Pilot Plant Quotation by Karunya Institute of Technology and Sciences

REQUEST FOR QUOTATION (RFQ)

FOR

SUPPLY AND INSTALLATION OF 2 TPD ROTARY KILN GASIFICATION PILOT PLANT 2TPD 190821

FROM

Purchase Department, Karunya Institute of Technology and Sciences Karunya Nagar, Coimbatore Tamil Nadu 641114 Ph: 9487846521, 9442291395

REQUEST FOR QUOTATION (RFQ) FOR SUPPLY AND INSTALLATION OF 2 TPD ROTARY KILN GASIFICATION PILOT PLANT TABLE OF CONTENTS

1. OBJECTIVES OF THE RFQ ................................................................................................. 3 2. PROJECT OVERVIEW ......................................................................................................... 3 3. ABOUT KITS ........................................................................................................................ 3 4. TECHNICAL DETAILS ......................................................................................................... 4 4.1.

Technical Details.......................................................................................................... 4

5. SCHEDULE OF BIDDING PROCESS .................................................................................. 6 6. GENERAL TERMS OF BIDDING ......................................................................................... 7 7. CHANGE IN OWNERSHIP ................................................................................................... 8 8. COST OF BIDDING .............................................................................................................. 8 9. VERIFICATION OF INFORMATION ..................................................................................... 8 10. VERIFICATION AND DISQUALIFICATION .......................................................................... 8 11. CONTENT OF THE BIDS ..................................................................................................... 9 11.1. Part A - Technical Bid .................................................................................................. 9 11.2. Part B – Cost Bid ....................................................................................................... 10 12. BID SUBMISSION PROCESS ............................................................................................ 10 13. BIDDER EVALUATION CRITERION .................................................................................. 11 13.1. Technical Bid ............................................................................................................. 11 13.2. Cost Bid ..................................................................................................................... 11

LIST OF APPENDICES

Appendix 1

2TPD 190821

Scope of Supply

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REQUEST FOR QUOTATION (RFQ) FOR SUPPLY AND INSTALLATION OF 2 TPD ROTARY KILN GASIFICATION PILOT PLANT 1. OBJECTIVES OF THE RFQ Supply and installation of 2 TPD Rotary Kiln Gasification Pilot Plant The objective for the RFQ is to invite bids for supply of a 2 Tons Per Day (TPD) Rotary Kiln Gasification pilot plant at a designated site by Karunya Institute of Technology and Sciences (KITS) in Coimbatore and install it at site to make it fully operational. 2. PROJECT OVERVIEW Karunya Institute of Technology and Sciences (KITS) is setting up an R&D prototype of 2 TPD Rotary Kiln Gasification pilot plantfor converting non-recyclable plastic waste into high quality syngas. This system is designed and developed together with KITS’ Technology Partner, especially for KITS, Coimbatore to accomplish the project objectives outlined in its proposal submitted to the Department of Science and Technology, India under the program for waste management technologies. The primary goal of the proposed project is to improve the quality of syngas during the gasification of waste. Gasification is known to be the cleanest mode of energy recovery from plastic wastes with no negative impact on the environment. Rotary Kiln gasification system provides the most reliable, cost effective, and environmentally sound solution for converting nonrecyclable plastic waste into high calorific syngas. The flexibility of the system with respect to its ability to operate with varied source of waste with vastly different physical and chemical properties makes this system unique and versatile for broader application. Environmentally, the system is prevented from generating carcinogens, it is associated with producing least amounts of NOx, and the emission of sulfur, carbon monoxide, and particulates are maintained below the regulatory limits. 3. ABOUT KITS Karunya Institute of Technology and Sciences, was founded with the noble vision to raise professionals and leaders of high academic calibre and unblemished character, nurtured with a strong motivation and commitment to serve humanity. The institution is the fulfillment of the vision of its founders Late Dr. D. G. S. Dhinakaran and the present Chancellor Dr. Paul Dhinakaran. Established in 1986 as an Engineering College, it was granted an autonomous status in 1999 and declared Deemed-to-be University by the University Grants Commission (UGC) in recognition of its academic excellence by the Ministry of Human Resources Development under section 3 of the UGC Act, 1956 vide 2TPD 190821

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notification no 9-3-2000-U3 dated 23.6.2004 of the Government of India. Accredited by NAAC, the institution offers a wide array of Bachelors, Masters and Doctoral Degree programs in various branches of Engineering, Biotechnology, Food processing and Agricultural Sciences. From a humble beginning of 180 students, the institution has rapidly grown to 8491 students and 452 faculty representing 18 academic departments. In the three decades of service to higher education, Karunya Institute of Technology and Sciences has made significant progression in teaching learning, research and consultancy, innovation and transfer of technology, community service and value education. Translating the vision of the Founders into action, the institution is currently engaged in finding solutions to human problems in the four major areas such as Water, Food, Healthcare, and Energy through scientific and technological interventions. 4. TECHNICAL DETAILS 4.1. Technical Details The waste is thermally treated to convert the solid hydrocarbons into syngas. Syngas is composed primarily of carbon monoxide (CO) and hydrogen (H2) and smaller quantities of carbon dioxide, water, and methane, based on the input feedstock. The heat for this thermal treatment is generated by partial combustion of solid hydrocarbon with substoichiometric amount of air. By introducing only, a small amount of air amounting to far less than that would be required for complete combustion; the presence of free oxygen is eliminated in the gasifier. The syngas produced by this gasification process is a clean fuel that is combustible and can be used to generate electricity, steam or even hot air, or as a basic building block for chemical manufacturing. With appropriate approvals even hazardous waste processing will be possible. Syngas can then easily replace the conventional fuels to produce energy in the form of steam, which can used to produce electricity or air-conditioning or for effluent treatment. Alternatively syngas can be cleaned and then used to produce electric power or further chemical process to produce other chemicals. A schematic of the gasification system is shown in Figure 1. The gasifier or the first stage operated at 9800C and operates in the reducing regime unlike an incinerator where the mode is oxidation. The evolution of free chlorine radicals is arrested keeping the environment devoid of the primary contributors to the formation of carcinogens and the absence of free oxygen that prevents the waste bound nitrogen from being converted to NOX. The sulfur if any, present in the waste is converted to H2S. In the reducing regime, the chlorine present in the solid waste is converted into Hydrogen Chloride, which is easily removed during fuel gas cleanup before it is used as fuel. In contrast, the incinerator converts all the chlorines into carcinogens (Dioxins). Also, because of the reducing regime, all the nitrogen bound into the waste is converted to molecular nitrogen (N2). This improved system thus 2TPD 190821

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eliminates a profound source of NOX. In contrast, all the N2 bound in the solid wastes is converted into the oxides of nitrogen (NOx), which is a major link in the greenhouse gas production. The syngas produced from the solid waste has a calorific value of 850 to 1100 KCal/Nm3 compared to 8000 KCal/Nm3 for natural gas. When natural gas is utilized as fuel, the flame temperature is approximately 2200 oC. In contrast when fuel gas from Rotary Kiln Gasification is utilized as fuel; the flame temperature is less than 1500oC. Hence, the thermal NOx produced by syngas is an order of magnitude less than that from natural gas, because of the lower flame temperature. This is also an important environmental consideration in country’s continuous quest to reduce the emission of greenhouse gases from all sources. The sulfur likewise is removed from the fuel gas in the form of solid sulfides prior to its use, thereby further adding to the cleaner environment mandate.

SCIENTIFIC

GASIFICATION SYNGAS

Agriculture

BOILER

STEAM

Petroleum

GASIFICATION

Figure 1: Schematic of the Rotary Kiln Gasification System Figure 1. Schematic of the Rotary Kiln Gasification System

There will like like ash, ash, which which will be will initially planned into a scientific and There will be beother otheroutputs outputs be initially planned into landfill a scientific subsequently after analyzing the ash for its worthiness; it could be sold to cement factory; generating landfill and subsequently ashincludes for its the worthiness; could be sold additional revenue. The designafter of theanalyzing gasificationthe system preliminary itplant design for converting 2 TPD of non-hazardous wastes into clean fuel gas and the subsequent utilization of the syngas to cement factory for making fly ash bricks; generating additional revenue. The as mentioned above.

design of the gasification system includes the preliminary plant design for converting The design is carried out in sufficient details to enable accurate determination of the cost for the plant 2components TPD of non-hazardous wastes into clean fuel gas and the subsequent utilization of and comprises of: the syngas as mentioned above. • Process Flow Diagram • Process Description for the plant 2TPD 190821 Page 5 of 11 • Heat and Mass Balances and Potential Energy Output • Utility Requirements • Equipment list and specifications The overall material balance at the various components is shown in Figure 2. The 2 TPD Waste to energy system consists of 5 subsystems. These subsystems are 1) Feed Subsystem; 2) Gasifier Subsystem; 3) Gas

The 2 TPD Waste to Energy system consists of 5 subsystems. These subsystems are 1) Feed Subsystem; 2) Gasifier Subsystem; 3) Gas Cleanup Subsystem; 4) Steam Generation Subsystem and 5) Auxiliary Subsystem. The feed preparation and delivery equipment will be supplied by others. Further technical details including – 1) Process Flow Diagram 2) Process Description for the plant 3) Heat and Mass Balances and Potential Energy Output 4) Utility Requirements 5) Equipment list and specifications areprovided in the Appendix 1 of Scope of Supply. The appendix also includes the necessary design drawings of the pilot plant. It is the responsibility of the bidder to review, understand the technical requirements of the bid. Any deviation from the technical details may result in the bid being disqualified.Hence the bidder is advised to review the detailed scope of supply provided in the Appendix 1thoroughly. 5. SCHEDULE OF BIDDING PROCESS Date of RFQ Last date for receiving queries Reponses to the queries by KITS

23.08.2021 31.08.2021

Bid Due Date

15.09.2021

Opening of Bids

17.09.2021

Letter of Award(LOA)

05.10.2021

Validity of Bids

60 Days of Bid Due Date

Signing of Acceptance letter

Within 7 days of award of LOA

2TPD 190821

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6. GENERAL TERMS OF BIDDING 6.1. No Bidder shall submit more than one Bid for the Project. 6.2. For all technical details refer Scope of Supply in Appendix 1. Any deviation from the technical details may result in the bid being disqualified. Hence the bidder is advised to review the technical details provided in the appendix thoroughly. 6.3. The Bid should be furnished in the format described in section11 of this document, clearly indicating the bid amount in both figures and words, in Indian Rupees, and signed by the Bidder’s authorised signatory. In the event of any difference between figures and words, the amount indicated in words shall be taken into account. 6.4. Any condition or qualification or any other stipulation contained in the Bid that is not in the RFQ or contravenes any condition or qualification mentioned in the RFQ, shall render the Bid liable to rejection as a non-responsive Bid. 6.5. The Bid and all communications in relation to or concerning the Bidding Documents and the Bid shall be in English language. 6.6. The documents including this RFQ and all attached documents, provided by KITS are and shall remain or become the property of the KITS and are transmitted to the Bidders solely for the purpose of preparation and the submission of a Bid in accordance herewith. Bidders are to treat all information as strictly confidential and shall not use it for any purpose other than for preparation and submission of their Bid. 6.7. This RFQ is not transferable. 6.8. Any award of Contract pursuant to this RFQ shall be subject to the terms of Bidding Documents. 6.9. The bidder will be expected to coordinate and work closely with KITS’ technology partner (together called the consortium) for engineering design and technical aspects and will have to comply to the technical requirements of the consortium.

2TPD 190821

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7. CHANGE IN OWNERSHIP By submitting the Bid, the Bidder shall be deemed to have acknowledged and agreed that in the event of a change in control of an Associate whose Technical Capacity and/ or Financial Capacity was taken into consideration for the purposes of pre-qualification under and in accordance with the RFQ, the Bidder shall be deemed to have knowledge of the same and shall be required to inform KITS forthwith along with all relevant particulars about the same and KITS may, in its sole discretion, disqualify the Bidder or withdraw the LOA from the Selected Bidder. 8. COST OF BIDDING The Bidders shall be responsible for all of the costs associated with the preparation of their Bids and their participation in the Bidding Process. KITS will not beresponsible or in any way liable for such costs, regardless of the conduct or outcome of the Bidding Process. 9. VERIFICATION OF INFORMATION It shall be deemed that by submitting a Bid, the Bidder has: 1. made a complete and careful examination of the Bidding Documents; 2. received all relevant information requested from KITS. All queries should be sent by email only to ps@karunya.edu with a copy to madhuganesh@karunya.edu No phone or postal mail enquires will be accepted. 10. VERIFICATION AND DISQUALIFICATION KITSreserves the right to verify all statements, information and documents submitted by the Bidder in response to the RFQ. The bidder has to make available all such information, evidence and documents as may be necessary for such verification. Any such verification or lack of such verification, by KITS shall not relieve the Bidder of its obligations or liabilities. KITS reserves the right to reject any Bid and appropriate the Bid Security if: (a) at any time, a material misrepresentation is made or uncovered, or (b) the Bidder does not provide, within the time specified by KITS, the supplemental information sought by KITS for evaluation of the Bid.

2TPD 190821

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Such misrepresentation/ improper response shall lead to the disqualification of the Bidder. If such disqualification / rejection occurs after the Bids have been opened and the Lowest Bidder gets disqualified / rejected, then KITS reserves the right to: 1. considerthe remaining bids for evaluation 2. take any such measure as may be deemed fit in the sole discretion KITS, including annulment of the Bidding Process. 11. CONTENT OF THE BIDS 11.1.Part A - Technical Bid Item

Description

Detailed technical proposal including specifications and overall GA drawings, if applicable.

List all items from technical evaluation criterionlisted in Section 13.1

Corporate Profile

Engineering personnel and support staff details. These details must indicate the capability for mechanical and process design and production of manufacturing quality drawings

Fabrication and assembly facility details

Provide details for the experience of assembling, installing, integrating and commissioning at least one waste to energy plant, of similar or higher capacity preferably based on rotary kiln gasification technology

Reference letters for supply of waste to energy projects preferably of rotary kiln gasification technology of equal or higher of the requested capacity in the bid

Delivery Schedule The equipment should be delivered within 9 months from award of contract and installed within 12 months from award of contract. All equipment must be available for periodic inspections by a team designated by KITS and any rectification necessary shall be implemented at vendor’s cost. These rectifications should not affect the delivery schedule.

