Our Technology
GKNS Energy Private Limited going to employ the best proven technology in energy recovery from
waste with the installed capacity of 8.5MW.
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Brief Technology Description
The reverse acting reciprocating grate technology used for the proposed project activity
is a state of an art technology and is being implemented for the for an Integrated Waste
Management Project. Implementation of the proposed project activity would help in promotion
and replication of similar technology in other areas of the country. The two-segment
reciprocating stroke system, which considers the characteristics of municipal solid waste
such as lower heat value and higher water content, owns advantages of being applied to a
broad heat value, having a good load adjusting capacity and operation performance and
highly automatic. These technologies can efficiently combust RDF fluff without the support
of any other fossil fuel and also lead to sustained combustion.
Preparation of Waste Input Material:
All “hard” materials such as stones, glass, metals, ceramics and the like, have to be removed.
The incoming waste which arrives at the plant with moisture of 60-65% has to be dried to residual
moisture of less than 17%.
The waste is dumped into the receiving area and then picked up by a
Payloader equipped with a crusher shovel. A coarse grinding mechanism
built into the shovel opens plastic bags and reduces the particles to <50 mm.
Oversize parts such as bicycle frames, refrigerators, etc. remain in the shovel and
can be simply tilted out.
The pre-shredded material passes a magnetic separator as well as an Eddy-current
separator and is subsequently sent through our proprietary autoclave system where it is broken down to fluff.
Conversion of MSW to RDF fluff
Receipt of MSW:
GKNS Energy Will collect daily 600 TPD from GMCH Dumping Sites to plant having a distance of
40 KM with the help of Tipper trucks or lorries that will bring the MSW will be weighed on
the weighbridge station at the plant before they are unloaded in the MSW Receiving
Yard of the plant. MSW from the MSW Receiving Yard will be lifted by Grab Crane and
put on the Inclined Feeding Belt Conveyor. The MSW feeding by Grab crane is also
expected to homogenize the MSW prior to feeding and will be considered as an
alternative. Herbal disinfectant-cum-deodorant will be sprayed on the MSW to reduce mal-odor
and repel insects and birds
Steam Generating System
The steam generating system for the power plant will consist of Two (2) No. Reverse
acting and reciprocating type grate fired boiler of capacity 28 TPH with outlet steam
parameters of 40 ata, 400 Deg.C. The boiler shall be semi-outdoor unit and shall be of
single drum, natural circulation, balanced draft, and membrane wall radiant furnace design
with two-(2) stage super heaters and inter stage de-super heater. The main and design fuel will be MSW to RDF
Homogenization:
Inclined Feeding Belt Conveyor will feed MSW into a Rotary Screen-I to de-lump and to remove dust,
sand, earth and other inert materials of less than 40 mm particle size. Dust, sand, earth and other
inert materials separated in this process will be extracted and transferred to a Composting
Yard through a Compost Transfer Belt Conveyor. Rotary Screen-I will deliver MSW on a Horizontal Sorting
Conveyor Belt to separate big objects by manual activity, which may spoil the downstream equipment,
like machinery parts, lead acid batteries, big stones, tyres, etc. The big objects that are separated
will be picked up and dropped through gravity – chutes on the ground for on-ward disposal.
Large sized inert and noncombustible objects like boulders, construction debris, large trees
cuttings, etc. will be lifted manually and disposed to designated landfill sites. The Horizontal
Sorting Conveyor will deliver MSW to Rotary Screen-II. Rotary Screen-II will separate MSW into two fraction:
Fraction#1 RDF fluff – < 100 mm,
Fraction#2 RDF fluff – >= 100 mm
Fraction # 2 RDF fluff will fall on the Belt Conveyor and will be delivered to the Fuel Storage Pit
For feeding into the boiler.
Solar Drying:
MSW in the country has been generally found to have high moisture content even during nonrainy
days and requires drying to produce fuel with reasonable heating value. Fraction#1 RDF fluff
will be transferred by Extraction and Transfer Belt conveyor to the Intermediate Storage
Yard and will be dried in the Solar Drying Yard.
Magnetic Separation:
Fraction#1 RDF fluff will be transferred from Solar Drying Yard to Magnetic Separation Unit
for removal of ferrous components from the garbage for recycling. RDF fluff from Magnetic
Separation Unit will fall on the Belt Conveyor and will go to Fuel Storage Pit for feeding into boiler.
Flue-gas cleaning system:
- The flue-gas enters the flue-gas cleaning system downstream of the HRSG. The plant is equipped
with a dry flue-gas cleaning system consisting of a bag-house filter, a storage silo for lime and
activated carbon and a filter dust silo.
- Lime and activated carbon is injected at the inlet of the bag house filter.
- The lime absorbs acid components in the flue-gas, while activated carbon adsorbs dioxin,
TOC and heavy metals.
Power Generation:
The power generation plant will support combustion of RDF fluff. It will include
receiving and feeding system, refuse incineration, waste heat utilization, flue gas treatment,
automatic control system, electrical equipment, ash disposal system, water supply and drainage
system and compressed air system. The power project will install two boilers and one extraction
cum condensing turbo generator for power generation. The project will optimize power generation
with one stage of feed water heating. Extraction of steam and its usage in the Deaerator for
feed water heating will improve the efficiency of the plant.
RDF fluff will be combusted in the boiler on reverse acting reciprocating grate to generate steam.
Following are the boiler specification of boilers to be used:
Steam Generation 56 TPH
Pressure 40 ata
Temperature 400oC + 5oC
Steam generated in boilers will be fed to the single extraction condensing turbo generator.
The uncontrolled extraction from the turbine at 5.4 ata will give approximately 6.87 TPH of steam
at a temperature of 180°C. This steam will be entirely used for heating up the feed water in the thermal
deaerator. In addition to this steam, the flash steam recovered from the boiler blow down tank can be
used in the deaerator. The flash steam from the continuous blow down tank, equivalent to 0.237
TPH will be led into the deaerator for supplementing the steam supplied from the turbine
extraction for deaeration. Balance of steam will be supplied to the turbine, a quantity
of 52.6 TPH of steam, being the difference between input and extracted steam quantities
will be exhausted to the surface condenser of the power turbine. Condensate from the
condensate tank of surface condenser will be pumped to the feed water system by the
condensate extraction pumps. In addition to the above quantity, the condensate from
the gland steam condenser and the ejector condensers amounting to a total approximate
quantity of 0.476 TPH will be added to the feed water system through the condensate
tank The power project, after meeting its in house consumption, will export to Grid
Control and monitoring system.
- The plant is equipped with a separate proprietary control-and-monitoring-system.
- The system performs automatic control of the process during normal operating conditions and
gives the opportunity to monitor the different process sections through the man-machine interface.
All information is available for the operator via a screen.
- The system is designed for remote control and monitoring of the plant. Safety and
security is paramount in all aspects of the design.
- Logging of process parameters, including emissions monitoring parameters, is
controlled in a separate data logging system.
- Safety is taken care of in a separate and independent emergency shutdown system.
- The emissions to air such as dust, CO, HCl, Hg, TOC, SO2, NOx, O2, H2O and CO2 are
continuously monitored and displayed.
Utilities:
The GKNS Energy plant is equipped with the following utilities:
- Electrical system
- Emergency power generating unit
- Air supply system
- Re-circulated flue-gas system
- Compressed air system
- Hydraulic system
- Water cooling system
- Oil cooling system
- Leach ate from MSW Receiving Yard and Fuel Storage Pit will be collected in Neutralization
Tank for COD and BOD as per local Norms