stands for pressure reducing and de superheating system. The live
steam pressure and temperature would be reduced depending on the typical process requirement.
Like steam for boiling house, high pressure heater, sulphur burner, turbine gland packing, furnace
oil atomizing and soot blowing.

Figure 3.10 PRDS of Wonji/Shoa sugar factory.

Attemperator: - It is a device to control temperature of the super heated steam using feed
water as a cooling media prior to its entrance to Hp heater. There are two types of de-super
heater devices.

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 1. Sub Cooler Type

2. Spray type (the one used in wonji/shoa sugar factory)

3. Sub Cooler Type: - Sub cooler type is a tube and shell type heat exchanger that is
installed in the bottom of steam drum. The temperature is controlled by regulating super
heated steam flow to the cooler using attemperator valve.
4. Spray Type: - Spray type de-super heater uses same feed water to spray on superheated
steam
by directly applying the water in to the steam at the out let of primary super heater header.
Usually this type is applicable where operation by automation exists.

Soot blower: - is ash cleaning/removal equipment that use dry steam to improve heat transfer
in the following zones:

1. Super heater
2. Convection bank
3. Economizer

Motorized retractable soot blower arrangement shall be provided at super heater zone, one from
each side wall and one at the bottom. The retractable soot blowers shall be located in the hottest
zone of super heater. Drawing showing the location shall be submitted. At other zones, motorized
rotary soot blowing equipment shall be provided. The soot blowing shall be automatic
sequentially operated and controlled from control room. Steam for soot blowing system shall be
tapped from a suitable place on the boiler. Boiler steam generation capacity shall be net of soot
blowing requirement.

Wall Tube and Convection Bank: - The wall tubes are pipes with dia-4.06 mm made of
copper materials that pass through the furnace where combustion takes place. Copper materials
used for its higher heat transfer rate. As the water passes through this pipes it is further heated to
a higher temperature by the heat released from the combustion process. Convection bank tubes
shall be Seamless and conform to grade 360 of latest edition of BS: 3059/Part II, or equivalent.
Tube thickness shall be 4.06 mm. Evaporation rate based on mean diameter of tubes of
Convection bank, Furnace wall and Economizer shall not exceed 25 kg/m2/hour.

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Super heater headers: - The super heater headers are of two types, primary super heater
header (PSHH) and secondary super heater header (SSHH).they are mounted in the order of
their names but there is a device called an attemprator if positioned between them to regulate
the final temperature of the steam that enter the turbine.

Figure 3.11 super heater headers of Wonji/Shoa sugar factory.

Boiler Grate: - Boiler grate shall be of continuous ash discharge Travelling/Pulsating type,
suitable to work on bagasse. Drives for the grates shall be through hydraulic power pack or
Variable frequency electric drives (VFD). Effective grate area shall not be less than 67 m2 and
heat release rate shall not exceed 2.3 x 106 Kcal/m2/h. The front ash discharge chutes shall be
provided with by-pass chute with leak-proof gate valves.

Figure 3.12 Pulsating Grate of boiler furnace in wonji/shoa sugar factory.

ESP (Electrostatic precipitator): - ESP is a particulate control device that uses electrical
forces to move particles entrained within an exhaust stream onto collection surfaces. The
entrained particles are given an electrical charge when they pass through a corona, a region
where gaseous ions flow. Electrodes in the center of the flow lane are maintained at high voltage
and generate the electrical field that forces the particles to the collector walls. In wet ESPs, the
collectors are

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either intermittently or continuously washed by a spray of liquid, usually water or rapped by
hammer to release collected pollutants.

Figure 3.13 ESP used in Wonji/Shoa sugar factory.

Ash Handling System: - Separate ash handling system for each boiler shall be provided.
Boiler shall have following minimum ash discharge outlets:

a) Front grate discharge hopper discharging in Submerged Belt Conveyor.

b) Riddling hoppers below the grate discharging.
c) The hoppers below air heater discharging in screw conveyors.
d) Electrostatic precipitator discharging in screw conveyors.
e) Main belt conveyor leading to ash storage bin.
f) Ash handling /removal shall be considered for economizer / air heater.

Boiler stack: - Scope includes Boiler stack, separate for each boiler, of RCC construction.
Height of stack shall be 65 m above ground. The stack shall be provided with access ladder,
aviation lights, lightening arrestor etc. Inside clear diameter of stack shall be suitably designed
for flue gas velocity between 12 m/sec.

4. Boiler Mountings
These are fittings, primarily intended for safety of boiler and control of the steam generation
process. These are:
1. Pressure Gauge: - This indicates the pressure of the steam in the boiler.