2TPD 190821

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11.2.Part B – Cost Bid Item 1

Description Total bid cost in numbers and in words to meet the requirements listed under Appendix 1 of scope of supply Justification of bid cost with price breakup 1) Equipment supply cost including installation at designated project site by KITS (In categories as listed in Table 4 of Scope of Supply in Appendix 1 2) The cost must include all applicable taxes, loading, transportation, Insurance, handling, off-loading and manpower 3) Basis for any central, state or local taxes included in the bid cost must be stated clearly and separately 4) Payment Terms including schedule of payments Permanent Account Number (PAN) of the Bidder Goods and Services Tax registration number (GST) Bidder’s bank account details duly signed and sealed by their bank

3 4 5

12. BID SUBMISSION PROCESS The bids must be submitted by email in two PDF documents 1) Technical Bid 2) Cost Bid Each PDF document must have     

Project title RFQ number Bidder’s company name, address Bidder’s technical contact information Bidder’s commercial contact information

All pages shall be marked confidential. If a password is used for securing a PDF document, the password shall be sent in a separate email. Proposals should be sent on or before 15th September 2021 to the following Email ID ONLY :dsttdtwm201909g@karunya.edu The subject of the email shall be 2TPD 190821; Company Name” Any revisions to the submission prior to the bid acceptance date shall be indicated by revision numbers and all documents must be resubmitted. 2TPD 190821

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13. BIDDER EVALUATION CRITERION 13.1.Technical Bid 1) Bidder should have 5 years experience in manufacturing and supply of power and/or process plants. 2) Should have the experience of assembling, installing, integrating and commissioning at least one waste to energy plant of similar capacity or higher capacity, preferably with Rotary Kiln Gasification Technology. 3) TheBidder should have capability to design and produce manufacturing quality drawings on their own or through their consultants. If an external agency is used, it should be explicitly mentioned in the quote with experience details, resume and other credentials. 4) The Bidder should follow applicable Indian standards for manufacturing 5) The Bidder must have manufacturing facilities in India and must be able to support the project for 2 years from the date of installation 13.2.Cost Bid 1) The cost bid must be inclusive of – a. Equipment cost b. Freight, P&F and Insurance c. All applicable center and state taxes d. Installation cost that is inclusive for hiring equipment, manpower, travel to the site, lodging and boarding e. All Overheads 2) The total cost of the bid for the entire system including equipment supply to the site and installation to make the system operational shall be a criteriafor selection of the vendor. 3) The bidder requested payment terms shall be discussed with Purchase Committee of KITS and a mutually acceptable payment terms. 4) The equipment supplied shall be onsite warrantied for 1 year from the date of completion of installation. 5) The Bidder shall support the project for maintenance and repair of the equipment supplied for 2 TPD Rotary Kiln Gasification pilot plant for 2 years from the date of completion of installation. 6) A sum of Rs. 35 lacs shall be withheld from the total order value and reimbursed to the bidder subject to the following conditions a. Rs. 20 Lacs shall be reimbursed to the bidder after completing installation of the pilot plant b. Rs. 15 Lacs shall be reimbursed after 2 years of completing installation of the pilot plant 2TPD 190821

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SUPPLY AND INSTALLATION OF 2 TPD ROTARY KILN GASIFICATION PILOT PLANT 2TPD 190821

APPENDIX 1 SCOPE OF SUPPLY

FROM

Karunya Institute of Technology and Sciences Karunya Nagar, Coimbatore Tamil Nadu 641114

August 2021

APPENDIX 1 SCOPE OF SUPPLY SUPPLY AND INSTALLATION OF 2 TPD ROTARY KILN GASIFICATION PILOT PLANT TABLE OF CONTENTS 1. INTRODUCTION ................................................................................................................................... 3 2. PROCESS DESCRIPTION OF 2 TPD ROTARY KILN GASIFICATION PILOT PLANT ....................... 4 3. HEAT AND MASS BALANCE AND STREAM FLOW DIAGRAM .......................................................... 8 4. UTILITY REQUIREMENTS.................................................................................................................. 11 5. EQUIPMENT GROUPS ....................................................................................................................... 11 6. EQUIPMENT SPECIFICATIONS......................................................................................................... 13 7. INSTALLATION ................................................................................................................................... 21 8. DRAWINGS ......................................................................................................................................... 23 9. REFERENCES .................................................................................................................................... 24

LIST OF TABLES Table 1: Heat and Mass Balance for 2 TPD Rotary Kiln Gasification Pilot Plant ......................................... 8 Table 2: Utility Requirements for 2 TPD Rotary Kiln Gasification Pilot Plant ............................................. 11 Table 3: List of Equipment Groups and their Descriptions ......................................................................... 11 Table 4: Equipment Specifications for the 2 TPD Rotary Kiln Gasification Pilot Plant ............................... 13 Table 5: Specifications for Syngas Analyzer – (AI-680) ............................................................................. 24 Table 6: Specifications Flue Gas Analyzer (AI-710)................................................................................... 25 Table 7: List of Instruments ........................................................................................................................ 25 Table 8: List of Control Valves ................................................................................................................... 25 Table 9: List of Manual Valves ................................................................................................................... 25 Table 10: Electrical Cable Requirement and Specifications....................................................................... 26 Table 11: Motor Control Center (MCC) Specification ................................................................................. 26 Table 12: List of Motors .............................................................................................................................. 29 Table 13: Control System Specifications .................................................................................................... 30 Table 14: Specifications of Pipes and Fittings............................................................................................ 31

Page 2 of 32 Appendix 1 - 2TPD 190821

APPENDIX 1 SCOPE OF SUPPLY SUPPLY AND INSTALLATION OF 2 TPD ROTARY KILN GASIFICATION PILOT PLANT 1. INTRODUCTION Karunya Institute of Technology and Sciences (KITS) is setting up an R&D prototype of 2 Tons Per Day (TPD) Rotary Kiln Gasification pilot plant for converting non-recyclable plastic waste into high quality syngas. This system is designed and developed by KITS’ Technology Partner, especially for KITS, Coimbatore to accomplish the project objectives outlined in its proposal submitted to the Department of Science and Technology, India under the program for waste management technologies. The primary goal of the proposed project is to improve the quality of syngas during the gasification of waste. This document includes all the necessary technical information related to the design of the 2 TPD Rotary Kiln Gasification pilot plant to meet the following project objectives • • • •

Process non-recyclable plastic waste from Municipal Solid Waste (MSW) Use of enriched air for improving the calorific value of Syngas Integrate the gasifier system with steam or power generator Demonstrate sustainable waste to syngas production using rotary kiln gasification

The upcoming sections contain system configuration, system description, heat and mass balances, stream data, utility requirements, equipment list and general specifications and mechanical design drawings. The drawings provided in this document are design drawings and are not to be used for fabrication. The bidder is responsible for preparing manufacturing drawings necessary for executing the contract. Any deviation from the design objectives should be informed to the technical team at KITS prior to implementation. It is the responsibility of the bidder to review, understand the technical requirements of the bid. Any deviation from the scope of supply may result in the bid being disqualified. Hence the bidder is advised to review the detailed scope of supply provided here thoroughly.

Page 3 of 32 Appendix 1 - 2TPD 190821

2. PROCESS DESCRIPTION OF 2 TPD ROTARY KILN GASIFICATION PILOT PLANT The 2 TPD Rotary Kiln Gasification pilot plant achieves thermochemical conversion of non-recyclable plastics into high quality syngas (heating value of 1,200 kCal/Nm3 to 2300 kCal/Nm3) using enriched air (40% to 95% O2) gasification and then utilizing the high calorific syngas for producing steam for on-Campus consumption. The flue gas from the system is cleaned for the removal of sulfur and chlorine compounds as well as for the removal of the particulates before it is discharged to the atmosphere in order to comply with the local emission standards. The 2 TPD Rotary Kiln Gasification pilot plant consists of 5 subsystems. These subsystems are Feed Subsystem, Gasifier Subsystem, Gas Cleanup Subsystem, Steam Generation Subsystem and Auxiliary Subsystem. Each of these subsystems has unique process function. All of these operate in sync in order to achieve the objective of generating high calorific value syngas from non-recyclable plastic attendant with system’s additional objectives of operating in environmentally clean manner and delivering saturated steam as energy product for consumption on KITS campus. The system will also be able to generate hot water by providing additional equipment. All these subsystems are described in detail in the following section referring to the process flow diagram (PFD) for the system provided as Figure 1 below. • Feed Subsystem - Feed Subsystem will be provided by CMERI and is not part of Scope of Supply The feed subsystem will process 2 TPD of material, whose average composition is described in the heat and mass balance section below. The material will be processed by this feed system to a size not exceeding 50mm. and delivered to the gasifier for use in the pilot plant. Details of this feed system will be provided after the contract has been awarded. • Gasifier Subsystem The components of gasification subsystem include a Plastic Chopper (SH-010) to chop the size of the plastic waste into less than 15 mm size, a Transfer Conveyor (BC-020) to transfer chopped plastic into the gasification reactor, a Screw Feeder (SC-070) to introduce waste feed into the reactor, a Rotary Kiln Gasifier (RX-300) for gasification, a Start-up Burner (BRN-310) and associated Blower (BL-320) for preheating the gasifier, a Process Air Blower (BL-330) for air supply for waste gasification, oxygen supply components for supply of oxygen to enrich air to 40 to 95 % and an Air Distributor (AD340) to distribute air inside of the gasifier. Page 4 of 32 Appendix 1 - 2TPD 190821

The Rotary Kiln gasifier is a horizontal, refractory-lined kiln designed for high process temperatures. The start-up burner is located at the feed inlet side of the kiln to raise the gasifier temperature. The burner is equipped with its own air and fuel supply. LPG is used as the fuel for burner. Rented LPG cylinders supplies LPG for the burner operation. The burner is fired initially during start-up to raise the temperature inside the gasifier to near ignition temperature of the waste and also to preheat the refractory and the downstream equipment. Initial heating of the system is necessary to initiate partial combustion of the waste as well as to prevent condensation in the downstream equipment. After the desired temperature is attained with the start-up burner, waste is gradually introduced into the gasifier using Gasifier Screw Feeder (SC-070) while allowing the temperature to rise. Process water and enriched air (40 to 95 % O2) are used as gasification media and is introduced gradually along with the feed. The primary source of process air is the Process Air Blower (BL-330). Pure oxygen in rented cylinder gangs is added to the process air stream to enrich the air and bring the oxygen level to 40 to 95%. As the waste feed is increased, the LPG in the start-up burner is reduced. The feed nozzle is kept clear off the direct impingement from the burner flame. Gasification is a thermochemical process that uses heat and steam to convert wastes directly into syngas comprising primarily of carbon monoxide, methane, hydrogen, water vapor, carbon dioxide, and nitrogen. Heat necessary for gasification process is derived from partial combustion of waste with controlled amount of air and oxygen introduced along the length of the gasifier using the Gas Distributor (AD-340). The syngas has combustion characteristics similar to that of the natural gas; however, its calorific content for this project will vary from 1,500 – 2,300 kCal/Nm3. In order to accomplish the objective of producing high quality syngas, gasification medium is enriched with oxygen. This enriched gasification medium has an oxygen concentration of 40%. Metered quantity of pure oxygen from rented cylinders is mixed with air (21% O2) and is supplied to the gasifier. The system has all necessary instrumentation to achieve automatic mixing of oxygen with air. • Gas Cleanup Subsystem Gas clean-up Subsystem also knows as Flue gas Cleanup comprises of components for cleaning the syngas/flue gas produced by syngas combustion. The gas is cleaned to remove sulphur and chloride impurities before it is discharged to the atmosphere. These gaseous impurities are scrubbed off by reacting them with lime in the reaction chamber, Flue Gas Desulfurizer (FGD-675). A sorbent injection system (Sorbent Hopper (H-540), Sorbent Feeder (SC-550) and Rotary Valve (RV-560)) is included for storing and supplying sorbent to FGD. The particulates in the flue gas are removed using the Bag Filter (BF-600). The bag filter is capable of removing 99% of solids in the size range of 2 microns and larger. In the current design, the Flue Gas Desulphurizer (FGD-675) is Page 5 of 32 Appendix 1 - 2TPD 190821

integrated with the Bag Filter (BF-600) to make the system compact. Air required for the bag filter cleaning is provided by Air Compressor Package (C-900) included in Auxiliary group. An Induced Draft Blower (BL-660) assists the flow of gas from the gasifier through the gas utilization and clean-up system. The cleaned flue gas is released to the atmosphere. The solids collected in the FGD and bag filter are discharged and collected in separate residue bins. • Steam Generation Subsystem The syngas generated in the gasifier is directly combusted in a Combustion Chamber (CC-570), which is integrated to gasifier. Combustion Chamber is associated with a Burner (BRN-580) and an associated Blower (BL-585), Combustion Chamber Blower (BL-590) for supplying combustion air for syngas combustion, Moving Grate (FV-350) at the discharge side to ensure sealed discharge of solid residue from combustion chamber. The Heat Recovery Steam Generator (B-500) utilizes the energy in syngas to generate saturated steam at the header for further use in the campus. Supply of feed water from Fee Water Tank (TK-510) is also included. • Auxiliary Subsystem The major components in this group are Stack (ST-670) to release the clean flue gas from the gas cleanup components into the atmosphere, Air Compressor (C-900) for compressed air supply for the bag filter as well as instrument air supply for the control valves, Process Water Tank (TK-700) and Process Water Pumps (P-705A/B).

Page 6 of 32 Appendix 1 - 2TPD 190821

Figure 1: Process Flow Diagram of 2 TPD Rotary Kiln Gasification Pilot Plant

Page 7 of 32 Appendix 1 - 2TPD 190821

3. HEAT AND MASS BALANCE AND STREAM FLOW DIAGRAM Design of the 2 TPD Rotary Kiln Gasification Pilot Plant is based on material and energy balance presented in Table 1. The stream flow diagram is also presented in Figure 2 below. Table 1: Heat and Mass Balance for 2 TPD Rotary Kiln Gasification Pilot Plant Parameter Capacity

Value

Unit 2.00

Waste Name

TPD

Mixed Waste

Gasification Mode

Enriched Air (40% O2)

Waste Composition (Dry Weight Basis) C

60.00

7.20

20.60

0.00

1.00

10.20

5.00

20.00

Ash Moisture in Feed Moisture for Gasification Additional Water Required

kg/h

HHV, (Dry) (Dulong)

6398

kCal/kg

HHV, (Wet) (Dulong)

6078

kCal/kg

Total Feed Rate

kg/h

Dry Feed Rate

kg/h

Moisture Feed Rate (Moisture in feed + water added)

Gasification Temperature

kg/h

900

Oxidant Feed Rate

4.2

mol/h

Oxidant Feed Rate

123

kg/h

Oxidant Flow Rate

Nm3/h

Oxidant Composition (Mole Basis)

Page 8 of 32 Appendix 1 - 2TPD 190821

Parameter

Value

Unit

Syngas Produced

9.7

mol/h

Syngas Produced

214

kg/h

Syngas Mol Wt

22.1

kg/kgmol

Syngas Produced

227

Nm3/h

Syngas Produced

923

Am3/h

Syngas Composition (Mol Basis) CO

22.50

23.20

CH4

2.05

CO2

12.80

H2O

17.50

H2S

0.22

21.35

HCl

0.20

0.18

Ash Produced HHV of Syngas (wet)

8 1529

kg/h kCal/Nm3

Total Heat Input

506,490

kCal/h

Heat in Syngas

347,842

kCal/h

Sensible Heat in Syngas

61,827

kCal/h

Latent Heat in Syngas

16,369

kCal/h

409,668

kCal/h

Steam Pressure

4.5

Bar A

Steam Temperature

144

Enthalpy of Steam

655

kCal/kg

496

kg/h

Total Heat Available for Recovery

Feed Water Temperature Steam Generation Potential

The stream balance block diagram for 2 TPD Rotary Kiln Gasification Pilot Plant is shown as Figure 2.

Page 9 of 32 Appendix 1 - 2TPD 190821

Figure 2: Stream Balance Block Diagram for 2 TPD Rotary Kiln Gasification Pilot Plant

NON-RECYCLABLE PLASTIC WASTE 2 mTPD 5 % Moisture

FEED SYSTEM

NON-RECYCLABLE PLASTIC WASTE 83 kg/h 6,078 kCal/kg

AIR 73 Nm3/h 89 kg/h

OXYGEN (95%) 25 Nm3/h 34 kg/h

SYNGAS 227 Nm3/h 214 kg/h 900 °C CH – 347,840 kCal/h SH – 61,820 kCal/h LH – 16,370 kCal/h SOLIDS 2 kg/h SH – 1,100 kCal/h

WATER 16 kg/h

GASIFIER

SOLID RESIDUE 6 kg/h SH- 3,163 kCal/h

AIR 658 Nm3/h 803 kg/h

COMBUSTION CHAMBER

FLUEGAS 834 Nm3/h 1,017 kg/h 1,200 °C SH – 380,060 kCal/h LH – 45,970 kCal/h SOLIDS 2 kg/h SH – 1,424 kCal/h

FLUEGAS 834 Nm3/h 1,017 kg/h 150 °C SH – 39,440 kCal/h LH – 45,970 kCal/h SOLIDS 1 kg/h SH – 381 kCal/h

WATER 510 kg/h

BOILER

BLOW DOWN 16 kg/h

COMPRESSED AIR 34 Nm3/h 41 kg/h

LIME 3 kg/h

ACTIVATED CARBON 1 kg/h

FLUEGAS 867 Nm3/h 1,057 kg/h 110 °C SOLIDS 0.0004 kg/h

FLUEGAS CLEANUP SOLID RESIDUE 7 kg/h

SOLID RESIDUE 1 kg/h

STEAM 494 kg/h 4.5 barA 144 °C

Legend CH – Chemical Heat SH – Sensible Heat LH – Latent Heat

PROJECT NAME

2 TPD ROTARY KILN GASIFICATION SYSTEM

STREAM FLOW DIAGRAM -40% ENRICHED AIR USED AS OXIDANT RVS 25-JUN-2021

Prepared By:

Checked By:

Approved By

Date :

SM 30-JUN-2021

GK 02-JUL-2021 20-DEC-2018

Project No.

169

Document No.

169-100-002B

REV No.

DESCRIPTION

SCALE : SCALE

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING

DATE

SHEET:1 OF 1

DOCUMENT TITLE

REVISIONS REV

VER No.

