T h e id ea fo r th e p la n t w a s a n n o u n c e d b y P rim e M in is ter In d ira G a n d h i in 1 9 7 0 , w ith c o n s tru c tio n

c o m m en c in g in 1 9 8 2 . T h e p la n t w a s b u ilt w ith a s s is ta n c e fro m th e U S S R a n d G erm a n y, a n d its f irs t

b la s t fu rn a c e b e c a m e o p era tio n a l in 1 9 9 2 . T h e es ta b lis h m en t o f th e p la n t w a s th e re s u lt o f s ig n ific a n t

p u b lic d em a n d a n d a c tivis m , in c lu d in g a n o ta b le h u n g er s trik e b y T . A m ru th a R a o , w h o c o in ed th e

s lo g a n "V is a k h a U k k u — A n d h ru la H a k k u " ("V is a k h a p a tn a m S tee l is th e rig h t o f th e A n d h ra s ") .

V S P s p e c ia lize s in p ro d u c in g lo n g s tee l p ro d u c ts s u c h a s w ire ro d s , re-b a rs , a n g les , c h a n n els ,

b lo o m s , a n d b illets . A s o f th e 2 0 2 1 – 2 2 fin a n c ia l yea r, th e p la n t p ro d u c ed a p p ro x im a tely 5 .8 m illio n

to n n es o f h o t m eta l a n d 5 .3 m illio n to n n e s o f liq u id s te el . T h e p la n t h a s u n d erg o n e e xp a n s io n s to

in c rea s e its c a p a c ity, w ith p la n s to fu rth e r a u g m en t liq u id s tee l p ro d u c tio n fro m 6 .3 to 7 .3 m illio n

to n n es p e r a n n u m .

O c c u p yin g a ro u n d 8 ,8 2 7 h ec ta res , w ith 3 ,2 4 0 h e c ta res d ed ic a ted to th e p la n t its elf, V S P is

s u p p o rte d b y s ev era l c a p tive re s o u rc e s :

1 . Limestone Mine : L o c a te d a t J a g g a yya p e ta in K ris h n a D is tric t.

7
2 . Dolomite Mine : S itu a ted a t M a d h a ra m in K h a m m a m D is tric t.

3 . Manganese Ore Mine : F o u n d at C h e ep u ru p a lli in Viz ia n a g a ra m D is tric t.

4 . Water Supply: T h e K a n ith i B a la n c in g R es e rvo ir, fe d b y a c a n a l fro m th e Y eleru R ive r,

s u p p lie s w a ter to th e p la n t a n d its to w n s h ip .

8
V S P h o ld s a s p e c ia l p la c e in th e h ea rts o f th e lo c a l p o p u la tio n , o f te n re fe rred to a s "V is a k h a U k k u . "

O v er th e yea rs , it h a s f a c ed m u ltip le p riva tiza tio n a tte m p ts , lea d in g to w id es p re a d p ro tes ts a n d

re s is ta n c e f ro m w o rk ers a n d th e c o m m u n ity. In 2 0 2 1 , th e g o v ern m e n t's p ro p o s a l fo r 1 0 0 %

d is in ve s tm en t in R IN L s p a rk ed s ig n ific a n t o p p o s itio n , res u ltin g in th e p la n b e in g p u t o n h o ld .

T h e s p ec ia lty o f a s te el p la n t— lik e th e Vizag Steel Plant— re fers to its u niq u e f ea tu re s , f u n c tio n s ,

a n d s tre ng th s in th e p ro d u c tio n o f s te el. H e re's a c o n c is e e xp la na tio n o f w h a t m a k es a s te el p la n t

"s p ec ia l":

A fully integrated steel plant lik e V iza g S teel p e rfo rm s th e e ntire p ro c e s s o f s tee l m a n u fa c tu rin g in

o n e p la c e— fro m :

Raw material processing (lik e iro n o re , c o a l, a n d lim es to n e)

Coke making

Iron making (Blast Furnace)

Steel making (Basic Oxygen Furnace or Electric Arc Furnace)

Rolling and finishing

T h is m a k e s it s e lf-relia n t a n d effic ien t.

V iz a g S te el s p e c ia liz es in long steel products, s u c h as:

R eb a rs (rein fo rc em en t b a rs fo r c o ns tru c tio n )

W ire ro d s

A n g le s , c h a n n els , a n d b illets

T h es e a re c ru c ia l fo r construction, infrastructure, and manufacturing sectors.