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2.Water Level Indicator: - This indicates the water level in the boiler. The water level in the
boiler should not fall below a particular level otherwise the boiler will be overheated and the
tubes may burn out.
3. Safety Valve: - The function of the safety valve is to prevent the increase of steam pressure
in
the boiler above its design pressure. When the pressure increases above design pressure, the valve
opens and discharges the steam to the atmosphere. When this pressure falls just below design
pressure, the valve closes automatically. Usually the valve is spring controlled.
4.Fusible Plug: - If the water level in the boiler falls below a predetermined level, the boiler
shell
and tubes will be overheated. And if it is continued, the tubes may burn, as the water cover will
be removed. It can be prevented by stopping the burning of fuel on the grate. When the
temperature of the shell increases above a particular level, the fusible plug, which is mounted
over the grate, melts and forms an opening. The high-pressure steam pushes the remaining water
through this hole on the grate and the fire is extinguished.
5. Blow-off Cock: - The water supplied to the boiler always contains impurities like mud,
sand
and, salt Due to heating, these are deposited at the bottom of the boiler, and if they are not
removed, they are accumulated at the bottom of the boiler and reduce its capacity and heat
transfer rates. Also the salt content will goes on increasing due to evaporation of water. These
deposited salts are removed with the help of blow off cock. The blow-off cock is located at the
bottom of the boiler and is operated only when the boiler is running. When the blow-off cock is
opened during the running of the boiler, the high-pressure steam pushes the water and the
collected material at the bottom is blown out. Blowing some water out also reduces the
concentration of the salt
6. Steam Stop Valve: -It regulates the flow of steam supply outside. The steam from the
boiler
first enters into an ant-priming pipe where most of the water particles associated with steam is
removed.
7.Feed Check Valve: - The high pressure feed water is supplied to the boiler through this
valve. This valve opens towards the boiler only and feeds the water to the boiler. If the feed water
pressure is less than the boiler steam pressure then this valve remains closed and prevents the
back flow of steam through the valve.

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 Figure 4:- General Arrangement of a Water Tube Boiler Showing All Parts and Auxiliaries.
5. Water/Steam Flow in Boiler Auxiliaries
The conversion of water in to steam involves a closed vessel water tube boiler which operates
based on Rankine cycle. In order to convert water to pressurized steam, it must pass through
different types of boiler auxiliaries like tankers, tubes, pumps, valves and etc.

For simplicity of our report, it better to start the water/steam cycle from condensate tanker.

 The temp. of water at the outlet of condensate tanker is around 750c and pass through
condensate pump to be stored in the DM Tanker for deposit and ph treatment.

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 The water that stored in the DM Tanker passes to Hot-Well tank with the help of make-up
pump.

 The water in the hot-well tank then pass through feed water Transfer pump to be
further treated in the De-aerator with inlet temp. of 80 – 850C and leaves with the outlet
temp. of around 1050C.
 The water that stored in de-aerated storage tanker flows down by gravity and passes
through HP heater with the help of Feed water pump.
 The HP heater, heat the feed water to around 1600C and then passes to economizer to be
further heated.
 The water in the economizer heated to around 250 – 2600C and pass through water drum.
 Water from water drum inters into boiler bank for further heating and then pass into wall
tube through water drum.
 From wall tube it inters a steam drum and passes through primary and secondary super
heater with outlet temp. of 510 + 50C with a temp. controlling device called Attemperator.
Them the super heated steam goes to turbine class to rotate the turbine blade and generate
electricity and other goes to process for different use.
 The steam that rotates the turbine blade then condensed inside a condenser to finish its
cycle.

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 Hot Well Tanker

DM Tanker Make-up water Pump

Condensate Pump
De-aerator

Deaerated Feed Water

Storage Tanker

Condensate Tanker Transfer Pump

HP Heater

Feed Water Pump

Economizer

Water Drum

Boiler Bank

Wall Tube

Steam Drum

PSHT

Attemprator Turbine G

To Process
Pump SSHT
Condenser

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Cooling
 6. Bagasse Flow
Sugarcane bagasse is a fibrous agricultural biomass that results from the crushing and milling of
sugarcane stalks. Bagasse is widely recognized as an abundant and low cost fuel, with a global
annual production of approximately 54 million dry tones, increasing in the cost of energy and the
well-known energy properties of bagasse have given rise to its use as a viable alternative fuel for
cogeneration. The use of bagasse as a biofuel for the cogeneration of steam and excess electrical
energy is central to the operation of many sugar processing facilities.

In Wonji/Shoa sugar factory the bagasse flow is represent as the following.