Page 10 of 32 Appendix 1 - 2TPD 190821

4. UTILITY REQUIREMENTS The design utility requirements for 2 TPD Rotary Kiln Gasification Pilot Plant are listed in Table 2. Table 2: Utility Requirements for 2 TPD Rotary Kiln Gasification Pilot Plant Item

Utility Name

User

Quantity 16 10 512

Unit lph lph lph

Process Water

Boiler Feed Water

Gasifier Ash Quenching Boiler

Lime Powder

Dry Scrubber

kg/h

LPG

Oxygen

Start-Up Burner-Gasifier Start-Up Burner-Boiler Gasifier

12 12 25

kg/h kg/h Nm3/h

Compressed Air

Plant Operation

Nm3/h

Electricity

Plant Operation

5. EQUIPMENT GROUPS All the equipment in 2 TPD Rotary Kiln Gasification Pilot Plant except those for the feed system are grouped under 7 categories as shown in table 3. Feed System Components will be provided by others and is not part of this RFQ. The following list of components will form the basis of the bid package to be submitted by the bidder. It is expected that the bidder will provide the bid costing for supply and installation of components with a breakup according to the groups listed below, in addition to freight, taxes and other costs that form the total cost of the bid package. Do not include any cost information in technical part of the bid package. Table 3: List of Equipment Groups and their Descriptions Item 1

Group Name Gasifier Components

Group Descriptions This includes all the components required for the gasification of prepared feed material and converts it into Syngas for further energy recovery. This is an integral part of the gasification system. These specially designed components ensure maximum conversion of the waste into syngas. These components are to be installed and integrated into the other components in the gasification system at the KITS project site. The key components are Plastic Chopper (SH010), Waste Transfer Conveyor (SC-055), Gasifier Screw Feeder (SC-070), Gasifier (RX-300), Process Air Blower (BL-330), Air Distributor (AD-340), Startup Burner (BRN-310) and Shredder (SH-010). This also include Page 11 of 32

Appendix 1 - 2TPD 190821

Item

Group Name

Steam Generation Components

Flue Gas Cleanup Components

Electrical & Instrumentation Components

Auxiliary Components

Ducting and Piping

Refractory

Group Descriptions associated accessories like Startup Burner Blower (BL-320). The Steam generation components utilizes the chemical energy in syngas produced in the gasifier and converts it to thermal energy to produce steam using a heat recovery exchanger. The design of each component in the group is unique and should work concurrently with the upstream and downstream components. These components are to be installed and integrated with the Kiln and Gas Cleanup components. This includes key equipment like Combustion Chamber (CC-570), Heat Recovery Steam Generator (B-500) and Combustion Blower for CC-570 (BL-590). The subsystem also includes Burner for CC-570 (BRN-580), Blower for BRN-580 (BL-585), Moving Grate (FV-350), Ash Bin (BN-360) and Feed Water Tank (TK-510) as accessories. This consists of components for removing acid gas pollutants as well as particulates in the combustion products after heat recovery from the steam generation components. This group includes a specially designed bag filter with an integrated reaction chamber for acid gas removal along with other components. These components are to be assembled and installed at the site along with the other components in the gasification system. The key equipment in this group are Sorbent Injection System (H-630), Flue Gas Desulphurizer (FGD-675) integrated with Bag Filter (BF-600), Carbon Bed Filter (CF-620), ID Fan (F-660) and Ash Bin (BN-677). This is also an integral part of the gasification system that is exclusively chosen for the specially designed components in various component groups. This group enables the proprietary control system to work efficiently. All the components in this group are to be installed and integrated into the gasification system at the KITS project site. This group includes the key components like the Motor Control Center (MCC) and the Cabinet for accommodating the PLC and its accessories. This also includes all the instrumentation specifically required for the operation and monitoring of the gasification system. Most of the instruments are specially designed to work in concurrence with the gasification equipment and are to be integrated into each group during the manufacturing stage. All these components are to be installed at the KITS project site. The key components are the Field Instruments, Control Valves, Shut off Valves, Manual Valves and Control System including Programmable Logic Control (PLC) and Human Machine Interface (HMI) for plant operation. The Auxiliary Component group includes the auxiliary equipment required for the gasification system. These components are to be installed and integrated into other components in the gasification system at the KITS project site. The major components in the subsystem are the Process Water Tank (TK-700), Process Water Pumps (P-705 A/B), Air Compressor (C-900) and Stack (ST670). The Piping and Ducting Component group includes all the piping and ducting for the integration of each component group. These ducts and pipes must align with the components in each component group and has to be included along with each component group for integration at the KITS project site. Some of the Gasification and the Steam generation components operate at high temperatures and hence high temperature insulation is required to protect Page 12 of 32

Appendix 1 - 2TPD 190821

Item

Group Name

Group Descriptions the equipment. The Gasifier (RX-300), Combustion Chamber (CC-570) and Heat Recovery Steam Generator (B-500) are provided with high temperature castable refractory coating to protect the metal components directly coming in contact with hot and corrosive gases from the process.

6. EQUIPMENT SPECIFICATIONS The 2 TPD Rotary Kiln Gasification Pilot Plant is designed to generate high CV syngas from enriched air gasification of non-recyclable plastic waste in municipal solid waste (MSW), primarily focusing on the utilization of syngas from gasifier to produce steam. The list of components for the system along with their specifications are shown in the below table. The component sizes are selected for processing 2 ton per day (TPD) nonrecyclable plastic waste as feed. The capacity numbers for each equipment are derived from a theoretical Heat & Mass balance. All the equipment are designed with sufficient margin and turn down to process 2 TPD capacity. Though the system is intended for demonstration purpose with intermittent operation, the design supports continuous operation. The equipment specifications are detailed out in Table 4 below. Table 4: Equipment Specifications for the 2 TPD Rotary Kiln Gasification Pilot Plant Item

Tag No.

Tag Name

Specification

1. GASIFIER COMPONENTS 1

SH-010

Feed Chopper

Application – To reduce the pre-processed waste feed size to less than 15 mm size Type – Single Shaft Chopper Capacity – 100 kg/h Incoming Feed Size- 150 mm (maximum) Feed Bulk Density – 100-200 kg/m3 Size Reduction – Less than 15 mm Operation –Designed for 24x7 operation Power Supply – 415V/50Hz/3Ph

Page 13 of 32 Appendix 1 - 2TPD 190821

Item 2

Tag No. BC-020

Tag Name Transfer Conveyor

Specification Application – Transfer chopped feed to gasifier screw feeder Type – Z Type Belt Conveyor Capacity – 100 kg/h Belt – Nylon/ Rubber Other Components – Carbon Steel Belt Width – 500 mm Operation – Designed for 24x7 operation Power Supply – 415V/50Hz/3Ph Reference Drawing – 169-D-GG-020-1000

SC-070

Gasifier Screw Feeder

Application – To feed the waste material into the gasifier Type – Screw Conveyor with external Jacketed chute Capacity – 100 kg/h MOC: • •

Screw – Wear Resistant Steel Other components – Carbon Steel

Operation – Continuous Power Supply – 415V/50Hz/3Ph Reference Drawing – 169-D-GG-070-1000 4

RX-300

Gasifier

Type – Rotary Kiln Capacity – 100 kg/h Max Operating Temperature – 900 0C MOC – Carbon Steel Insulation – Castable Refractory. 230 mm refractory lined on the inside which consists of 100 mm dense phase & 130 mm insulation phase Kiln Inside Diameter with Refractory Lining – 600 mm Kiln Length – 1200 mm Drive – Induction motor controlled by a variable frequency drive Turndown Ratio – 4:1 Operation – Continuous Power Supply – 415V/50Hz/3Ph Reference Drawing – 169-D-GG-300-1000 Page 14 of 32

Appendix 1 - 2TPD 190821

Item

Tag No.

Tag Name

BRN-310

Startup Burner

Application – To heat up the gasifier Capacity – 125,000 kCal/h Fuel – LPG Provisions Included: • Safety systems • Fuel train components • Controls and safety interlocks. Operation – Equipment designed for 24x7 operation but will be operated for 10 to12 hrs. during start-up process.

BL-320

Startup Burner Blower

Type – Centrifugal Blower Application – To supply fuel required for start-up burner (BRN-310) Capacity – 240 Nm3/h MOC – Carbon Steel Operation – Equipment designed for 24x7 operation, but will be operated in conjunction with BRN-310 Power Supply – 415V/50Hz/3Ph

BL-330

Process Air Blower

Type – Centrifugal Blower Application – To supply process air for gasifier Capacity – 240 Nm3/h MOC – Carbon Steel Operation – Continuous Power Supply – 415V/50Hz/3Ph

AD-340

Air Distributor

Type – Concentric Tube Size – As per Drawing Capacity- 240 Nm3/h MOC- Stainless Steel Operation – Continuous Reference Drawing – 169-D-GG-070-1000

Oxygen Cylinders

Application – To supply oxygen for enriched air gasification Type – Rented oxygen cylinders sourced locally

Syngas Analyzer

Application – To measure syngas composition Type – Syngas Analyzer Reference – Table 5

AI-680

Specification

Page 15 of 32 Appendix 1 - 2TPD 190821

Item

Tag No.

Tag Name

Specification

2. STEAM GENERATION COMPONENTS 11

CC-570

Combustion Chamber for Boiler-500

Application – For complete combustion of Syngas Design Temperature – 1,200 0C Design Syngas Flow Rate – 380 Nm3/h Syngas Temperature – 900 0C Syngas Inlet Pressure – (-)5 to 0 mmWC Combustion Efficiency – 99.99% Gas Retention Time – 2 seconds Gas Heating Value Range – 1,000 to 2,000 kCal/Nm3 MOC - Carbon Steel Insulation – Membrane Water Wall. Refractory if needed, as recommended by bidder Approximate Inside Dimensions (LxWxH) – 3000 mm x 1800 mm x 1300 Maximum Particulate in Syngas – 50 kg/h Initial Heat up – Using a pilot burner Operation – Continuous Reference Drawing – 169-D-GG-570-1000

BRN-580

Burner for CC-570

Application – To preheat the Combustion chamber to required temperature Capacity – 125,000 kCal/h Fuel – LPG Provisions Included: Safety systems Fuel train components Controls and safety interlocks Installation Location – On the combustion chamber Operation – Equipment designed for 24x7 operation, but will be operated initially during system dry out and for 3 to 4 hrs during start-up process

BL-585

Blower for BRN580

Application – To supply air for burner Capacity – 240 Nm3/h Static Pressure – 500 mmWC MOC – Carbon Steel Power Supply – 415V/50Hz/3Ph Operation – Continuous

Page 16 of 32 Appendix 1 - 2TPD 190821

Item

Tag No.

Tag Name

Specification

BL-590

Combustion Application – Combustion Air Supply to CC-570 Blower for CC-570 Type – Centrifugal Capacity – 900 Nm3/h Discharge Pressure – 200 mmWC MOC – Carbon Steel Power Supply – 415V/50Hz/3Ph Operation – Continuous

FV-350

Mini Travelling Grate

Application –To Combust the solids coming out of the gasifier Type – Travelling Grate Solid Burning Capacity – 100 kg/h Power Supply – 415V/50Hz/3Ph Operation – Continuous

B-500

Heat Recovery Steam Generator

Application –To recover heat in the flue gas produced by the combustion chamber and produce steam Type – Water Tube Boiler Flue Gas Flowrate – 1,200 Nm3/h Design temperature – 1,200 0C MOC • Body – Carbon Steel • Tubes – Boiler Grade Steel Steam Pressure – 4.5 barA Steam Pressure – 144 0C Max Steam production capacity – 600 kg/h Maximum Allowable Pressure drop – 100 mmWC Inside insulation – 100 mm thick refractory on the inlet nozzle or as recommended by bidder Outside Insulation – 50 mm Mineral wool with GI cladding Operation – Continuous Reference Drawing – 169-D-GG-500-1000

TK-510

Feed Water Tank

Application –To store feed water for boiler Type – Storage Tank Capacity – To match with boiler requirement MOC – As recommended by bidder

Page 17 of 32 Appendix 1 - 2TPD 190821

Item 18

Tag No. P-520 A/B

Tag Name Feed Water Pumps

Specification Application –To supply feed water to the boiler Type – Centrifugal or as recommended by bidder Capacity – To match with boiler requirement Head - To match with boiler requirement MOC – As recommended by bidder

3. FLUE GAS CLEANUP COMPONENTS 19

H-540/ SC-550/ RV-560

Sorbent Injection System (Sorbent Hopper/Sorbent Feeder/Rotary Airlock for SC550)

BF-600 & Bag Filter & FGD-675 Flue Gas De-sulphurizer

Application – To store and supply sorbent for acid neutralization Type – Storage Hopper with bottom conical discharge Capacity – 25 kg Normal Discharge rate – 4 kg/hr Maximum Discharge rate – 8 kg/hr Turn Down Ratio – 5:1 Bulk density of Sorbent - 600-700 kg/m3 Accessories: • Sorbent Feeder (SC-550) – To ensure uniform discharge • Rotary Valve (RV-560) – To prevent false air entry MOC: • Hopper – Carbon Steel • Sorbent Feeder – Wear Resistant Steel • Other components – Carbon Steel Operation – Equipment designed for continuous operation, but will only be operated according to requirement Application – To separate particulates as well as acid gases from flue gas Type – Reverse Pulse Jet Bag Filter with integrated reaction chamber Gas Flowrate – 1,400 Nm3/h (2,000 Am3/h) Gas Temperature – 150 0C Design Temperature – 220 0C MOC – Carbon Steel Filtration Efficiency – 99.99 % for 2 microns and larger Maximum Allowable Pressure drop – 150 mmWC Outside Insulation – 50mm Mineral wool with GI cladding Page 18 of 32

Appendix 1 - 2TPD 190821

Item

Tag No.

Tag Name

Specification Operation – Continuous Special Provision – Additional volume at the inlet for maintaining sorbent reaction time. Residue Discharge Provision – Leak proof arrangement Power Supply – 415V/50Hz/3Ph Ref Drawing – 169-D-GG-675-1000

CF-620

Carbon Bed Filter

Application – To separate particulates from flue gas Adsorbent Material - Activated carbon Maximum Temperature – 120 0C Tray Thickness - 50mm Filter Size - 300mm X 600 mm Filter Efficiency – 90% to 99% Particle removal size – Up to 3 microns Filter Efficiency Rating - MERV 7 Carbon Concentration – 0.33 g/cm2 Ref Drawing – 169-D-GG-620-1000

F-660

ID Fan

Application – To generate draft to carry the gases all the way from gasifier to the exhaust Type – Induced Draft Centrifugal Fan Capacity – 1,400 Nm3/h (2,000 Am3/h) Suction Pressure – 900 mmWC Discharge Pressure – 100 mmWC Inlet Gas Temperature – 150 0C Design Temperature – 175 0C Drive Arrangement – VFD controlled direct drive through coupling. MOC • Impeller – Carbon Steel • Casing – Carbon Steel Additional Provision: • Online Impeller cleaning • Anti-vibration mounts • Impellor designed for medium dust loading Operation – Continuous Power Supply – 415V/50Hz/3Ph

Page 19 of 32 Appendix 1 - 2TPD 190821

Item 23

Tag No. AI-710

Tag Name

Specification

Flue Gas Analyzer Application – To measure flue gas composition Type – Flue Gas Analyzer Reference – Table 6

4. AUXILIARY COMPONENTS 24

ST-670

Stack

Application - To exhaust the flue gas from syngas combustion Type - Self supported Gas Flowrate – 1, 400 Nm3/h (2,000 Am3/h) Gas Temperature – 150 0C MOC - Carbon Steel with 45 % alumina refractory lining at the bottom Height – To meet local codes Diameter – To match with the flow rate and height

TK-700

Process Water Tank

Application – To store process water Type – Storage Tank Capacity – 2 m3 MOC – HDPE

P-705 A/B

Process Water Pump A/B

Application – To supply process water for gasifier Type – Centrifugal Capacity – 0.5 m3/h Head – 100 m MOC – Carbon Steel Power Supply – 415V/50Hz/3Ph

C-900

Air Compressor Application – To supply compressed air for Package instruments Type – Rotary Screw Capacity - 50 m3/h (30 CFM) Discharge pressure - 7 barg Accessories: • Air Dryer – 50 m3/h (30 CFM) • Air receiver tank - 200 litres Operation - Continuous

5. ELECTRICAL AND INSTRUMENTATION COMPONENTS 28

Inst-01

Field Instruments

Reference - Table 7

Valve-01

Control Valves

Reference - Table 8

Valve-01

Manual Valves

Reference - Table 9 Page 20 of 32

Appendix 1 - 2TPD 190821

Item

Tag No.