V iz a g S te el is In d ia ’ s first shore-based steel plant, lo c a te d n ea r th e c o a s t. T h is h a s a d v an tag es :

E a s y a c c es s to im p o rted ra w m a te ria ls via p o rt

C o s t-e ffe c tive lo g is tic s fo r exp o rts

M o d e rn s te el p la n ts u s e a d v a n c e d te c h n o lo g ie s lik e:

9
Continuous casting

Energy-efficient blast furnaces

Automation and control systems

10
T h is e n h a n c e s p ro d u c t q u a lity a n d red u c e s en v iro n m e n ta l

im p a c t. T h e s te el p ro d u c e d is :

K n o w n fo r high strength and ductility

S u ita b le fo r critical infrastructure , ra ilw a ys , a n d

d e fen s e M a n y m o d e rn p la n ts in ve s t in :

Waste heat recovery

Water recycling

Emission control systems

V iz a g S te el h a s green belts a n d ISO certifications fo r q u a lity a n d

en v iro n m e n t. S tee l p la nts lik e V iz a g S tee l:

Pro vid e e m p lo ym en t to th o u s an d s

S up p o rt lo c a l ec o n o m ies a n d ind us tries

H a v e s tro n g c o m m u n ity d e ve lo p m e nt p ro g ram s

H ere a re th e key achievements of Vizag Steel Plant (RINL - Rashtriya Ispat Nigam Limited):

Top Achievements of Vizag Steel Plant:

 India’ s First Shore-Based Integrated Steel Plant

Lo c a ted o n th e ea s t c o a s t a t V is a k h a p a tn a m , A n d h ra P ra d e s h.

H e lp e d re d u c e tra n s p o rta tio n c o s ts a n d en a b led e a s y e xp o rt/ im p o rt v ia s e a ro u tes .

 Specialization in Long Steel Products

Pro d u c e d h ig h -q u ality re b a rs , w ire ro d s , b ille ts , a n d s tru c tu ra l s tee l.

W id ely u s ed in in f ra s tru c tu re , ra ilw a ys , d e fen s e , a n d c o n s truc tio n .

 Capacity Expansion
E x p a n d ed liq u id s te el p ro d u c tio n c a p a c ity f ro m 3.0 MTPA to 6.3 MTPA , n o w m o v in g

to w a rd s 7.3 MTPA .

 ISO Certifications
A w a rd ed ISO 9001 (Q u a lity), ISO 14001 (E n viro n m en t), a nd OHSAS 18001 (O c c u p a tio n al
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 H ea lth & S a fety).

 Development of Value-Added Steel Grades

E a rth q u a k e-re s is ta n t T M T b a rs

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 S te el fo r a u to a n d n a v a l a p p lic atio n s

S p ec ia l s tee l fo r n u c le a r p o w er p la n ts

 Energy and Environment Achievements

W a s te h e a t rec o v ery a n d g a s -b a s ed p o w e r g e ne ra tio n

G ree n b elt d e ve lo p m e n t o ve r la rg e areas

E n v iro n m en t-f rien d ly s tee lm a k in g p ro c es s es

 Awards & Recognition

R ec eiv ed th e Prime Minister’ s Trophy fo r B e s t In te g ra te d S te el Pla n t

R ec o g n ize d f o r CSR initiatives in h ea lth , ed u c a tio n , a n d ru ra l d eve lo p m en t

 Export Performance
E x p o rted s te el to o ve r 2 0 c o u n tries in c lu d in g S o u th e a s t A s ia , E u ro p e , a n d th e M id d le E a s t.

 Skilled Workforce and Training

O p e rate s a w o rld -c la s s training institute (VIGYAN) fo r te c h n ic a l a n d s a fety tra inin g .

R u n s apprenticeship programs fo r yo u th s k ill d eve lo p m en t.

Steel and Iron

S te el is no th in g b u t a n a llo y o f Iro n . T h e m ain d iffe re n c e b e tw e en Iro n a n d S tee l is th a t th e y d if fer in

th e ir p e rc en ta g e o f C a rb o n a n d h a s th e a d va n ta g e o f h ig h te n s ile s tren g th a n d lo w c o s ts . T he reb y,

in c rea s in g its c o n s u m p tio n in a ll e n g in ee rin g a c tiv itie s .

