TRANSPARENT ENERGY SYSTEMS PVT.LTD.
1st Floor, Pushpa Heights, Bibwewadi Corner, PUNE 411 037.
Ph.No.+91 (020)-24211347 /24215665 / 24212390, Fax No.: 24212533
Email:- trans@pn2.vsnl.net.in ; projectsales@tespl.com
ENQUIRY FORM
FOR
WASTE HEAT RECOVERY FOR ALUMINIUM INDUSTRY
1.0
Contact Information:
1.1
Customer Name
: ______________________________________________
1.2
Address
: ______________________________________________
: ______________________________________________
1.3
Telephone No.
: _________________ Fax No.: _____________________
1.4
E-mail address
: ________________________________
1.5
Cell phone No.
: ________________________________
2.0
Aluminum Plant Data (Source of available Waste Heat)
Sr.
No.
2.1
1
2
3
Unit
Alumina Reduction Cell Production
Capacity
Exhaust Gas Quantity at Alumina
Reduction Cell outlet
Exhaust Gas Temperature at Alumina
Reduction Cell outlet
Permissible pressure drop across
Waste Heat Recovery Boiler Systems
on exhaust gas side
4
Dust load
2.2
Secondary Aluminum Production
Furnace Capacity
Exhaust Gas Quantity at Furnace
outlet
1
2
3
4
2.3
Exhaust Gas Temperature at Furnace
outlet
Permissible pressure drop across
Waste Heat Recovery Boiler Systems
on exhaust gas side
Cell 1
Cell 2
Cell 3
Cell 4
F–1
F–2
F–3
F–4
Ton/day
Kg/hr.
Nm3/hr
Deg. C
mm WC
Gms
/Nm3
Ton/day
Kg/hr.
Nm3/hr
Deg. C
mm WC
gms/Nm
3
Dust load
Anode Baking Furnaces:
Number of Furnaces
Number of Burning groups
Number of Suction Groups
Number of Burner Bridges
:
:
:
:
:
Page 1 of 6
Number of Cooling Blowers :
Heating and cooling Cycle time:
Temperature and flow profile of exhausted cooling air:
Flue Gas temperature and flow from burners:
Sr.
No.
2.4
1
2
3
4
Unit
F–1
Aluminum Casting Furnace
Production Capacity
Ton/day
Exhaust Gas Quantity at Aluminum
Casting Furnace outlet
Exhaust Gas Temperature at
Aluminum Casting Furnace outlet
Permissible pressure drop across
Waste Heat Recovery Boiler Systems
on exhaust gas side
Dust load
Kg/hr.
Nm3/hr
Deg. C
F–2
F–3
F–4
mm WC
gms/Nm
3
2.5 Exhaust Gas composition of Primary Aluminum production Furnace/Secondary
Furnace/Anode baking Furnace/ Aluminum Casting Furnace (% by volume):
Content
Kiln
Furnace
CO2
O2
H2O
N2
2.6 Kindly provide the Process Flow Diagrams of the process.
2.7 In case recovered waste heat to be converted into steam for supply to Process please
provide following data:
Sr. No.
Description
2.7.1
Steam quantity required for Process
2.7.2
Steam pressure required
2.7.3
Steam temperature
2.7.4
Existing Steam Boiler Capacity
2.7.5
2.7.6
2.7.7
Fuel used in existing steam Boiler
( HSD / LDO / FO / NG / Any other )
Fuel consumption in existing steam
boiler (Kg for liquid fuel / SM3 for gas
fuel )
Fuel cost
Units
Details
Kg / Hr
Kg/cm2(g)
o
C
TPH
Kg/hr
Kg / Hr
SM3 / Hr
Amount /
Kg
Amount/
SM3
Page 2 of 6
3.0
Choice of condensing system for power generation Water Cooled / Air Cooled
(Depending upon availability and cost of raw water)
4.0 Raw Water
:
4.1 Source of Raw water
4.2 Raw water cost
4.3 Raw water analysis:
: Bore Well / River / Lake / Dam on River
: _____________ per m3 (1000 lit)
Total Solids
Magnesium Hardness as
CaCO3
Suspended Solids
Total Hardness as CaCO3
Volatile Solids
Dissolved Iron as Fe
PH
Acidity / Alkalinity as
CaCO3
Sulphates as SO
Manganese as Mn
Chlorides as Chlorine
Calcium Hardness as
CaCO3
Nitrate Nitrogen
Silica As SiO2
Lime as CaO
Magnesium as
MgO
Colour
Turbidity
Smell
Electrical
Conductivity
5.0 Existing Power Generation data :
5.1 Total Power requirement
a) Peak
b)
Average
__________________________MW.
__________________________MW.
5.2 Present Source of Power
Grid / Captive / Both
5.3 Grid Power Consumption
a) Peak
_________________________MW.
b) Average
5.4 Source of Captive power
_________________________MW.
Rankine Cycle / Combined Cycle / Otto Cycle / Diesel Cycle
(Steam Turbine / Gas Turbine / D.G.Set)
1) Rankine Cycle Power Plants:
i.
ii.
Installed Capacity
Actual generation
__ ______________________MW
a) Peak
_________________________MW
b) Average
_________________________MW
iii.
Fuel used
iv.
Calorific Value
LCV
HCV
_________________________Kcal/kg
_________________________Kcal/kg
Fuel Analysis
__________________________
v.
_________________________
Page 3 of 6
vi.
vii.
Steam Boilers
Sr.
No.
Details
a)
Capacity
b)
Type
c)
Make
d)
Steam Pressure
e)
Temperature
plant1
Plant2
Plant3
Plant 1
Plant 2
Plant 3
Plant 1
Plant 2
Plant 3
Steam Turbine
Sr.
No.
a)
b)
c)
d)
e)
Details
Capacity
Type
Make
Inlet Steam