Tag Name

Specification

MCC-01

Motor Control Centre

Reference – Table 10 Table 11 Table 12

CS-01

Control System

Reference - Table 13

6. DUCTING AND PIPING COMPONENTS 33

PI-01

Piping and Ducting

Reference - Table 14

7. REFRACTORY COMPONENTS 34

Ref-01

Refractory

Dense Refractory Service Temperature – 1450 0C Bulk Density – 2.45 g/cc Permanent Linear Change @ 1100 0C – (0.18) % Cold Crushing Strength @ 1100 0C – 300 kgf/cm2 Alumina - >60% Iron - <1.0% Thermal Conductivity @ 450 0C– 0.95 kCal/h.m.0C Insulation Refractory Service Temperature – 1350 0C Bulk Density – 1.45 g/cc Permanent Linear Change @ 1100 0C – 30 % Cold Crushing Strength @ 1100 0C – 30 kgf/cm2 Iron – 3.5% Thermal Conductivity @ 450 0C– 0.32 kCal/h.m.0C

7. INSTALLATION The 2 TPD Rotary Kiln Gasification pilot plant will be installed at the project site in KITS campus near Coimbatore, India. All components in the bid package must be supplied to the project site and installed. Detailed information on the project site will be provided after the contract is awarded. The 2 TPD Rotary Kiln Gasification pilot plant must be installed such that it is ready to be operational. All labour, equipment, consumables, utilities and any other associated cost must be borne by the bidder. Do not include any cost information in the technical bid package. Page 21 of 32 Appendix 1 - 2TPD 190821

The following points may be noted for installation. i.

The bidder is responsible for installation of all the equipment as per the engineering drawings provided and make the system operational.

ii.

The bidder should prepare necessary installation drawings and send for approval for KITS project in-charge, prior to starting the installation activities.

iii.

Necessary drawings for the civil foundations and structures should be provided to KITS well in advance, by the bidder, if any.

iv.

The bidder is responsible for arranging all installation items such as fasteners, foundation bolts, safety equipment, other necessary tools, consumables, spares and other accessories.

Arrangement of necessary heavy equipment (Cranes, Forklift, etc.)needed for installation are within the bidder’s scope of supply.

vi.

The bidder shall arrange necessary local manpower required for installation. Any insurance requirements for installation is bidder’s responsibility.

vii.

A site in-charge should be appointed by the bidder, who will be responsible for communicating with KITS’ technical team.

viii.

Installation must be completed within the schedule approved during finalization of the contract.

ix.

The bidder shall setup all the necessary arrangements required for installation of the components including scaffolding and other structures.

Utilities such as compressed air, diesel, auxiliary power etc. as required for the installation shall be arranged by the bidder.

xi.

Installation manuals of all items should be supplied along with the installation documents.

Page 22 of 32 Appendix 1 - 2TPD 190821

8. DRAWINGS Item

Drawing Number

Drawing Title

Layout Drawings 1

169-D-GG-000-1001

Layout

169-D-GG-000-1002

Front Elevation

169-D-GG-000-1003

Left Side Elevation

169-D-GG-000-1004

Right Side Elevation

Equipment Group Drawings 5

169-D-GG-300-2000

Gasifier Components

169-D-GG-500-2000

Steam Generation Components

169-D-GG-600-2000

Flue Gas Cleanup Components

169-D-GG-900-2000

Auxiliary Components

Equipment Drawings 9

169-D-GG-020-1000

Transfer Conveyor

169-D-GG-070-1000

Gasifier Feed Screw

169-D-GG-300-1000

Gasifier

169-D-GG-570-1000

Combustion Chamber for Boiler-500

169-D-GG-500-1000

Heat Recovery Steam Generator

169-D-GG-675-1000

Flue Gas De-sulphurizer

169-D-GG-620-1000

Carbon Bed Filter

Page 23 of 32 Appendix 1 - 2TPD 190821

2.4m

2.9m PLANT CAPACITY & PROCESS FEED

STACK HEIGHT MUST BE AS PER LOCAL CODES AND REGULATIONS, STACK LOCATION IS SUBJECT TO CHANGE AS PER SITE CONDITION

COMPONENT NO.

TAG NO.

EQUIPMENT

SH-010

PLASTIC CHOPPER

2TPD GASIFICATION SYSTEM

BC-020

TRANSFER CONVEYOR

MIXED PLASTIC

SC-070

GASIFIER SCREW FEEDER

RX-300

GASIFIER

BRN-310

STARTUP BURNER

BL-320

STARTUP BURNER BLOWER

BL-330

PROCESS AIR BLOWER

AD-340

AIR DISTRIBUTOR

PROJECT OVER VIEW

ASH DISCHARGE

STEAM OUTLET

TROLLEY FOR ASH BIN MOVEMENT

2.8m

1.4m

16 ASH DISCHARGE

13.2m

CONTROL ROOM & OFFICE SPACE 14

3.6m

15m 3m

5.0

12 13

ACCESS PLATFORM FOR FEEDING

1.8m

5.8m

2.2m

FEED INLET

AI-680

SYNGAS ANALYZER

CC-570

COMBUSTION CHAMBER

BRN-580

BURNER FOR CC-570

BL-585

BLOWER FOR COMBUSTION CHAMBER BURNER

BL-590

BLOWER FOR COMBUSTION CHAMBER

FV-350

MINI TRAVELLING GRATE

BN-360

ASH BIN

B-500

HEAT RECOVERY SYSTEM

TK-510

FEED WATER TANK

P-520 A/B

FEED WATER PUMPS

SORBENT INJECTION SYSTEM

H-540/SC550/RV-560 BF-600 & FGD-675

BAG FILTER & FLUEGAS DESULPHURIZER

CF-620

CARBON BED FILTER

F-660

ID BLOWER

BN-610 & BN-675

ASH BIN FOR BF-600 & FGD-675

AI-710

FLUEGAS ANALYZER

ST-670

STACK

TK-700

PROCESS WATER TANK

P-705 A/B

PROCESS WATER PUMP A/B

C-900

AIR COMPRESSOR PACKAGE

MCC-01

MOTOR CONTROL CENTRE

- ALL STAIRCASE AND PLATFORMS SHOULD HAVE HANDRAILS AS PER INDIAN STANDARD. - SAFETY GUARD SHOULD BE PROVIDED FOR ALL ROTATING EQUIPMENT WHEREVER REQUIRED. - WARNING & SAFETY LABELS , ELECTRICAL AND FLOW INDICATORS MUST BE PROVIDED WHERE EVER APPLICABLE AS PER INDIAN STANDARDS. - PIPE & PIPE RACKS , CABLE & CABLE TRAY PIPE SUPPORTS ARE NOT SHOWN IN THE LAYOUT. - LAYOUT IS SUBJECT TO CHANGE AS PER FINAL DESIGN AND SITE CONDITION.

1.6m 4.5m 11m

2.9m REFERENCE DRAWING LIST

NOTES: - THIS IS A PRELIMINARY DRAWING ISSUED FOR RFQ PURPOSE ONLY, NOT FOR CONSTRUCTION OR INSTALLATION. - THE OVERALL DIMENSIONS AND EQUIPMENT SIZE IS SUBJECT TO CHANGE BASED ON FINAL SITE CONDITION AND DESIGN. - CIVIL STRUCTURES SHOWN IN THIS DRAWING IS ONLY FOR REFERENCE.

REVISIONS REV.

DATE

DRAWING NO.

DRAWING TITLE

169-D-GG-000-1002

FRONT ELEVATION

DRAWING TITLE

PROJECT NAME

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

LAYOUT CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-000-1001

REV NO:

VER NO:

SCALE :1:200

OXYGEN CYLINDERS

SHEET:1 OF 1

STACK HEIGHT MUST BE AS PER LOCAL CODES AND REGULATIONS, STACK LOCATION IS SUBJECT TO CHANGE AS PER SITE CONDITION

COMPONENT NO.

TAG NO.

EQUIPMENT

SH-010

PLASTIC CHOPPER

2TPD GASIFICATION SYSTEM

BC-020

TRANSFER CONVEYOR

MIXED PLASTIC

SC-070

GASIFIER SCREW FEEDER

RX-300

GASIFIER

BRN-310

STARTUP BURNER

BL-320

STARTUP BURNER BLOWER

BL-330

PROCESS AIR BLOWER

AD-340

AIR DISTRIBUTOR

PROJECT OVER VIEW PLANT CAPACITY & PROCESS FEED 26

CC-570

COMBUSTION CHAMBER

BRN-580

BURNER FOR CC-570

BL-585

BLOWER FOR COMBUSTION CHAMBER BURNER

BL-590

BLOWER FOR COMBUSTION CHAMBER

FV-350

MINI TRAVELLING GRATE

BN-360

ASH BIN

B-500

HEAT RECOVERY SYSTEM

TK-510

FEED WATER TANK

P-520 A/B

FEED WATER PUMPS

SORBENT INJECTION SYSTEM BAG FILTER & FLUEGAS DESULPHURIZER

CF-620

CARBON BED FILTER

F-660

ID BLOWER

BN-610 & BN-675

ASH BIN FOR BF-600 & FGD-675

AI-710

FLUEGAS ANALYZER

ST-670

STACK

TK-700

PROCESS WATER TANK

P-705 A/B

PROCESS WATER PUMP A/B

C-900

AIR COMPRESSOR PACKAGE

MCC-01

MOTOR CONTROL CENTRE

6.9m * 09

EL 0.0 14

SYNGAS ANALYZER

AI-680

H-540/SC550/RV-560 BF-600 & FGD-675

11 CONTROL ROOM & OFFICE SPACE

OXYGEN CYLINDERS

10.9m 11m

REV.

DATE

DRAWING TITLE

169-D-GG-000-1001

LAYOUT

DRAWING TITLE

PROJECT NAME

SHEET:1 OF 1

REVISIONS

DRAWING NO.

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

FRONT ELEVATION CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-000-1002

REV NO:

VER NO:

SCALE :1:200

REFERENCE DRAWING LIST

STACK HEIGHT MUST BE AS PER LOCAL CODES AND REGULATIONS, STACK LOCATION IS SUBJECT TO CHANGE AS PER SITE CONDITION

COMPONENT NO.

TAG NO.

EQUIPMENT

SH-010

PLASTIC CHOPPER

2TPD GASIFICATION SYSTEM

BC-020

TRANSFER CONVEYOR

MIXED PLASTIC

SC-070

GASIFIER SCREW FEEDER

RX-300

GASIFIER

BRN-310

STARTUP BURNER

BL-320

STARTUP BURNER BLOWER

BL-330

PROCESS AIR BLOWER

AD-340

AIR DISTRIBUTOR

PROJECT OVER VIEW PLANT CAPACITY & PROCESS FEED

CONTROL ROOM & OFFICE SPACE

6.9m *

EL 0.0 27

AI-680

SYNGAS ANALYZER

CC-570

COMBUSTION CHAMBER

BRN-580

BURNER FOR CC-570

BL-585

BLOWER FOR COMBUSTION CHAMBER BURNER

BL-590

BLOWER FOR COMBUSTION CHAMBER

FV-350

MINI TRAVELLING GRATE

BN-360

ASH BIN

B-500

HEAT RECOVERY SYSTEM

TK-510

FEED WATER TANK

P-520 A/B

FEED WATER PUMPS

SORBENT INJECTION SYSTEM

H-540/SC550/RV-560 BF-600 & FGD-675

BAG FILTER & FLUEGAS DESULPHURIZER

CF-620

CARBON BED FILTER

F-660

ID BLOWER

BN-610 & BN-675

ASH BIN FOR BF-600 & FGD-675

AI-710

FLUEGAS ANALYZER

ST-670

STACK

TK-700

PROCESS WATER TANK

P-705 A/B

PROCESS WATER PUMP A/B

C-900

AIR COMPRESSOR PACKAGE

MCC-01

MOTOR CONTROL CENTRE

OXYGEN CYLINDERS

13.2m 15m

REV.

DATE

DRAWING TITLE

169-D-GG-000-1001

LAYOUT

DRAWING TITLE

PROJECT NAME

SHEET:1 OF 1

REVISIONS

DRAWING NO.

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

LEFT SIDE ELEVATION CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-000-1003

REV NO:

VER NO:

SCALE :1:40

REFERENCE DRAWING LIST

PROJECT OVER VIEW 2TPD GASIFICATION SYSTEM

TAG NO.

EQUIPMENT

SH-010

PLASTIC CHOPPER

BC-020

TRANSFER CONVEYOR

SC-070

GASIFIER SCREW FEEDER

RX-300

GASIFIER

BRN-310

STARTUP BURNER

BL-320

STARTUP BURNER BLOWER

BL-330

PROCESS AIR BLOWER

AD-340

AIR DISTRIBUTOR

STACK HEIGHT MUST BE AS PER LOCAL CODES AND REGULATIONS, STACK LOCATION IS SUBJECT TO CHANGE AS PER SITE CONDITION

MIXED PLASTIC

26 20

21 17 02

TROLLEY FOR ASH BIN MOVEMENT

SYNGAS ANALYZER

CC-570

COMBUSTION CHAMBER

BRN-580

BURNER FOR CC-570

BL-585

BLOWER FOR COMBUSTION CHAMBER BURNER

BL-590

BLOWER FOR COMBUSTION CHAMBER

FV-350

MINI TRAVELLING GRATE

BN-360

ASH BIN

B-500

HEAT RECOVERY SYSTEM

TK-510

FEED WATER TANK

P-520 A/B

FEED WATER PUMPS

SORBENT INJECTION SYSTEM

H-540/SC550/RV-560 BF-600 & FGD-675

BAG FILTER & FLUEGAS DESULPHURIZER

CF-620

CARBON BED FILTER

F-660

ID BLOWER

BN-610 & BN-675

ASH BIN FOR BF-600 & FGD-675

AI-710

FLUEGAS ANALYZER

ST-670

STACK

TK-700

PROCESS WATER TANK

P-705 A/B

PROCESS WATER PUMP A/B

C-900

AIR COMPRESSOR PACKAGE

MCC-01

MOTOR CONTROL CENTRE

EL 0.0 01

AI-680

13.2 m

15m

REFERENCE DRAWING LIST

REVISIONS REV.

DATE

DRAWING NO.

DRAWING TITLE

169-D-GG-000-1001

LAYOUT

DRAWING TITLE

PROJECT NAME

DESCRIPTION

2 TPD ROTARY KILN GASIFICATION SYSTEM

RIGHT SIDE ELEVATION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-000-1004

REV NO:

VER NO:

SCALE :1:200

6.9 m *

OXYGEN CYLINDERS

SHEET:1 OF 1

PLANT CAPACITY & PROCESS FEED

COMPONENT NO.

COMPONENT TAG NO. NO

11m

10.9m

1.9m

1.8m

15m

SH-010

PLASTIC CHOPPER

BC-020

TRANSFER CONVEYOR

SC-070

GASIFIER SCREW FEEDER

RX-300

GASIFIER

BRN-310

STARTUP BURNER

BL-320

STARTUP BURNER BLOWER

BL-330

PROCESS AIR BLOWER

AD-340

AIR DISTRIBUTOR

OXYGEN CYLINDERS

2.8m

1.0m

2.2m

1.2m

1.0m

0.6m 2.6m

AI-680

SYNGAS ANALYZER

NOTES: - THIS IS A PRELIMINARY DRAWING ISSUED FOR RFQ PURPOSE ONLY, NOT FOR CONSTRUCTION OR INSTALLATION - THE OVERALL DIMENSIONS AND FINAL SIZE IS SUBJECT TO CHANGE BASED ON FINAL SITE CONDITION AND DESIGN. -CIVIL STRUCTURE SHOWN IN THIS DRAWING IS ONLY FOR REFERENCE

0.3m

EQUIPMENT

0.4m 2.2m

1.7m

0.8m

0.6m

1.6m

TOP VIEW

3.8m

ISOMETRIC VIEW SCALE 1 : 100

EL 0.0

DRAWING TITLE

169-D-GG-000-1001

LAYOUT

REV.

DATE

DRAWING TITLE

PROJECT NAME

SHEET:1 OF 1

REVISIONS DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

GASIFIER COMPONENTS CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-300-2000

REV NO:

DRAWING NO.