V is a k h a p a tn a m S tee l P la n t is a n in teg ra ted p la n t a n d it c o n s is ts o f va rio u s d ep a rtm en ts in w h ic h

Iro n is c o n v erted to S tee l a n d S te el is d ivid e d in to S a le a b le Ste el a n d th e rem a in in g is c o n v erted in to

s ev era l p ro d u c ts .

Different Departments

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B ein g a p io n e er in s tee l m a k in g , V iza g Ste el, h a s s ev era l d ep a rtm en ts th a t w o rk ro u n d th e c lo c k to m ee t

th e d e m a n d a n d p ro p o rtio n a l p ro d u c tio n .

S o m e o f th e m a in a nd im p o rta n t d ep a rtm en ts th a t d ire c tly p a rtic ip a te in th e Ste el M a k in g p ro c es s a re:

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 OVERVIEW OF RINL STEEL PLANT

The various departments available in the VSP include:

 RMHP (RAW MATERIAL HANDLING PLANT)
 CO & CCP (COKE OVENS & COAL CHEMICALPLANT)
 SP (SINTER PLANT)
 BF (BLAST FURNACE)
 SMS (STEEL MELTING PLANT)
 ROLLING MILLS RS & RS (ROLL SHOP &REPAIR SHOP)
 TPP (THERMAL POWER PLANT)

 RMHP:

VSP annually requires quality materials like iron ore, fluxes, coking & non coking
coals etc., for the production of 6.3MT of steel to produce materials. In order to
handle the target volume of the incoming raw material received from the different
sources and to ensure timely supply of the consistent quality of feed materials to
various other departments for carrying out the vital functions.
  CO & CCP:

Coke is manufactured by the heating of the crushed coking coal in the absence of
air at 1273K for a span of 16 to 18hrs. The coal chemicals such as Benzol,
Ammonium sulphate etc... are extracted in the coal chemical plant for the CO
gas. After recovering the coal chemicals, the gas is used as the by product by
mixing with the BF gas, LD gas, etc. as a fuel.

 SINTER PLANT:

Sinter is a hard and porous ferrous material obtained by agglomeration of Iron Ore
fines, coke breeze, lime stone fines, Metallurgical wastes viz. flue dust, mill scale, LD
slag etc.,

Sinter is a better feed material to Blast Furnace in comparison to iron ore lumps and
its usage in Blast Furnace help in increasing productivity decreasing the coke rate and
improving the quality of Hot metal produced.
Sintering is done in 3no.s of 312sq. Mt. Sinter machines of Dwight woyd type by
heating the prepared feed on a continuous metallic belt made of pallets at 1200 -
1300°C.

Hot sinter discharged from sintering machine is crushed to +5 to -50mm size and
cooled before dispatching to blast furnace.

Hot sinter discharged from Sintering machine is crushed to +5 mm – 50 mm

size and cooled before dispatching to Blast Furnaces
Parameters of Sintering Machines are:

- Effective area : 312 Sq. Meter

- Sintering area : 276 Sq. Meter
- Sinter bed height : 300 mm
- Capacity : 450 TPH each
- No. of wind boxes : 26

The dust laden air from the machines are cleaned in scrubbers and electrostatic
precipitators to reduce the dust content to 100 mg/m3 level before allowing to
escape into the atmosphere and thus helping in maintaining a clean and dust free
environment.

BLAST FURNACE:

Hot metal is produced in Blast Furnace which is tall vertical furnaces; the furnace
is named BF as it is run with at high pressure and temperature. Raw material such
as sinter/Iron ore lumps, fluxes and coke ore charged from the top and hot blast at
1100°C - 1300°C and 5.75kg/cm^2 is blown almost from the bottom. The
furnaces are designed for 80% sinter in the burden.

VSP has three of capacity [Link] BF’s equipped with Paul worth bell less
top equipment with conveyor charging. Rightly named as “Godavari” and
“Krishna” after the two rivers of AP, the furnaces will help VSP in bringing the
prosperity to the state of AP.

