GET REPORT

BY:

TAUSIF SHAIK

SAHA-IN

126916
OWNER - RSPL (Rohit surfactants pvt. Ltd.)

CONSULTANT - JACOBS

VENDOR - FLSMIDTH , THERMAX , SCHIEDER ELECTRIC, Etc.,

CONTRACTORS - KGPS, DKI, SAHYOG, JAI SHAKTI, Etc.,

WHAT?

Lets first understand, what the plant is about.

The plant is been designed to manufacture the end product, ghadi detergent washing powder.

It involves the manufacturing of soda ash include lime production and soda production.

How?
Now, lets discuss about the process. The process involved here to manufacture soda ash is solvay
process.

Raw material:

Limestone, ammonia(catalyst), brine.

Solvay process:

CaCO3 CaO + CO2 (gas)

NaCl + CO2 + NH3 + H2O NaHCO3 + NH4Cl

2 NaHCO3 Na2CO3 + H2O + CO2

2 NH4Cl + CaO 2NH3 + CaCl2 + H2O

The above are the basic reactions happening in the process, where calcium chloride is a by-
product.

The first one is a calcination reaction which takes place in kiln.

Plant capacity:

The design capacity of the plant is 500,000 MTPA light soda ash or 1500 MTPD light
soda ash.
The design capacity of the plant is 2,50,000 MPTA dense soda ash or 770 MTPD.
Provision is made for conversion of light soda in dense soda ash manufacturing, for the
process needs (brine purification and etc.) as well as a commercial product.
The light and dense soda are continuously and daily fed to the silos.
Light and dense soda Bagging can be done in one or two shifts.

THE EXPECTED BUDGET OF THE RSPL PROJECT IS 3000 CRORE.

FLSMIDTH SCOPE :

Vertical shaft kilns (6 no.)

Raw material handling systems.
Coal and lignite handling system.
Limestone and coke handling system.
Salt handling system.
Conveyors.
Daybin.
Yard equipments (stackers and reclaimers).
Vertical roller mills.
Hydraulic press.
Brine settlers( 2 no.)
 EXPECTED BUDGET OF FLSMIDTH PROJECT IS 400 CRORE.

Flsmidth policy:

safety is our first priority.

Key safety learnings:

Aim is zero harm.

Safety is to protect ourselves, our health and thereby contributing to the success of the
company.
Reflectory jacket, safety shoe, safety helmet and safety goggles are mandatory things to
be worn by the people working at sites.
With safe practices, we can promote the moral, legal and economical values.
Near misses, unsafe acts and conditions are to be reported.
Fall arrestors and safety harness are to be worn by the people working in heights.
Tool box talk by the safety engineers.
OHSAS 18001 requirements.

PROJECT DETAILS:

Name : 6 x 350 TPD Lime Kiln and Raw Material Handling Package System.
Location : Kuranga Village, Dev Bhumi, Dwarka District, Gujarat.
Scope : Design, Basic Detailed Engineering, Procurement, Manufacturing,
Supply of Material, Inspection, Testing, Painting, Transportation, Erection &
Commissioning of 6 x 350 TPD Lime Kiln & Raw Material Handling Package
System.
PLANT LAYOUT:

VERTICAL SHAFT KILN:

Basic design:

There are three zones in a vertical shaft kiln, one is preheating zone, calcining zone and the other
one is cooling zone.

The temperature maintained respectively are as follows:

Preheating zone : 600o c

Calcination zone : 8000 c

Cooling zone : 400o c

General process:

Charging system:

The limestone of fraction size 60-120 mm and 20-60mm are used as raw materials for
obtaining lime and carbon dioxide gas.
Coke of fraction size 30-60 mm and coke briquettes will be used as fuel for coarse
limestone, and coke of fraction size 10-30 mm will be used as fuel for fine limestone.
Raw materials and fuel mixture is transported by skip hoist to the top of lime kiln.
For uniform burning and widening the scope of limestone and coke fractions big fractions
of limestone and coke mixture are loaded to the center of kiln, and small fractions are
loaded on its perimeter.
Pre silo level control device generates empty signal. Skip hoist fills charging device
hopper by opening upper hopper flap.
When pre silo hopper gets filled the flap valve is closed with hydraulic cylinder.
The kiln is charged by revolving chute with distribution channel and four charging
chutes.

Discharging system:

The lime is discharged by hydraulically driven push rods over tables in the lime bunker
of the kiln.
Level regulator in the lime hopper storage signalizes when hopper storage must be
discharged.
 Lime discharge consists of two vibration tubes with flaps below the storage.
Discharges lime from hopper storage to one of the two lime belt conveyors.

All the bolded words are the equipments supplied and erected by FLSMIDTH.

*Various drawings are worked out to support the erection of kiln.

Welding :

Types of welding
Groove (G)
Fillet (F)

Welding positions

Types of electrodes used:

7018 (Low Hydrogen)

6013
Ovens:

Ovens are used for preheating the low hydrogen electordes. It is done to attain the
specified weld strength and property. There are three types of ovens

Baking oven
Holding oven
Portable oven

Welding process:

PQR - Procedure Qualification Record

WPS Welding Process Specification It specifies the size of the electrode,
current, voltage to be used for the process.
WPQR Welder Performance Qualification Record.