FRONT VIEW

VER NO:

SCALE :1:40

REFERENCE DRAWING LIST

COMPONENT TAG NO. NO

11m

CC-570

COMBUSTION CHAMBER

BRN-580

BURNER FOR CC-570

BL-585

BLOWER FOR COMBUSTION CHAMBER BURNER

BL-590

BLOWER FOR COMBUSTION CHAMBER

FV-350

MINI TRAVELLING GRATE

BN-360

ASH BIN

B-500

HEAT RECOVERY SYSTEM

TK-510

FEED WATER TANK

P-520 A/B

FEED WATER PUMPS

9.5m

15m

** TROLLEY

EQUIPMENT

3.7m

4.7m

0.3m

TOP VIEW

REFERENCE DRAWING LIST

EL 0.0

FRONT VIEW REVISIONS REV.

DATE

DRAWING NO.

DRAWING TITLE

169-D-GG-000-1001

LAYOUT

DRAWING TITLE

PROJECT NAME

DESCRIPTION

2 TPD ROTARY KILN GASIFICATION SYSTEM

STEAM GENERATION COMPONENTS

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-500-2000

REV NO:

VER NO:

SCALE :1:50

ISOMETRIC VIEW SCALE 1 : 100

SHEET:1 OF 1

4.3m

** The Ash bin is Placed on a movable trolley which will move the Ash bin in and out from its location for ash removal.Trolly will be pulled out and then the Ash bin will be moved out by using a forklift or similar arrangement.The ash can be emptied as per site facility available. In its place an empty Ash bin can be placed and the trolly can be pushed back to its original location. A flexible joint made up of high temp , non breathable ceramic fibre cloth or similar is being used between Mini travelling grate and Ash bin. This Flexible joint must be leak proof and quick releasable type.

1.4m

COMPONENT TAG NO. NO

SORBENT INJECTION SYSTEM

H-540/SC550/RV-560 BF-600 & FGD-675

CF-620

CARBON BED FILTER

F-660

ID BLOWER

BN-610 & BN-675

ASH BIN FOR BF-600 & FGD-675

AI-710

FLUEGAS ANALYZER

15m

3.5m

3.2m

EQUIPMENT

BAG FILTER & FLUEGAS DESULPHURIZER

NOTES: - THIS IS A PRELIMINARY DRAWING ISSUED FOR RFQ PURPOSE ONLY, NOT FOR CONSTRUCTION OR INSTALLATION - THE OVERALL DIMENSIONS AND FINAL SIZE IS SUBJECT TO CHANGE BASED ON FINAL SITE CONDITION AND DESIGN. - CIVIL STRCTURE SHOWN IN THIS DRAWING IS ONLY FOR REFERENCE

11m

TOP VIEW

6.9m

21 22

ISOMETRIC VIEW SCALE 1 : 100 23 24

REV.

DATE

169-D-GG-000-1001

LAYOUT

DRAWING TITLE

PROJECT NAME

SHEET:1 OF 1

REVISIONS

DRAWING TITLE

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

FLUEGAS CLEANUP COMPONENTS CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-600-2000

REV NO:

FRONT VIEW

DRAWING NO.

VER NO:

SCALE :1:40

REFERENCE DRAWING LIST

EL 0.0

1.1m

COMPONENT TAG NO. NO

1.3m 0.03m 1m

ST-670

STACK

TK-700

PROCESS WATER TANK

P-705 A/B

PROCESS WATER PUMP A/B

C-900

AIR COMPRESSOR PACKAGE

1.8m

2.8m

EQUIPMENT

15m

1.2m 1m

2.7m 2.8m

0.7m

0.6m

3.7m

11m

TOP VIEW

STACK HEIGHT AS PER LOCAL CODES & REGULATIONS 26

1.5m

ISOMETRIC VIEW SCALE 1 : 100

EL 0.0

DRAWING TITLE

169-D-GG-000-1001

LAYOUT

REVISIONS REV.

DATE

DRAWING TITLE

PROJECT NAME

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

AUXILIARY COMPONENTS CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-900-2000

REV NO:

DRAWING NO.

FRONT VIEW

VER NO:

SCALE :1:40

REFERENCE DRAWING LIST

SHEET:1 OF 1

0.4m

1.2m

TAG NUMBER

DESCRIPTION

BC-020

TRANSFER CONVEYOR

DESIGN SPECIFICATION

788

701

1254 580

TOP VIEW

831

ISOMETRIC VIEW

3497

CAPACITY

100 kg/hr WITH 20% DESIGN MARGIN

MATERIAL

SHREDDED PLASTIC

BULK DENSITY

100-200 kg/m3

MATERIAL SIZE

1/2 - 1 " PRE SHREDDED

MOISTURE

MAX 20%

CONVEYOR TYPE

SIDE WALL CONVEYOR

BELT TYPE

RUBBER CLEATED

BELT MUST BE COVERED TO PREVENT SPILLAGE AND DUST

3380

* GEARED MOTOR IS NOT SHOWN IN THE DRAWING, REFER EQUIPMENT SPECIFICATION SHEET FOR MORE DETAILS

** THIS ANGLE CAN BE INCREASED TO MAXIMUM POSSIBLE TO REDUCE THE FOOT PRINT

577

1103

630

2286

SIDE VIEW

REV.

DATE

DRAWING TITLE

PROJECT NAME

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

TRANSFER CONVEYOR CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-020-1000

REV NO:

VER NO:

SCALE :1:20

REVISIONS

FRONT VIEW NOTES: - THIS IS A PRELIMINARY DRAWING ISSUED FOR RFQ PURPOSE ONLY, NOT FOR CONSTRUCTION OR INSTALLATION. - EQUIPMENT SIZE, DIMENSION AND SHAPE ARE SUBJECT TO CHANGE BASED ON FINAL SITE CONDITIONS AND DESIGN. SHEET:1 OF 1

PROJECTION

COMPONENT NO.

4511

MACHINING TOLERANCE FOR LINEAR GENERAL TOLERANCE FOR LINEAR SURFACE FINISH SYMBOLS DIMENSIONS, IS-2102(MEDIUM) DIMENSIONS, IS-2102(COARSE) ⁓ 30 120 400 1000 2000 OVER 0.5 3 30 120 400 1000 2000 ROUGHNESS 6 OVER 0.5 3 6 SYMBOL 30 120 400 1000 2000 4000 UPTO 3 6 30 120 400 1000 2000 4000 UPTO 3 6 N1 N2 N3 N4 N5 N6 N7 N8 N9 3.0 1.2 4.0 2.0 0.2 0.3 0.5 0.8 1.2 2.0 0.1 0.1 0.2 0.3 0.5 0.8 TOL TOL 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50 Ra, µm ANGULAR DIMENSIONS: 1 ANGULAR DIMENSIONS: 1

REFERENCE DRAWING LIST DRAWING NO. DRAWING TITLE 169-D-GG-000-1001 LAYOUT 169-D-GG-300-2000 GASIFIER COMPONENTS

THIS IS THE FEED CHUTE MATCHING FLANGE AND HAS TO BE WELDED AT SITE

DRAWING NO.

DRAWING TITLE

169-D-GG-000-1001

LAYOUT

169-D-GG-300-2000

GASIFIER COMPONENTS

COMPONENT NO.

TAG NUMBER

SC-070

DESCRIPTION GASIFIER SCREW FEEDER

DESIGN SPECIFICATIONS PRE PROCESSED WASTE FEED 100 kg/hr CAPACITY

SS-304 SCREW DIA 240mm PITCH 1:1

610

370

M10 STUD SHOULD BE WELDED TO THE ACCESS DOOR. SILICON GASKET TO BE CONSIDERED FOR PROPER SEALING

FEED DENSITY

100 TO 200 kg/m3

MAX. LUMP SIZE

25 mm

FEED MOISTURE

20% MAX.

SCREW INSTALLATION

CANTILEVER

MOTOR POWER

3 HP *

695

REFER EQUIPMENT SPECIFICATION SHEET FOR MORE DETAILS * SUBJECTED TO CHANGE AS PER FINAL DESIGN

545 TOP VIEW

FEED INLET 10"CARBON STEEL SCH40 PIPE

212

1342 ISOMETRIC VIEW

361 265

SQ.TUBE 70X70X5.0

700

1336

SQ.TUBE 100X100X3.2

1701

2062

FEED DISCHARGE

SECTION A-A 629 916

2044

A SIDE VIEW

FRONT VIEW

REV.

DATE

DRAWING TITLE

PROJECT NAME

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

GASIFIER SCREW FEEDER CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-070-1000

REV NO:

VER NO:

SCALE :1:20

REVISIONS

NOTES: - THIS IS A PRELIMINARY DRAWING ISSUED FOR RFQ PURPOSE ONLY, NOT FOR CONSTRUCTION OR INSTALLATION. - EQUIPMENT SIZE, DIMENSION AND SHAPE ARE SUBJECT TO CHANGE BASED ON FINAL SITE CONDITIONS AND DESIGN. SHEET:1 OF 1

PROJECTION

REFERENCE DRAWING LIST

DRAWING TITLE

169-D-GG-000-1001

LAYOUT

169-D-GG-300-2000

GASIFIER COMPONENTS

04.10 04.02

04.17

462

04.11

2600*

04.01 KILN

IS 2062 Gr A,1060mm ID x 1080mm OD x 10mm Thk

345

04.02 INLET HOOD

INTEGRATED INLET HOOD DESIGN, SS 310, 300mm LG x 10mm THK, WITH 50mm REFRACTORY

100

04.03 TYRES

IS 2708, 1120mm ID x 1270mm OD x 75mm W , HARDNES 220-230 BHN

125 ea

04.04 MAIN SPROCKET

EN9, BRN 200-230, 104 TEETH, 1.5" PITCH, 1242mm PCD x 23.1mm THK, ANSI CHAIN NO.120 OR EQUIVALENT, 4 PIECE DESIGN

04.05 PINION SPROCKET

EN9, BRN 200-230, 15 TEETH, 1.5" PITCH, 181mm PCD x 15mm THK, ANSI CHAIN NO.120 OR EQUIVALENT

04.06 IDLER SPROCKET

EN9, BRN 200-230, 15 TEETH, 1.5" PITCH, 181mm PCD x 15mm THK, ANSI CHAIN NO.120 OR EQUIVALENT

04.07 PINION SHAFT

EN19, 60mm OD X 450mm LG

04.08 LOCK RING

25 ea

1 ea

04.11 INTEGRATED FEED CHUTE

IS 2062, 1120mm ID x 1190mm OD x 20mm THK IS 2062, 50mm W x 38mm H x 12mm THK IS 2062 WITH HIGH TEMP FLEXIBLE NON BREATHABLE SEAL SS 310, 263mm ID x 5mm THK , AIR COOLED AND PROCESS INTEGRATED

04.12 BURNER NOZZLE

04.20

04.12

04.18

04.05 04.13

04.15

150

600

04.07

04.14

135

237

04.16

300

04.19

FOR 04.09 SUPPORT MAIN SPROCKET HOOD 04.10 INLET SEAL CHAMBER

1769 08

TO SUIT BURNER DIMENSIONS ***

04.13 ROLLER

IS 2708, 170mm DIA, 210mm COLLAR OD, 125mm WIDTH

15 ea

04.14 ROLLER SHAFT

EN19, 60mm OD X 310mm LG

6 ea

04.15 PILLOW BLOCK

SKF OR EQUIVALENT, MODEL: SY50TR, BALL BEARING SHAFT DIA 50mm

3 ea

04.16 COUPLING

FCL 180

04.17 CHAIN

ANSI CHAIN NO.120, 4.7m LG **

04.18 CHAIN COVER

IS 2062

04.19 GEAR MOTOR

3HP, GEARBOX OUTPUT RPM 32 KILN RPM 0.3 TO 3 VFD CONTROLLED **

04.20 CHAIR PLATE

IS 2062, 150mm W x 95mm L x 10mm THK

04.21 DENSE REFRACTORY

80mm THK ACID RESISTANT DENSE REFRACTORY, 60% ALUMINA **

570

04.22 INSULATION REFRACTORY

150mm THK CASTABLE INSULATION REFRACTORY ** 3" SCH40 PIPE WITH ANSI 150# FLANGE

800

FEED INLET

ISOMETRIC VIEW

TOP VIEW A

1620 1300, KILN LENGTH

150

04.22

300

800

102

04.21

350

23°

216

1270 TYRE OD

536

1080

1060

AIR INLET

600, KILN ID 760

388 08

TRUE R85 ROLLER RADIUS 30°

300

SECTION A-A

967

TYPE OPERATING TEMPERATURE FEED CAPACITY

150

950

SHREDDED PLASTIC 100 TO 200 kg/m3

ROTATION SPEED 0.3 to 3 RPM TURNDOWN RATIO 4:1 REFER EQUIPMENT SPECIFICATION SHEET FOR MORE DETAILS

REVISIONS DATE

DESIGN SPECIFICATIONS ROTARY KILN 900 deg C 100 kg/hr

FEED TYPE FEED DENSITY

FRONT VIEW

REV.

AIR DISTRIBUTOR

* THE WEIGHT SHOWN IS WITHOUT SUPPORT STRUCTURES. ** SUBJECTED TO CHANGE AS PER FINAL DESIGN *** BURNER CAPACITY 125,000 KCal/h MUST BE USED FOR PRE HEATING PURPOSE (REFER SPECIFICATION SHEET) - 60 DEG V SHAPE 6mm DIA SS310 REFRACTORY ANCHORS PLACED 4" APART TO BE CONSIDERED. - 2 COAT ZINC RICH PRIMER AND 2 COAT ENAMEL PAINT MUST BE APPLIED. - CHAIN AND COUPLING GUARDS MUST BE PROVIDED AS PER OSHA. - HEAT TREATMENT FOR THE COMPONENT MUST BE CONSIDERED AS PER DESIGN REQUIREMENT. - THRUST ROLLER MUST BE CONSIDERED (NOT SHOWN IN THE DRAWING) - AN EXTENDED ASH CHUTE (SS310) AT KILN DISCHARGE SIDE MAY BE REQUIRED AS PER MINI TRAVELLING GRATE FEED INTAKE POSITION (NOT SHOWN IN THE DRAWING)

1701

1264 MAIN SPROCKET OD

ROTARY KILN GASIFIER

DISCHARGE

04.06

150 75

GASIFIER (RX-300)

DRAWING TITLE

PROJECT NAME

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

GASIFIER CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-300-1000

REV NO:

VER NO:

SCALE :1:20

04.08

SPECIFICATION

QTY

APPROX. WEIGHT (kg)

DESCRIPTION

04.01

300 PROJECTION

DRAWING NO.

04.09 04.04

COMPONENT NO.

SHEET:1 OF 1

04.03

2°

REFERENCE DRAWING LIST

169-D-GG-500-2000

COMPONENT NO.

ITEM

DESCRIPTION

B-500

HEAT RECOVERY SYSTEM

STEAM GENERATION COMPONENTS DESIGN SPECIFICATIONS

3161 1000

TYPE

WATER TUBE BOILER

GAS FLOW RATE

1200 Nm3/hr

INLET GAS TEMPERATURE

1200 deg C

OUTLET GAS TEMPERATURE

150 deg C

ASH CARRY OVER IN FLUEGAS 2 kg/hr

484

918

568

350

STEAM PRODUCTION

MAX. 500 kg/hr

STEAM DICHARGE PRESSURE

4.5 barA

REFER EQUIPMENT SPECIFICATION SHEET FOR MORE DETAILS - THE MODEL SHOWN IN THE DRAWING IS ONLY FOR REFERENCE * SUBJECTED TO CHANGE

326

TOP VIEW

8" * FLUE GAS EXIT NOZZLE

2" * STEAM EXIT NOZZLE

1003

INTEGRATED STEAM DRUM

406

ISOMETRIC VIEW

467

1499

2524

8" DENSE PHASE REFRACTORY COATED FLUE GAS INLET DUCT

1835 FRONT VIEW

SIDE VIEW

REV.