Flow

Pressure

Temperature
Condenser Pressure
viii.
Condenser Type
Water Cooled / Air cooled
ix.
Please furnish Heat Mass Balance Diagram ( HMBD)
2) D. G. Set / Gas Turbine based Captive Power.
i.
No. of D G Sets / Gas Turbines
Captive _______
Standby _________
ii.
No. of Hours D G Set runs continuously
iii.
Capacity (Rated)
__________________ Kva/Kw.
iv.
Normal Usage
__________________ Kva/Kw.
v.
Fuel
_________________Hrs/Month
HSD/LDO/FO/Any other (Pl.Specify)
Page 4 of 6
(Fill up the following table only if D.G. set is running continuously)
Operating Parameters
Unit
Output As % Of Rated Capacity
100%
80%
60%
50%
Kg/hr.
Exhaust Gas Quantity
Nm3/hr
Exhaust Gas Temp
Fuel Consumption
Permissible Back Pressure On
Flue Gas At Outlet Manifold Engine
Generator
Cooling Water Flow Rate
(High Temp. Circuit).
Cooling Water Outlet Temp
(High Temp.Circuit)
Cooling Water Return Temp
(High Temp.Circuit)
Deg. C
Kg/hr.
mm WC
Cu.Mtr/Hr.
Deg.C.
Deg.C.
5.5 Cost of Power
1) Cost of Grid Power
a) Fixed
_________________
b) Variable
_________________
2) Cost of Captive Power
a) Fixed
_________________
b) Variable
6.0 Ambient Temperature:
_________________
Month
Dry Bulb
Max.
Wet Bulb
Min.
Max.
Min.
January
February
March
April
May
June
July
August
September
October
November
December
Page 5 of 6
Special requirements/remarks:
__________________________________________________________________________________
__________________________________________________________________________________
Enquiry Form filled by:
Name
Designation
Date
: _________________________________
: _________________________________
: _________________________________
Page 6 of 6