STEEL MELTING SHOP:

Steel is an alloy of iron with carbon up to 1.8%. Hot metal produced in BF’s
contains impurities such as carbon (3.5 – 4.25%), silicon (0.4 – 0.5%), manganese
(0.3 – 0.4%), sulphur (0.04%max) and phosphorous (0.14%max) is not suitable
as a common engineering material. To improve the quality the impurities are to
be eliminated or decreased by oxidation process.
VSP produces steel employing three numbers of top blown oxygen LD converters
or Basic Oxygen furnaces /converters. Each converters is having 133m^3 volume
capacity of producing 3 million tons of liquid steel annually. Beside hot metal,
steel scrape, fluxes such as calcined lime or Dolomite from part of the charge to
converters.

CHARACTERISTICS OF VSP CONVERTERS:-

 Capacity - 1.5*100tons per heat/blow
Volume - 133m^3
Converter specific vol. - 0.886m^3/Tons
Tap to Tap time - 45 – 60Mts
Ht. to Dia ratio - 1.36
Lining 1) working - Tar Dolomite Bricks
2) Permanent - Chrome Magnesite Bricks
Avg. lining life - 4000heats (2009)

ROLLING MILLS:
Blooms produced in SMS-CCD do not find much applications as such and are
required to be shaped into products such as billets, rounds, squares, angles (equal
and unequal) channels I-PE beams, HE beams, wire rods and reinforcements bars
by rolling them in three sophisticated high capacity, high speed, fully automated
rolling mills, namely & medium merchant mills (LMMM) wire rod mill (WRM)
and medium merchant and structural mill (MMSM).

◗ WIRE ROD MILL (WRM):

 The mill produces rounds in 5.5 – 12 mm range and rebars in 8 – 12 mm range.
The mill is equipped with standard and retarded stelmore lines for producing high
quality Wire rods in low, medium and high carbon grade meeting the stringent
national and international standards viz., BIS, DIN, JIS, BS etc., and having high
ductility, uniform grain size excellent surface finish.

◗ Light and Medium Merchant Mill (LMMM):

LMMM comprises of two units. In the billet/break down mill 250 X 320 MM size
blooms are rolled into billets of 125 X 125 mm size after heating them into two
number of walking beam furnaces of 200 tons/hr. capacity each. This unit
comprises of 7 stands (2 horizontal 850 X 1200 mm) and 5 alternating vertical and
horizontal stands (730 X 1000 mm X 630 X 1000 mm) billets are supplied from
this ill to bar mill of LMMM and wire rod mill.
 The billets for rolling in bar mill of LMMM are first heated in 2 strand roller hearth
furnace of 200 T/hr. capacities to temperature of 1150 C – 1200 C. The bar mill
comprises of 26 strands – 8 strand double stand roughing train, 2 Nos. of 5 strand,
double stand intermodal train and two nos. 4 stand single strand finishing trains.

The mill is facilitated with temp core heat treatment technology evaporative cooling
system in walking beam furnaces automated pilling and bundling facilities, high
degree of automation and computerization.

The mill is designed to produce various finished products such as rounds, rebars, and
squares, flats, angles, channels besides billets for sale.

◗ MEDIUM MERCHANT AND STRUCLTURAL MILL (MMSM):

This mill is a high capacity continuous mill consisting of 20 stands arranged in 3

trains.

- Roughing train having a 8 stands (4 two high horizontal stands, 2 vertical

stands and 2 combination stands)
- Intermediate train has 6 mill stands as per details given
- 2 high horizontal stands
- 2 combination stands
 - 2 horizontal stands/two universal stands
- finishing train consists of 6 stands
- 2 combination stands

UTILITIES AND SERVICES:-

1. Water Management Department (WMD)
2. Utilities
3. Power Generation & Distribution
4. Traffic Department
5. Quality Assurance & Technology Department
6. Production Planning & Monitoring (PPM)
7. Calcining & Refractory Material Plant (CRMP)
8. Engineering Shops & foundry (ES&F)
9. Field Machinery Department (FMD)
10. Power Engineering Maintenance (PEM)
11. Central Maintenance Mechanical (CMM)
12. Plant Design (PD)
13. Central Maintenance Electrical (CME)
14. Electrical Repair Shop (ERS)
15. Instrumentation
16. Electro Technical Laboratory (ETL)
17. Telecommunications (TELECOM)
18. Information Technology (IT)
19. Engineering Management Department (EMD)
20. Environment Management Department (EnMD)
 BASIC CONCEPTS
TQ DIAGRAM OF WATER:

SENSIBLE HEAT:
The heat which is used to change the temperature without anychange
in phase is known as sensible heat.