DATE

DRAWING TITLE

PROJECT NAME

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

HEAT RECOVERY SYSTEM CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-500-1000

REV NO:

VER NO:

SCALE :1:20

REVISIONS

PROJECTION

REFERENCE DRAWING LIST DRAWING NO. DRAWING TITLE 169-D-GG-000-1001 LAYOUT

TAG NUMBER

DESCRIPTION

CC-070

COMBUSTION CHAMBER

STEAM GENERATION COMPONENTS DESIGN SPECIFICATIONS

526

WATER WALL CONSTRUCTION

INLET SYNGAS FLOW RATE

172 Nm3/hr

OUTLET FLUEGAS FLOW RATE

876 Nm3/hr

DESIGN TEMPERATURE

1200 deg C

SYNGAS TEMPERATURE

900 degC

SYNGAS INLET PRESSURE

-5 TO 0 mmWC *

PREHEATING BURNER CAPACITY 0.125 MMkcal/hr *

1628

2684

CONSTRUCTION

MAXIMUM SKIN TEMPERATURE

150 deg C

THE OUTER SHELL SHOULD BE INSULATED WITH 2" CERAMIC WOOL WITH GI CLADDING. ( SUBJECTED TO CHANGE AS PER DESIGN REQUIREMENT 26 0

TOP VIEW

REFER BURNER MOUNTING FLANGE DIMENSIONS

8" DENSE PHASE REFRACTORY LINED FLUE GAS OUTLET DUCT ( NOT SHOWN )

BURNER MOUNTING FLANGE

WATER WALLED CONSTRUCTION

SUITABLE AIR TIGHT SEALING ARRANGEMENT MUST BE CONSIDERED BETWEEN COMBUSTION CHAMBER AND ASH DISCHARGE MECHANISM

ISOMETRIC VIEW 266

784

467

692

829

FROM GASIFIER

929

FLUE GAS EXIT

1777

114

3633

SIDE VIEW

FRONT VIEW

REFER EQUIPMENT SPECIFICATION SHEET FOR MORE DETAILS - THE MODEL SHOWN IN THE DRAWING IS ONLY FOR REFERENCE * SUBJECTED TO CHANGE

DATE

DRAWING TITLE

PROJECT NAME

DESCRIPTION

2 TPD ROTARY KILN GASIFICATION SYSTEM

COMBUSTION CHAMBER

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING. CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-570-1000

REV NO:

VER NO:

SCALE :1:20

690

554

685

REFRACTORY LINED INLET

SHEET:1 OF 1

PROJECTION

169-D-GG-500-2000

COMPONENT NO.

4 13

REFERENCE DRAWING LIST DRAWING NO. DRAWING TITLE 169-D-GG-000-1001 LAYOUT

DRAWING TITLE

169-D-GG-000-1001

LAYOUT

169-D-GG-600-2000

FLUEGAS CLEANUP COMPONENTS

343

315

345

433

TAG NUMBER

DESCRIPTION

CF-620

CARON BED FILTER

DESIGN SPECIFICATIONS ADSORBENT MATERIAL

ACTIVATED CARBON. RE-USABLE CARTRIDGE SIZE-L 300mmX W 600mmX T 50mm,2 NOS

MAXIMUM TEMPERATURE

120 deg C

FILTRATION EFFICIENCY

90% TO 99%

PARTICLE REMOVAL SIZE

UPTO 3 MICRONS

FILTER EFFICIENCY RATING MERV 7 CARBON CONCENTRATION

300 g/ft3

NOTE:ACTIVATED CARBON CARTRIDGES NOT SHOWN IN THE DRAWING

558

REFER EQUIPMENT SPECIFICATION SHEET FOR MORE DETAILS THE MODEL SHOWN IN THE DRAWING IS ONLY FOR REFERENCE * SUBJECTED TO CHANGE

758 TOP VIEW ISOMETRIC VIEW

INLET NOZZLE 8" ANSI 150 CLASS FLANGE 3

MOC: CARBON STEEL

EXIT NOZZLE 8" ANSI 150 CLASS FLANGE

356

175

ACCESS DOOR WITH QUICK RELEASE LATCHES

886

255

435

FLUE GAS INLET

100

TYP.25

SIDE VIEW

SECTION A-A

A FRONT VIEW FLUE GAS EXIT

REV.

DATE

DRAWING TITLE

PROJECT NAME

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

2 TPD ROTARY KILN GASIFICATION SYSTEM

CARBON BED FILTER CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

DRAWING NO:

169-D-GG-620-1000

REV NO:

VER NO:

SCALE :1:10

REVISIONS

PROJECTION

DRAWING NO.

COMPONENT NO.

REFERENCE DRAWING LIST

H-540/SC550/RV-560 SORBENT INJECTION SYSTEM

BF-600 & FGD-675

BAG FILTER & FLUE GAS DESULPHURIZER

DESIGN SPECIFICATIONS FOR BAG FILTER & FLUEGAS DESULPHURIZER

2320 21 FLUE GAS INLET

FLUE GAS EXIT

1922

TOP VIEW

ISOMETRIC VIEW

1400 Nm3/hr

GAS TEMPERATURE

150 degC

SOLIDS BULK DENSITY

100 TO 200 kg/m3

FILTER SIZE

2 MICRONS

FILTRATION EFFICIENCY

99.99% FOR TWO MICRON AND LARGER

SOLID CONCENTRATION

0.9 gm/m3

CONE ANGLE

70 DEG

NO. OF BAGS

BAG DIAMETER

160 mm

BAG LENGTH

2000 mm

1350 4" SORBENT INJECTION NOZZLE

INLET NOZZLE 8" SCH40 ANSI CLASS FLANGE

HOPPER CAPACITY

1349

FINE ASH EXIT

SIDE VIEW

FRONT VIEW

REVISIONS DATE

NORMAL DISCHARGE RATE

4 kg/hr

MAX. DISCHARGE RATE

8 kg/hr

TURN DOWN RATIO

5:1

BULK DENSITY OF SORBENT

600 TO 700 kg/m3

REFER EQUIPMENT SPECIFICATION SHEET FOR MORE DETAILS

REV.

DISCHARGE

THROUGH ROTARY AIRLOCK VALVE-VENTURY WITH COMPRESSED AIR LIME AUTOMIZATION

*ALL PLATFORMS AND STAIRCASES SHOULD HAVE HANDRAILS AS PER INDIAN STANDARDS. ASH HOPPER AND SEALED MECHANISM NOT SHOWN IN THE DRAWING ACCESS LADDERS MUST BE CONSIDERED FLUE GAS DUCT FLUSHING AND DRAIN POINTS NOT LESS THAN 2" MUST BE CONSIDERED BY-PASS DUCT MUST BE CONSIDERED-REFER P&ID

1380

FINE ASH DISCHARGE NOZZLE 6" SCH40 ANSI CLASS FLANGE

4809

C CHANNEL 100X10

INTEGRATED LIME REACTION CHAMBER, STORAGE HOPPER WITH BOTTOM CONICAL DISCHARGE 25 kg

TYPE

2238

C CHANNEL 100X10

6858

DESIGN SPECIFICATIONS FOR SORBENT INJECTION SYSTEM

1204

DISCHARGE NOZZLE 8" SCH40 ANSI CLASS FLANGE

2054

PIPE 1 1/4"

DRAWING TITLE

PROJECT NAME

DESCRIPTION

ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED. DO NOT SCALE DRAWING.

BAG FILTER & FLUE GAS DE-SULPHURIZER CAD By: DATE:

25-JUN-2021

CHD By: DATE:

30-JUN-2021

APPD By: DATE:

02-JUL-2021

PROJECT NO:

169

2 TPD ROTARY KILN GASIFICATION SYSTEM DRAWING NO:

169-D-GG-675-1000

REV NO:

VER NO:

SCALE :1:50

1500

GAS FLOW RATE

1244

DESCRIPTION

SHEET:1 OF 1

PROJECTION

COMPONENT TAG NUMBER NO.

REFERENCE DRAWING LIST DRAWING NO. DRAWING TITLE 169-D-GG-000-1001 LAYOUT 169-D-GG-600-2000 FLUEGAS CLEANUP COMPONENTS

9. REFERENCES This section contains the reference information for the equipment specifications section. Table 5: Specifications for Syngas Analyzer – (AI-680)

The primary purpose of the Gas Analyzer is to measure the composition of Syngas. The analyzer is placed at the exit of gasifier. Syngas analyzer package should be a combination of sampling system and analyzer. The specification of syngas analyzer is as follows: Design Parameter Type Syngas Temperature at sampling system inlet Measuring Range

Value Online Continuous monitoring 100-150 0C CO

0 - 50 %

v/v

0 - 50 %

v/v

CH4

0 - 20 %

v/v

0 - 25%

v/v

CO2

0 - 25 %

v/v

Particulates in Syngas

2 to 5 g/m3

Accessories

1. Integrated sampling system to be included 2. Provision for data feedback to PLC Slightly negative, -5 mm WC 415V, 3 Phase, 50 Hz 230V, 1 Phase, 50 Hz

Syngas Pressure Power Supply

Notes

Suction pump must be considered

Documents to be supplied: 1. 2. 3. 4.

General arrangement drawings Equipment specification Operating instructions Catalogues or cut sheets for bought out items

Page 24 of 32 Appendix 1 - 2TPD 190821

Table 6: Specifications Flue Gas Analyzer (AI-710)

The primary purpose of the flue gas analyzer is to measure the composition of flue gas. The analyzer is placed at the exit of ID fan. Flue gas analyzer package should be a combination of sampling system and analyzer. The design requirement for the flue gas analyzer is as follows: Design Parameter

Value

Notes

Type

Online Continuous monitoring

Flue gas Temperature at Sampling system inlet Measuring Range

~ 150 0C NOx

0 - 2000 ppm

v/v

SOx

0 - 2000 ppm

v/v

0 - 9999 ppm

v/v

CO2

0 - 20%

v/v

0 - 25 %

v/v

O2 3

Particulates in Syngas

0 to 1 mg/m

Accessories

1. Integrated sampling system to be included 2. Provision for data feedback to PLC 100 mm WC

Syngas Pressure Power Supply

Suction pump must be considered

415V, 3 Phase, 50 Hz 230V, 1 Phase, 50 Hz

Documents to be supplied: 1. 2. 3. 4.

General arrangement drawings Equipment specification Operating instructions Catalogues or cut sheets for bought out items

Table 7: List of Instruments Table 8: List of Control Valves Table 9: List of Manual Valves

Page 25 of 32 Appendix 1 - 2TPD 190821

Table 7: List of Instruments

Item

Tag

Description

Working Medium

Signal Type

Water

FE-300

Flow Measuring Orifice for Process Water Flow to RX300

FT-300

Flow Transmitter for Process Water Flow to RX-300

4-20mA

PT-307A

Pressure Transmitter for Gasifier RX-300 Inlet Hood

Syngas

4-20mA

PT-307B

Pressure Transmitter for Gasifier RX-300 Outlet Hood

Syngas

4-20mA

FE-330

Flow Measuring Orifice for Process Air Flow to RX-300

FT-330

Flow Transmitter for Process Air Flow to RX-300

FE-360

Flow Measuring Orifice for oxygen Flow to RX-300

FT-360

Flow Transmitter for Oxygen to RX-300

PG-330

Pressure Gauge for Process Air to RX-300

TE-311

Temperature Control Element at RX-300 Zone-1

TI-311

Temperature Indicator at RX-300 Zone-1

TE-314

Temperature Control Element at RX-300 Zone-4 Temperature Indicator at RX-300 Zone-4

Range, Min

Range, Max

Range, Unit

Thermo well

Probe length

Line Size

MOC

Metal Tube Rotameter

lph

1/4"

SS-304

Flow Transmitter

lph

-25

mmWC

-25

mmWC

Type

Piezo resistive Sensor Piezo resistive Sensor

YES

SS-310

1/2" BSP

0.1

YES

SS-310

1/2" BSP

0.1

YES

SS-304

3" ANSI 150 Flange

0.1

YES

CS-Zn Coated

Oxygen

4-20mA

Air

Diaphragm Gauge

250

Syngas

K Type thermocouple

1500

YES

10 feet

1/2"

SS-310

1/2" BSP

Nm3/hr

Casing

4-20mA

250

Dial Size

Accuracy (% Span)

Air

Syngas

Orifice Plate

Process Connection 1/4" ANSI 150 Flange

DP Transmitter Orifice Plate

Nm3/hr

DP Transmitter mmWC C

1/2"

SS-304

1/2" ANSI 150 Flange

0.1

YES

SS-304

1/2" BSP

1/2"

SS-310

1/2" BSP

CS-Zn Coated

1500

0.1

YES

1 feet

1/2"

SS-304

1/2" BSP

bar

SS-304

1/2" BSP

0.1

YES

1 feet

1/2"

SS-304

1/2" BSP

4-20mA

1500

Air

Temperature Gauge

100

Oxygen

Diaphragm Gauge

Oxygen

Temperature Gauge

100

0.1

YES

CS-Zn Coated

TI-314

TG-330

PG-360

TG-360

PG-382

Upstream Pressure Gauge for PCV-382

LPG

PG-383

Downstream Pressure Gauge for PCV-382

LPG

PSL-384

Low Pressure Switch for LPG to BRN-310

LPG

24VDC

Pressure Switch

PSH-384

High Pressure Switch for LPG to BRN-310

LPG

24VDC

Pressure Switch

LG-720

Level gauge for TK-700

Water

Gauge Glass

PG-705A

Pressure Gauge at the discharge of P-705A

Water

Bourdon Gauge

Bar

3/4"

SS-304

1/2" BSP

PG-705B

Pressure Gauge at the discharge of P-705B

Water

Bourdon Gauge

Bar

3/4"

SS-304

1/2" BSP

PSL-705

Pressure switch at the discharge of P-705A/B

Water

Low pressure switch

Bar

1/2" BSP

TE-500

Temperature Control Element for CC-570

Syngas

K Type thermocouple

1500

YES

3 feet

SS-304

1/2" BSP

TI-500

Temperature Indicator Controller for CC-570

4-20mA

Transmitter

1500

YES

CS-Zn Coated

27 28

LG-510 PG-520A

Level gauge for TK-510 Pressure Gauge at the discharge of P-520A

Water Water

N N

Gauge Glass Pressure Gauge

PG-520B

Pressure Gauge at the discharge of P-520B

Water

Pressure Gauge

PSL-920

Pressure switch at the discharge of P-520A/B

Water

Pressure Switch

PG-530

Bourdon Gauge

SS-304

1/2" BSP

TE-530

Pressure Gauge for Steam at Steam Drum Header Temperature Control Element for Steam Temperature at Steam Drum Header

Steam

K Type thermocouple

300

YES

1 feet

SS-304

1/2" BSP

TI-530

Temperature Indicator for Steam at Steam Drum Header

4-20mA

Transmitter

300

YES

PT-530

Pressure Transmitter for Steam at Steam Drum Header

Steam

4-20mA

Piezo resistive Sensor

Bar

SS-304

1/2" BSP

0.1

YES

FE-530

Flow Measuring Orifice for Steam Flow from Steam Drum

Steam

Orifice Plate

500

Kg/hr

SS-304

1" ANSI 150 Flange

YES

CS-Zn Coated

Temperature Control Element for Process Air to RX-300 Pressure Transmitter for Process air to RX-300 Temperature Control Element for Process Air to RX-300

CS-Zn Coated -

10 feet

K Type thermocouple Temperature Transmitter

CS-Zn Coated CS-Zn Coated CS-Zn Coated

Mounting Bracket

YES

Temperature Transmitter

Local Display

Preessure Gauge Preessure Gauge

FT-530

Flow Transmitter for Steam Flow from Steam Drum

37 38 39 40

LSL-530 LSLL-530 LSH-530 PG-581

Level Sensor for Steam Drum Low Level Level Sensor for Steam Drum Low Low Level Level Sensor for Steam Drum High Level Upstream Pressure Gauge for PCV-580

4-20mA

Water Water Water LPG

NO-Contact NO-Contact NO-Contact N

DP Transmitter

PG-582

Downstream Pressure Gauge for PCV-580

LPG

Pressure Gauge

PSL-580

Low Pressure Switch for LPG to BRN-580

LPG

N/O Contact

Pressure Switch

PSH-580

High Pressure Switch for LPG to BRN-580

LPG

N/C Contact

Pressure Switch

Mobrey Level Switch Mobrey Level Switch Mobrey Level Switch Pressure Gauge

Burner - Manufacturers's Recommendation

C C

Boiler - Manufacturers's Recommendation

500

Bar C

Kg/hr

Boiler - Manufacturers's Recommendation

Burner - Manufacturers's Recommendation

0.1

CS-Zn Coated CS-Zn Coated

Table 7: List of Instruments

Item

Tag

Description

Working Medium

Signal Type

Type

FE-570

Flow Measuring Orifice for Air flow to CC-570

Air

FI-570

Flow Measuring Orifice indicator for Air flow to CC-570

Air

4-20mA

TG-570

Temperature Gauge on Combustion Air line

Temperature Gauge

PG-570

Pressure Gauge on Combustion Air line

Diaphragm Gauge

TE-550

Temperature Control Element at B-500 Outlet

Flue Gas

Orifice Plate

Range, Min

Range, Max

Range, Unit

Thermo well

Probe length

Line Size

MOC

900

Nm3/hr

YES

DP Transmitter

K Type thermocouple

100 0C 500 mmWC 0

250

Process Connection 6" ANSI 150 Flange

Accuracy (% Span)