Sugar cane

Milling Machine

Bagasse Raw sugar juice

Molasses Clarified Juice

Sugar crystal

Belt conveyer (BC 1) Belt conveyer (BC 3) Bagasse Elevator (BE)

Main Bagasse Conveyer Silo Screw Conveyer Feeder

Furnace

The wet bagasse is taken directly wet bagasse conveyer 1 and is delivered to the bagasse elevator
by belt conveyor 3.The bagasse elevator is a conveyer with a grabbing forks and it has a 45
degree inclination angel. it takes the bagasse to the main bagasse carrier (MBC).the main bagasse
carrier enters the bagasse into the silos and takes the remaining bagasse to belt conveyor 01
which then gives it to belt conveyor 5 to be stored for use when system fail is occurs. The
bagasse in the silos
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is feed to the screw conveyer by a toothed scrubber. The screw conveyer takes the bagasse in to
the furnace for combustion. When faller occurs the bagasse is feedback by BS 5 and BC 01 to the
MBC. This is possible because these components can work in both directions. These conveyers
are all driven by electric motors.

Figure 6: - the overall bagasse flow in wonji/shoa sugar factory.

7. Feed and Boiler Water Treatment

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The principal problem in modern high pressure boilers is the control of corrosion and steam
quality. Internal corrosion and deposition may cost the sugar plants a huge amount of many in
repairs and lost availability. Modern steam turbines rated for high capacities call for stringent
steam quality to avoid damages. Without strict control of impurities in steam, deposits will be
formed over turbine blades and nozzles and output will be reduced. Thus the successful
operation of high pressure boiler / turbine units require a thorough understanding of the
aspects of water treatment Impurities present in water used for steam generation and other
power plant and process duties may cause trouble by forming deposits on component and
equipment surfaces, thus impairing heat transfer, fluid flow etc. Such deposits may also
contribute to corrosion of metal surfaces, degrading equipment reliability.
The main groupings of impurities are dissolved mineral and organic matter, dissolved gases,
suspended matter, taste and color and microbiological organisms. Insoluble matter constitutes
the most readily recognized impurity. Known as turbidity, it includes sediment-coarse
particles that quickly settle out of standing water.
Feed water is used as desuperheating spray and any contamination of feed water directly
enters superheated steam. Impure feed water increases blow down which is uneconomical.
Hence feed water is to be very pure for high pressure boilers. This, in turn, necessitates high
purity for make-up water.
Demineralization can only produce acceptable make-up quality for high pressure boilers of
the order of specific electrical conductivity less than 0.5 mmho/cm with hardness completely
removed and silica less than 0.02 ppm. When dissolved solids are removed by
demineralization, suspended solids, organic matter and turbidity are to be removed in the
pretreatment stage normally comprising of chlorination, coagulation, clarification and
filtration. The removal of suspended impurities is important for efficient operation of
demineralization and to avoid problems inside boilers.

7.1 Controlling Corrosion

De-aeration: The principal contributors to corrosion in boiler systems are deposits,

(particularly with copper tube feed water heaters) and low PH. As well as, oxygen (O2) dissolved in

boiler water having traces of chlorides and solids can cause pitting corrosion of metal
surfaces. The resulting condition may be severe, even at low pressures.

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Oxygen (O2) and other gases are removed from feed water before they can enter the boiler. Removal is

accomplished both mechanically and chemically. Mechanical de-aerators are either of the

vacuum or pressure type. With proper operation, either can reduce O2 content to 7 ppb (parts per billion)

or less.
Vacuum de-aerators, use steam-jet ejectors or mechanical pumps to pull the necessary vacuum
on the condenser air-removal section, the degree depending on water temperature.
Pressure type de-aerators are preferred for use on heated feed water streams, whey they serve
on contact heaters. Also known as de-aerating heaters, they use steam to break up water into a

spry or film, they sweep the steam across and through it to force out dissolved gases. O2 can be reduced

below detect-ability. Typical unit has a heating / de-aerating section plus storage for hot de-
aerated water. A separate tank is usually provided above, alongside or underneath to hold
about a 20 minutes supply at rated capacity.

Effect of pH: The reaction of feed water and steel is spontaneous and rapid at high
temperatures. The only reason that boiler steel can survive corrosion and product at normal
operating conditions is that, magnetite (Fe3O4) forms a protective barrier on the metal
surface, which stifles further corrosion. In the simplest analysis, the function of alkalinity
control is to maintain an environment in which the oxide film is stable and protective. The
objective of water treatment in boilers is to protect this film against the aggressive action of
impurities introduced into the boiler with the feed water.
The protective oxide is soluble at pH values below 5.0 and above 13.0. Minimum corrosion is
indicated at pH values of 9.0 to 11.0. Although corrosion is low over a wide band of pH
values, unfortunately corrosion occurs by concentration at the local tube metal and not by
concentrations existing in the bulk boiler water. Local concentrations change the pH
drastically and corrosion takes place. Due to the limitations of chemicals used, an optimum
pH of 8.8 to
9.2 is recommended for feed water. Boiler water pH is elevated to the recommended level by
the use of tri-sodium phosphate. The use of caustic soda is not recommended for this purpose,
as it has the danger of concentration and destruction of protective oxide film to cause
corrosion.
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