LATENT HEAT:
The heat which causes change in phase without any change in
temperature is known as latent heat.
SATURATION TEMPERATURE:
Saturation temperature is the temperature at which phase change starts at a
particular pressure.

The saturation temperature of water for liquid to vapour phase change

  Corresponding to 1 atmosphere pressure is 373K.

 Corresponding to 5 bar is 425K.

 Corresponding to 10 bar is 453K.

SATURATION PRESSURE:
Saturation pressure is the pressure at which phase change startsat
particular temperature.

The saturation pressure of water for liquid to vapour change

 Corresponding to 1 atmosphere pressure is 373K.

 Corresponding to 5 bar is 425K.

 Corresponding to 10 bar is 453K.

SATURATION LIQUID CURVE:

Saturation liquid curve is the locus of all states where liquid starts
converting into vapour at temperature equal to saturation temperature
corresponding to a particular pressure or at pressure equal to saturation pressure
corresponding to a particular temperature.

SATURATION VAPOUR CURVE:

Saturation vapour curve is the locus of all states where liquid completely
converts into vapour at temperature equal to saturation temperature corresponding
to a particular pressure or at pressure equal to saturation pressure corresponding
to a particular temperature.
SATURATED LIQUID:

A liquid that is about to vapourize is knows as saturated liquid.

SATURATED VAPOUR:
A vapour that is about to condense is knows as saturated vapour.

WET VAPOUR:
The mixture of saturated liquid and saturated vapour is known as wet
vapour.
CRITICAL POINT:
Critical point is defined as the state at which saturated liquid and
saturated vapour states are identical.

At critical point latent heat of vaporization is zero.

For water at critical point

 Tc = 3740C

 Pc = 221bar

 Vc = 0.003 m3/kg
SUBCOOLED LIQUID REGION:

Subcooled liquid region is the region in which

 Actual temperature (T) is less than corresponding

saturation temperature (Tsat) at a particular pressure (P).

 Actual pressure (P) is more than corresponding saturation

pressure (Psat) at a particular temperature (T).

SUPERHEATED VAPOUR REGION:

Superheated vapour region is the region in which

 Actual temperature (T) is more than corresponding

saturation temperature (Tsat) at a particular pressure (P).

 Actual pressure (P) is more than corresponding saturation

pressure (Psat) at a particular temperature (T).
WET REGION:
Wet region (excluding SLC & SVC) is the region in which

 Actual temperature is exactly equal to the saturation

temperature corresponding at a particular pressure.

 Actual pressure is exactly equal to the saturation

pressure corresponding at a particular temperature.

SUBCOOLED LIQUID:
Subcooled liquid is the liquid which is not about to vaporize.

SUPERHEATED VAPOUR:
Superheated vapour is the vapour, which is not about to
condense.

DRYNESS FRACTION:
Dryness fraction represents the fraction of saturated vapour present
in wet vapour (saturated liquid – saturated vapour mixture).

 Saturated liquid curve is the locus of all the states having dryness
fraction equal to zero (0)

 Saturated vapour curve is the locus of all the states having dryness
fraction equal to one (1).

For wet vapour dryness fraction is greater than zero but less than one.
MOLLIER DIAGRAM:
 Mollier diagram is specific enthalpy – specific entropy (h-s)
diagram.

 Mollier diagram is used in vapour power plant for evaluating

properties of superheated vapour and high quality wet vapour.
 T he T P P h o u s e s four Turbo Blowers, e ac h w ith a c a p a c ity o f a p p ro xim a te ly 40 MW.

Utilities Department

U tilitie s d e p a rtm e nt is o n e o f th e a u x ilia ry d ep a rtm en ts in V iza g S te el Pla n t. Its m a in ro le is to s u p p ly

u n in te rru p ted d e liv ery o f g a s e s s uc h a s O xyg en , N itro g e n, A rg o n , C o m p re s s ed A ir, D ry A ir a n d C h ille d

W a te r f o r A ir C o n d itio n in g s ys te m s .

T h is d ep a rtm en t th o u g h d o es n ’ t a p p e a r to d ire c tly p a rtic ip a te in th e m a n u fa c tu rin g p ro c es s its

p ro d u c ts

p ro d u c tio n a ff ec ts g rea tly p ro c es se s .