Dial Size

Casing

Local Display

Mounting Bracket

0.1

YES

CS-Zn Coated -

1/2" BSP

Transmitter

250

0.1

Glass tube

CS-Zn Coated -

4-20mA

Analyzer

Syngas

4-20mA

Analyzer

Gas Analyser(AI-680)

Syngas

4-20mA

Analyzer

AI-680-CO2

Gas Analyser(AI-680)

Syngas

4-20mA

Analyzer

AI-680-O2

Gas Analyser(AI-680)

Syngas

4-20mA

Analyzer

TI-315

Combustion chamber temperature element

Flue Gas

K Type thermocouple

1500

0.1

TE-315

Combustion chamber temperature indicator

Flue Gas

4-20mA

Transmitter

1500

YES

10"

1/2" BSP

CS-Zn Coated -

AI-710-NOx

Flue Gas monitor(AI-710)

Flue gas

4-20mA

Analyzer

2000

ppm

AI-710-SOx

Flue Gas monitor(AI-710)

Flue gas

4-20mA

Analyzer

2000

ppm

AI-710-CO

Flue Gas monitor(AI-710)

Flue gas

4-20mA

Analyzer

9999

ppm

AI-710-CO2

Flue Gas monitor(AI-710)

Flue gas

4-20mA

Analyzer

AI-710-O2

Flue Gas monitor(AI-710)

Flue gas

4-20mA

Analyzer

LSL-540

Level Sensor for H-540 Low Level

Lime

4-20mA

Level Switch

1/2" BSP

PG-600A

Pressure Gauge for Compressed Air Header to FGD-675

Compr Air

Bourdon gauge

Bar

SS-304

1/2" BSP

65 66

TE-600 TI-600

Temperature Element at FGD-675 Intlet Temperature Indicator at FGD-675 Intlet

Flue Gas

N 4-20mA

0 0

250 250

C 0 C

YES -

6" -

8" -

SS-304 -

1/2" BSP -

0.1

PT-600

Pressure Transmitter for CF-620 Outlet Pressure

Flue gas

4-20mA

-1250

100

mmWC

SS-304

1/2" BSP

0.1

CS-Zn Coated

PT-660

Pressure Transmitter for CF-620Outlet Pressure

Flue gas

4-20mA

200

mmWC

SS-304

1/2" BSP

PDIT-600

Differential Pressure Across FGD-675

Flue gas

4-20mA

300

mmWC

YES

SS-304

1/2" BSP

0.1

YES

TE-660

Temperature Control Element at CF-620 Outlet

Flue gas

RTD Transmitter Piezo resistive sensor Piezo resistive sensor Piezo resistive sensor RTD

TI-660

Temperature Indicator at CF-620 Outlet

4-20mA

FE-660

Flow Measuring Orifice at CF-620 exit

FT-660

Flow Measuring Orifice transmitter CF-620 exit

TMR-600

Timer for CF-620 Purging

Compr Air

NO-Contact

PDI-620

Differential Pressure Across CF-620

Flue gas

PG-900

Pressure Gauge for Compressed Air Header

Air

PT-900

Pressure Transmitter for Compressed Air Header

Air

TI-550

Temperature Indicator Element at B-500 Outlet

LG-695

Level gauge for TK-695

AI-680-CO

Gas Analyser(AI-680)

Syngas

AI-680-H2

Gas Analyser(AI-680)

AI-680-CH4

4-20mA

Water

Flue gas

N 4-20mA

250

YES

3 feet

SS-304

1/2" BSP

Transmitter

250

0.1

Averaging Pitot Tube

1100

Nm3/hr

SS-304

1/2" BSP

DP Transmitter

1100

Nm3/hr

0.1

YES

Timer Panel

Bourdon Gauge

300

mmWC

YES

SS-304

1/2" BSP

Bourdon Gauge

Bar

SS-304

1/2" BSP

4-20mA

Piezo resistive Sensor

Bar

SS-304

1/2" BSP

YES

0.1

CS-Zn Coated CS-Zn Coated CS-Zn Coated CS-Zn Coated CS-Zn Coated

Table 8: List of Control Valves

Item

Tag

FCV-300

FCV-320 Flow control valve for BL-320

3 4

Description Flow Control Valve for Process Water to RX-300

Flow Control Valve for Process Air to RXFCV-330 300 Inlet Hood Flow Control Valve for Oxygen to RX-300 FCV-360 Inlet Hood Shut Off Valve for Air to BRN-310

Working Medium Water Air Air Oxygen Air

Type Globe Valve Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve

Feedback

Positioner Input

Operating Temp

Operating Press.

Flow Rate, Min

Flow Rate, Max

Unit

Line Size

Air to Open

4-20 mA

25 deg C

5 Bar

lph

1/4"

Pneumatic

Air to Open

4-20 mA

25 deg C

250 mmWC

250

Nm3/hr

Pneumatic

Air to Open

4-20 mA

25 deg C

250 mmWC

250

Nm3/hr

Pneumatic

Air to Open

4-20 mA

25 deg C

250 mmWC

Nm3/hr

1/2"

Air to Open

Open / Close

25 deg C

250 mmWC

A 216 WCC

Class IV

Actuator type

Action

Pneumatic

XV-320

XV-385A Shut Off Valve for LPG Line to BRN-310

LPG

Ball valve

Pneumatic

XV-385B Shut Off Valve for LPG Line to BRN-310

LPG

Ball valve

Pneumatic

FCV-525 Flow control valve for BL-585

Air

Butterfly Valve Globe Valve Butterfly Valve

Pneumatic

Air to Open

4-20 mA

25 deg C

Pneumatic

Air to Open

4-20 mA

Pneumatic

Air to Open

4-20 mA

9 10

FCV-570 Flow Control Valve for Air to CC-570

XV-583A Shut Off Valve for LPG Line to BRN-580

LPG

Ball valve

Pneumatic

XV-583B Shut Off Valve for LPG Line to BRN-580

LPG

Ball valve

Pneumatic

XV-530

Water

Ball valve

Pneumatic

Air to Open

Pneumatic

Air to Open

Pneumatic

Air to Open

Pneumatic

Air to Open

Pneumatic

Air to Open

Shutoff Valve for Water to Steam Drum Shut Off Valve for Process Air to BRN-580

Air

XV-525

XV-601A Shut Off Valve at Inlet of FGD-675

Flue gas

XV-601B Shut Off Valve at Outlet of CF-620

Flue gas

XV-601C Bypass Shut Off Valve for CF-620

Flue gas

SV-600

Solenoid Valve for FGD-675 Purging

Air

Butterfly Valve Butterfly Valve Butterfly Valve Butterfly Valve

Lug End

1/4" NPT 3" ANSI 150 Flange 3" ANSI 150 Flange 1/2" ANSI 150 Flange Lug End

A 216 WCC A 216 WCC A 216 WCC A 216 WCC A 216 WCC

Class IV Class IV Class IV Class IV Class IV

Burner - Manufacturers's Recommendation

Flow Control Valve for Steam from Steam FCV-530 Drum

Steam

24 V DC

Process Leakage Body MOC Connection Class

250 mmWC

250

Nm3/hr

300 deg C

5 bar

25 deg C

500 mmWC

500

kg/hr

900

Nm3/hr

3" ANSI 150 Flange 1"ANSI 150 Flange 6" ANSI 150 Flange

A 216 WCC A 216 WCC A 216 WCC

Class IV Class IV Class IV

Burner - Manufacturers's Recommendation Open / Close Open / Close Open / Close Open / Close Open / Close

24 V DC

25 deg C

10 Bar

3/4"

Lug End

24 V DC

25 deg C

250 mmWC

Lug End

24 V DC

200 deg C

-750 mmWC

Lug End

24 V DC

200 deg C

-750 mmWC

Lug End

24 V DC

200 deg C

-750 mmWC

Lug End

Flue Gas Desulphuriser - Manufacturers's Recommendation

A 216 WCC A 216 WCC A 216 WCC A 216 WCC A 216 WCC

Class IV Class IV Class IV Class IV Class IV

Table 9: List of Manual Valves

Item

Tag

Description

Working fluid Syngas Syngas Water

Line Size 1/2" 1/2" 1/4"

Ball Valve Ball Valve Ball Valve

Operating Temp degC 200 200 77

Operating Pressure -2 mmwc -2 mmwc 3 bar

Type

A 105 A 105 A 105

Ball/Globe/ Gate/ Butterfly MOC SS 304 SS 304 SS 304

Seat MOC PTFE PTFE PTFE

Leakage Class Class IV Class IV Class IV

End connection BSP BSP BSP

2 Piece Design 2 Piece Design 2 Piece Design

3 bar 3 bar

A 105 A 105

SS 304 SS 304

PTFE PTFE

Class IV Class IV

BSP BSP

2 Piece Design 2 Piece Design

Body MOC

Remarks

1 2 3

MV-307A MV-307B MV-300A

Isolation Valve for PT-307A Isolation Valve for PT-307B Upstream Isolation Valve for FCV-300

4 5

MV-300B MV-300C

Downstream Isolation for FCV-300 Bypass Isolation for FCV-300

Water Water

1/4" 1/4"

Ball Valve Globe Valve

77 30

MV-300D

Water Isolation Valve

Water

1/4"

Ball Valve

3 bar

A 105

SS 304

PTFE

Class IV

BSP

2 Piece Design

7 8

MV-330D MV-330

Isolation Valve for PG-330 Process Air Isolation Valve

Air Air

3" 3"

Ball Valve Butterfly Valve

30 30

250 mmWC 250 mmWC

A 105 ASTM A182

SS 304 SS 304

PTFE PTFE

Class IV Class IV

BSP Wafer type

2 Piece Design -

NRV-330

NRV for Process air line

10 11

NRV-360 MV-330A

NRV for Oxygen line Upstream Isolation Valve FCV-330

Air

Non return valve

250 mmWC

A 105

SS 304

PTFE

Class IV

Sandwich type

Oxygen Air

1/2" 3"

Non return valve Butterfly Valve

30 30

6 bar 250 mmWC

A 105 A 105

SS 304 SS 304

PTFE PTFE

Class IV Class IV

Sandwich type Wafer type

12 13

MV-330B MV-330C

Downstream Isolation Valve for FCV-330 Bypass Isolation for FCV-330

Air Air

3" 3"

Butterfly Valve Butterfly Valve

30 30

250 mmWC 250 mmWC

A 105 A 105

SS 304 SS 304

PTFE PTFE

Class IV Class IV

Wafer type Wafer type

MV-360

15 16

MV-360A MV-360B

Oxygen Isolation Valve

Oxygen

1/2"

Ball Valve

6 bar

ASTM A182

SS 304

PTFE

Class IV

BSP

2 Piece Design

Up stream Isolation for FCV-360 Downstream Isolation for FCV-360

Oxygen Oxygen

1/2" 1/2"

Ball Valve Ball Valve

30 30

6 bar 6 bar

ASTM A182 ASTM A182

SS 304 SS 304

PTFE PTFE

Class IV Class IV

BSP BSP

2 Piece Design 2 Piece Design

17 18 19

MV-360C

Bypass Isolation for FCV-360

Oxygen

1/2"

Globe Valve

6 bar

ASTM A182

SS 304

PTFE

Class IV

BSP

3 Piece Design

MV-360D MV-382

PG-360 Isolation valve Isolation Valve for PG-382

Oxygen LPG

1/2" 1/2"

Ball Valve

6 bar

ASTM A182

SS 304

PTFE

Class IV

BSP

2 Piece Design

20 21 22 23 24 25 26 27 28 29 30 31 32 33

MV-383 MV-381 PCV-382 NRV-300 FV-700 MV-700A MV-700 MV-700B MV-705A1 MV-705A2 MV-705A NRV-705A MV-706A MV-706C

Isolation Valve for PG-383 LPG Isolation Valve PressureRegulator for LPG to Gasifier RX-300 NRV for Process water line Float valve for TK-700 Isolation valve for TK-700 from Site water Isolation valve from TK-700 Drain for TK-700 P-705A Suction Valve Discharge Isolation Valve for outlet of P-705A Isolation Valve for PG-705A NRV for P-705A Process water header isolation PSL-705 isolation

LPG LPG LPG Water Water Water Water Water Water Water Water Water Water Water

1/2" 1/2" 1/2" 1/4" 2" 2" 1" 1/2" 1" 3/4" 1/2" 3/4" 1/4" 1/2"

Class Class Class Class Class Class Class Class Class Class Class

BSP BSP BSP BSP BSP BSP BSP BSP BSP BSP BSP

PCV-700

Pressure Control Valve for TK-700

Water

1/2"

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

MV-500A MV-580 MV-581 MV-582 MV-500B MV-570 MV-570A MV-570 B MV-570 C NRV-530 MV-530 MV-530A MV-530B MV-530C MV-530D ST-530 MV-532A MV-532B MV-532C MV-695A

Blow down valve for B-500 Isolation Valve from LPG Isolation Valve for PG-511 Isolation Valve for PG-512 Residue discharge isolation valve for B-500 Combustion Air Isolation Valve PG-570 Isolation Valve Isolation valve for Combustion air in CC-570 Isolation valve for Combustion air in CC-570 NRV for SD-530 Isolation Valve for PT-530 & PG-530 Upstream Isolation Valve for FCV-530 Down stream Isolation Valve for FCV-530 Bypass Isolation Valve for FCV-530 Steam outlet of SD-530 Steam trap for SD-530 Isolation Valve for LSH-530 Isolation Valve for LSL-530 Isolation Valve for LSLL-530 Isolation Valve Syngas to TK-695

Water LPG LPG LPG Ash Air Air Air Air Water Steam Steam Steam Steam Steam Steam Steam Steam Steam Water

3/4" 1/2" 1/2" 1/2" 1" 6" 1/2" 4" 1/2" 1" 1/2" 2" 2" 2" 2" 1/2" 1/2" 1/2" 1/2" 1/2"

Burner - Manufacturers's Recommendation

Non return valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Non return valve Ball Valve Ball Valve Back Pressure Regulating Valve Globe Valve

30 30 30 30 30 30 30 30 30 30 30

6 3 3 3 3 6 6 6 6 6 6

bar bar bar bar bar bar bar bar bar bar bar

A A A A A A A A A A A

105 105 105 105 105 105 105 105 105 105 105

304 304 304 304 304 304 304 SS 304 SS 304

PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE

SS SS SS SS SS SS SS

IV IV IV IV IV IV IV IV IV IV IV

Piece Design Piece Design Piece Design Piece Design Piece Design Piece Design Piece Design 2 Piece Design 2 Piece Design 2 2 2 2 2 2 2

BSP

100

5 bar

Boiler Grade

Class IV

BSP

Lug type Wafer type BSP Wafer type BSP Sandwich type BSP ANSI flange ANSI flange ANSI flange ANSI flange BSP BSP BSP BSP BSP

2 Piece Design 2 Piece Design 2 Piece Design 2 Piece Design

Burner - Manufacturers's Recommendation Ball Valve Butterfly Valve Ball Valve Butterfly Valve Ball Valve Non return valve Globe Valve Globe Valve Globe Valve Globe Valve Globe Valve Threaded Globe Valve Globe Valve Globe Valve Ball Valve

150 30 30 30 30 30 200 200 200 200 200 300 200 200 200 1000

-10 mmWC 500 mmWC 500 mmWC 500 mmWC 500 mmWC 6 bar 5 bar 5 bar 5 bar 5 bar 5 bar 5 bar 5 bar 5 bar 5 bar -2 mmwc

A 105 A 105 A 105 A 105 A 105 A 105 A 105 A 105 A 105 A 105 A 105 AISI 420 A 105 A 105 A 105 A 105

SS304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304 SS 304

PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE

Class Class Class Class Class Class Class Class Class Class Class Class Class Class Class Class

IV IV IV IV IV VI VI VI VI VI VI VI VI VI VI VI

Table 9: List of Manual Valves

Item

Tag

Description Isolation valve for Process water to TK-695 Isolation valve for Drain to TK-695 Pressure Regulator for LPG to BRN-580

Working fluid Water Water LPG

Line Size 1/4" 1/2" 1/2"

Ball Valve Ball Valve Regulator

Operating Temp degC 30 30 30

Operating Pressure 6 bar 1 bar 2 bar

2" 2"

Safety Valve Safety Valve

150 150

4.7 bar 4.9 bar

Type

Body MOC

Seat MOC PTFE PTFE -

Leakage Class Class VI Class VI -

End connection BSP BSP BSP

2 Piece Design 2 Piece Design -

ANSI flange ANSI flange

Remarks

55 56 57

MV-695B MV-695C PCV-580

58 59

PSV-530A Pressure Safety Valve for Stream Drum PSV-530B Pressure Safety Valve for Stream Drum

Steam Steam

MV-705B1 P-705B Suction Isolation Valve

Water

Ball Valve

6 bar

A 105

SS 304

PTFE

Class IV

BSP

2 Piece Design

61 62

MV-705B2 Discharge Isolation Valve for outlet of P-705B NRV-705B NRV for P-705B

Water Water

3/4" 3/4"

Ball Valve Non return valve

30 30

6 bar 6 bar

A 105 A 105

SS 304 -

PTFE PTFE

Class IV Class IV

BSP BSP

2 Piece Design -

MV-705B

Isolation Valve for PG-705B

Water

1/2"

Ball Valve

6 bar

A 105

SS 304

PTFE

Class IV

BSP

2 Piece Design

64 65

MV-706B MV-510

Process water isolation for RX-300 Boiler feed water isolation

Water Water

1/4" 1"

Ball Valve Ball Valve

30 30

6 bar 1 bar

A 105 A 105

SS 304 SS 304

PTFE PTFE

Class IV Class IV

BSP BSP

2 Piece Design 2 Piece Design

66 67

MV-510A FV-510

Process water isolation for TK-510 Float valve for TK-510

Water Water

1" 1"

Ball Valve Float Valve

30 30

1 bar 1 bar

A 105 A 105

SS 304 -

PTFE -

Class IV Class IV

BSP -

2 Piece Design -

MV-510B

Drain for TK-510

Water

Ball Valve

1 bar

A 105

SS 304

PTFE

Class IV

BSP

2 Piece Design

69 70

MV-521A P-520A Suction Valve NRV-520A NRV for P-520A

Water Water

3/4" 3/4"

Ball Valve Non return valve

30 30

6 bar 6 bar

A 105 A 105

SS 304 -

PTFE -

Class IV Class IV

BSP BSP

2 Piece Design -

MV-520A

Water

1/2"

Ball Valve

6 bar

A 105

SS 304

PTFE

Class IV

BSP

2 Piece Design

72 73

MV-521C P-520B Suction Valve NRV-520B NRV for P-520B

Water Water

1" 3/4"

Ball Valve Non return valve

30 30

1 bar 6 bar

A 105 A 105

SS 304 -

PTFE -

Class IV Class IV

BSP BSP

2 Piece Design -

74 75 76 77 78 79 80 81 82 83 84 85 86 87 88

MV-521D MV-520B MV-522B MV-660B MV-600A MV-600B MV-620C MV-661A MV-900A MV-900B MV-900C MV-901A MV-901B MV-901C MV-901D

Water Water Water Air Fluegas Fluegas Ash Fluegas Air Air Air Air Air Air Air

3/4" 1/2" 3/4" 1/2" 1/2" 1/2" 6" 1/2" 1" 1/2" 1/2" 1" 1" 1" 1"

Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve Ball Valve

30 30 30 30 200 200 150 200 30 30 30 30 30 30 30

6 bar 6 bar 6 bar 7 bar -750 mmWC -750 mmWC -750 mmWC 100 mmWC 7 bar 7 bar 7 bar 7 bar 7 bar 7 bar 7 bar

A A A A A A A A A A A A A A A

SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS

PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE PTFE

Class Class Class Class Class Class Class Class Class Class Class Class Class Class Class

BSP BSP BSP BSP BSP BSP BSP BSP BSP BSP BSP BSP BSP BSP BSP

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Isolation Valve for PG-520A

Discharge Isolation Valve for outlet of P-520B Isolation Valve for PG-520B Boiler Water Isolation for HRGS Isolation valve for PG-600 Upstream Isolation Valve for PDIT-600 Downstream Isolation Valve for PDIT-600 Residue discharge isolation valve for CF-620 Isolation valve for PT-660 Isolation valve for C-900 discharge Isolation Valve for PT-900 Isolation Valve for PG-900 Service Air Header Isolation Gasifier Instrument Air Header Isolation HRSG Instrument Air Header Isolation Gas Cleanup Instrument Air Header Isolation

A 105 A 105 -

Ball/Globe/ Gate/ Butterfly MOC SS 304 SS 304 Boiler Grade

105 105 105 105 105 105 105 105 105 105 105 105 105 105 105

304 304 304 304 304 304 304 304 304 304 304 304 304 304 304

IV IV IV IV IV IV IV IV IV IV IV IV IV IV IV

Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece Piece

Design Design Design Design Design Design Design Design Design Design Design Design Design Design Design

Table 10: Electrical Cable Requirement and Specifications

Two categories of cables shall be included in the scope of supply. Power cables for motors and signal cables for field instruments and valves. • • • • • • • •

All cables supplied shall be as per Indian Standards or equivalent All cable shall be of reputed make with CE or equivalent marking on it All cable shall be suitable for outdoor use All power cable shall be suitable for operating at 415V/3Ph/50Hz power supply All signal cables shall be suitable for 24VDC supply All cables for analog signals shall be shielded cables Insulations to follow Indian Standards All cable shall have the voltage ratings marked on the outer sheath

Reference: 1. Table 11: Motor Control Centre Specifications 2. Table 12: List of Motors 3. Table 7: List of Instruments Table 11: Motor Control Center (MCC) Specification

The design specification for the motor control center specification is as follows: Section

Objective

Scope

This section includes requirements for a Motor Control Center (MCC) and all required control devices and to be part of the MCC equipment.

Standards

Equipment shall be manufactured, designed and tested to the following standards: • Applicable Indian Standards • All components shall be CE marked • Enclosed Switchgear shall be rated for Internal Arcing Faults • MCCs shall be provided with documentation and labeling indicating equipment is rated for these applications

General Specification

• • • • • •

All the devices shall be sized for altitude of 100m Power: 415VAC, 50Hz, 3Ph+1N+GND Control Voltage 24VDC Cable entry: Rear Bottom Disconnect switches sized to system load. A lever handle operator must be provided A mechanical interlock shall prevent the operator from opening the unit door when the disconnect is in the ON position Page 26 of 32

Appendix 1 - 2TPD 190821

Section

Objective • • • •

Another mechanical interlock shall prevent the operator from placing the disconnect in the ON position while the unit door is open Pilot devices shall be rated IS Type Power status indicator lights shall be mounted on the enclosure door 230V outlet and RJ45 Ethernet connector mounted on the enclosure door

Motor Control Equipment

Electrical Ratings: • Variable Frequency AC drive controller unit shall be designed to operate from an input voltage of 415VAC ±10% • The AC drive controller unit shall operate from an input voltage frequency range of 50 ± 10% Hz • Protection: Motors and drives shall be protected by MPCBs (motor protection circuit board) • Control: • Pilot devices shall be industrial rated [22mm] [30mm] type control operators and used independently of the keypad display • Drives shall include network communication interface for data acquisition over Modbus TCP/IP • Each motor control shall be mounted on the enclosure door and include the following: o Local/Remote selector switch o Combo Start/Stop illuminated pushbutton o Motor Trip indicator (amber) o VFD’s keypad mounted on the panel

Control System

PLC: • Modular design with metal rack enclosure, power supply, controller CPU and user selectable I/O module • All I/O points shall be protected by fuses with burned fuse indicator • Interface relays • Separate Ethernet switches for remote I/O and remote access • Ethernet router with external antenna mounted on the enclosure with external range of 100m

DC Power Supply and Battery Backup

• • •

Individual power supplies for control signal, Digital I/O and Analog I/O Power supplies status indicator (blue) mounted on the door All control systems must have powered through the UPS system with external battery

Power Monitoring

•

Power Monitor with display mounted on the enclosure door

Page 27 of 32 Appendix 1 - 2TPD 190821

Section Enclosure and Terminals

Objective • •

• • • • •

•

Cabling

• •

• • •

Spare

The overall height of the MCC shall not exceed 2.1 meters Structures shall be totally enclosed, dead-front, free-standing assemblies Structure shall be capable of being bolted together to form a single assembly IP52 type enclosure Panel suitable to install inside a building The main horizontal bus shall be sized to system load extend the full length of the MCC Bus ratings shall be based on 65° C maximum temperature rise in a 40° C ambient Terminal blocks shall be the pull-apart type with a minimum rating of 250VAC for control and 600V for power. All current carrying parts shall be tin plated Terminals shall be accessible from inside the unit when the unit door is opened. Terminal blocks shall be DIN rail mounted with the stationary portion of the block secured to the unit bottom plate. All the low voltage cables shall be a minimum rating of 300VAC for control and 600V for power The Ethernet (Modbus TCP) communications network shall be configured in a star topology and connected to a central Ethernet switch unit located in the MCC The industrial Ethernet cable shall be 600V CE Category 6e Cable entry shall be provided from the top of the cabinet Cord grips shall be provided from the bottom of the cabinet for external cabling

Additional 10% space required for future modification if needed on: • Bus Bar • Din Rail • Sub Panel

Page 28 of 32 Appendix 1 - 2TPD 190821

Table 12: List of Motors Rated Power, HP

Rated Voltage, V

Rated Frequency, Hz

Rated Current, A

Control Method

10.00

415

12.99

Contactor

2.00

415

2.60

VFD

2.00

415

2.60

VFD

3.00

415

3.90

VFD

1.50

415

1.95

Contactor

1.50

415

1.95

VFD

Motor for Boiler Feed Water Pump

1.50

415

1.95

P-520B

Motor for Boiler Feed Water Pump

1.50

415

1.95

M-585

BL-585

Motor for Burner for CC-570

1.50

415

1.95

Contactor

M-590

BL-590

Motor for Combustion Chamber blower

4.00

415

5.20

Contactor

M-560

RV-560

Rotary Valve for SC550

0.25

415

0.32

Contactor

M-900

C-900

Motor for Air compressor

10.00

415

12.99

Contactor

M-705A

P-705A

Motor for Process Water Pump A

1.00

415

2.60

Contactor

M-705B

P-705B

Motor for Process Water Pump B

1.00

415

2.60

M-660

BL-660

Motor for ID Blower

15.00

415

19.48

VFD

M-550

SC-550

Motor for Vibro Feeder

0.25

415

0.32

VFD

Item

Tag

Equip. Tag No

M-010

SH-010

M-020

BC-020

M-070

SC-070

M-300

RX-300

M-320

BL-320

M-330

BL-330

M-520A

P-520A

M-520B

Description Motor for Shredder Motor for Waste transfer Conveyor Motor for Gasifier Screw feeder Motor for Gasifier Motor for Startup burner Blower Motor for Process Air Blower

Contactor Contactor

Contactor

Page 29 of 32 Appendix 1 - 2TPD 190821

Table 13: Control System Specifications

The control system for the 2 TPD Rotary Kiln Gasification System for High CV Syngas Production comprises of a control station within the facility, a bunch of field instruments, a programmable logic controller (PLC), interface between field instruments and PLC, a human machine interface (HMI) for communicating with the PLC and a set of hardware required for the network. This document provides basic specifications of the control system requirements for the project. The bidder shall provide basic programming of the PLC system during the installation of the pilot plant. This programming will include interlocks, control algorithms and any safety functions. Any costs associated with this shall be included in the cost of the control system. The details of this will be provided after the contract is awarded. Programmable Logic Controller (PLC) Specifications – PLC Model

Honeywell or equivalent

No of Analog Inputs

No of Analog Outputs

No of Digital Inputs

No of Digital Outputs

Communication Protocols

Modbus TCP/IP, Ethernet TCP/IP

Redundancy

Not required

Scan Time

<100 mS

Input/output Modules

To suit the selected controller

Power Supply Module

To suit the selected controller

IO Racks

To suit the selected controller

Human Machine Interface HMI Display Size

Min 15” Touch Screen

Processing Monitoring

Graphic Pages

Individual Tag Control

Faceplates

Data Input

Numeric/Slide Bar

Data Trends

Needed (1s/5s/1min/5min data point) Min 8 pens per trend set

History Data Capture

Needed Standard -1 min data points Other – 5 min/20 min Daily reports Event logging Alarms

Communication with PLC

Ethernet TCP/IP Page 30 of 32

Appendix 1 - 2TPD 190821

Table 14: Specifications of Pipes and Fittings Pipes and fittings required for the 2 TPD Rotary Kiln Gasification system is as follows: Description

Line Size, NB

Process Water line

Oxygen Line

Process Air Line

Start Up Burner Line

LPG line

Steam Line

Syngas Sample line

Process Water for Boiler

Combustion Air line for burner for combustion chamber LPG line for Combustion Chamber Combustion air line for syngas combustion

Material of Construction ASTM A 53 ERW Gr B or Equivalent ASTM A312 TP304 or Equivalent ASTM A106 ERW or Equivalent ASTM A106 ERW or Equivalent ASTM A106 Seamless or Equivalent ASTM A106 Seamless or Equivalent ASTM A312 TP304 or Equivalent ASTM A53 ERW Gr B or Equivalent

Type

Medium

Length, m

Quantity, Nos

Schedule 40

Water

Schedule 40

Oxygen

Schedule 10

Air

Schedule 10

Air

Schedule 40

LPG

Schedule 40

Steam

Schedule 40

Syngas

Schedule 40

RO Water

200

ASTM A106 ERW or Equivalent

Schedule 10

Air

ASTM A53 ERW Gr B or Equivalent

Schedule 40

LPG

150

ASTM A106 ERW or Equivalent

Schedule 10

Air

As per drawing

Syngas

Schedule 10

Flue Gas

Schedule 40

Compressed Air

ANSI 150

Syngas ducting

750

Flue gas ducting

200

Compressed air line

Flanges

ASTM A53 ERW Gr B or Equivalent ASTM A53 ERW Gr B or Equivalent ASTM A106 ERW or Equivalent ASTM A 105N or Equivalent ASTM A 105N or Equivalent

Page 31 of 32 Appendix 1 - 2TPD 190821

Description

Line Size, NB

Flanges

200

Flanges

750

Couplings

Bend

200

Bend

Material of Construction ASTM A182 F304 or Equivalent ASTM A 105N or Equivalent ASTM A 105N or Equivalent ASTM A182 F304 or Equivalent ASTM A 105N or Equivalent ASTM A181 or Equivalent ASTM A 234 Gr B or Equivalent ASTM A234 Gr B/ASTM A105 or Equivalent ASTM A234 Gr B or Equivalent ASTM A234 Gr B or Equivalent ASTM A403 WP304 or Equivalent ASTM A234 Gr B or Equivalent ASTM A234 Gr B or Equivalent ASTM A234 Gr B or Equivalent ASTM A 234 Gr B or Equivalent ASTM A234 Gr B or Equivalent

Type ANSI 150 ANSI 150 ANSI 150

Medium

Length, m

Steam Line

BSP, Class 3000

Schedule 40

Steam Line

Short Bend, Schedule 40

ANSI 150 ANSI 150 As per drawing BSP, Class 3000

Schedule 40 Schedule 40 Schedule 40 Schedule 40 Schedule 40 Schedule 40

Quantity, Nos 6 6 6 8 12 4 20 20 6 10 6

10 4 2 10 10

Page 32 of 32 Appendix 1 - 2TPD 190821

Pilot Plant Quotation

Articles inside

VERIFICATION OF INFORMATION.....................................................................................8

COST OF BIDDING..............................................................................................................8

SCHEDULE OF BIDDING PROCESS..................................................................................6

CHANGE IN OWNERSHIP...................................................................................................8

VERIFICATION AND DISQUALIFICATION..........................................................................8

ABOUT KITS........................................................................................................................3

GENERAL TERMS OF BIDDING .........................................................................................7