E v en d u rin g a n y ev en t o f p o w e r fa ilu re o r s h u td o w n , U tilities d e p a rtm e n t is c o m m itte d fo r ro u n d th e

c lo c k s u p p ly o f a ll its p ro d u c tio n .

T h e U tilitie s d ep a rtm en t he re in V iza g S tee l h o u s es

▶ A ir S ep a ra tio n P la n t – 4 u n its (A S U 1 ,2 ,3 ,4 )
▶ C o m p re s s o r H o u s e – 2 u n its (C H -1 & 2 )
▶ C h ille d W a te r P la n t – 2 u n its (C W P -3 & 4 )
▶ LP G a n d A c etylen e D is trib u tio n P lan t
▶ C ylind er F illin g S ta tio n (CF S )

Compressor House (CH – 1 & 2):

C o m p re s s o r H o u s e m ee ts th e c o m p re s s ed a ir a n d d ry a ir re q u irem en ts fo r th is s tee l p la n t.

36
C o m p re s s o r H o u s e c o n s is ts o f 2 u n its C H -1 a n d C H -2 , w h ic h va ry in the ir c a p a c itie s . T h es e u n its

p ro d u c e in d u s tria l g ra d e c o m p res s e d a ir a n d d ry a ir.

A tm o s p h e ric a ir is ta k en in a n d is filte red fo r th e rem o v a l o f d u s t a n d is c o m p re s s ed to

a p p ro xim a te ly 6 .3 7 b a rg (6 . 5 k s c g ) p res s u re in a fo u r s ta g e c en trifu g a l c o m p re s s o r w ith s in g le s ta g e

in te rc o o le r fo r e ve ry s ta g e o f

37
c o m p re s s io n . A f te r e ve ry s ta g e o f c o m p re s s io n , c o n d en s a tio n ta k e s p la c e s o a s to rem o v e w a te r

va p o r fro m a ir in the fo rm o f c o n d e n s ate .

T h is c o m p res s e d a ir is fe d in th e p la n t a ir n e tw o rk fo r m ee tin g th e req u irem en ts in th e p lan t.

A p a rt o f c o m p re s s ed a ir is fe d to d ryin g u n its w h ere rem a in ing a m o u n ts o f m o is tu re is re m o ve d b y

p a s s in g o v er a d s o rb en t b e d s in s ta lled in th e c o m p re s s o r h o u s e f o r p ro d u c in g d ry a ir.

T h is d ry a ir is a g ain fed to d ry a ir n e tw o rk a n d is s u p p lied to c u s to m e rs in th e p la n t.

C H -1 p ro v id es c o m p re s s ed a ir a n d d ry a ir fo r S M S, B F , S in ter P la n t a n d C C C D Z o n es . C H -2 f u lfills a ir

re q u irem en ts fo r R o llin g M ills a re a .

G e ne ra lly c o m p re s s ed a ir is u s ed f o r th e fu n c tio n in g o f p n eu m a tic v a lve s in ro llin g m ills a rea .

T a b le b e lo w s u m m a ris es th e eq u ip m e n ts , n u m b e r a n d c a p a c ity o f ea c h u n it in the C o m p re s s o r H o u s e:

U n it E q u ip m en t N o . o f u n its C a p a c ity (ea c h

un it)

C H -1 Pla n t A ir C o m p res so rs 4 4 0 ,0 0 0 N m 3/h r

A ir D ryin g U n its 4 4 5 0 0 N m 3/ h r

C H -2 Pla n t A ir C o m p res so rs 4 1 5 ,0 0 0 N m 3/ hr

A ir D ryin g U n its 2 1 5 0 0 N m 3/ h r

O u t o f th e 4 u n its o f Pla n t A ir C o m p re s s o rs a n d A ir d rying u n its in C H -1 , g e n era lly 3 u n its a re in

w o rk in g c o n d itio n a n d 1 u n it is in s ta n d b y. B u t th e p re s en t u tiliza tio n o f P la n t A ir C o m p res s o rs is 2

u n its in w o rk in g a n d 2 in s ta n d b y. A ll A ir d ryin g u n its a re in o p e ra tio n in C H -1 .

38
S im ila rly C H -2 ha s 4 p la n t a ir c o m p re s s o rs o u t o f w h ic h a re 3 a re in w o rk in g c o n d itio n a n d 1 is in

s ta n d b y. T he p re s en t u tiliz a tio n is 1 in w o rk in g a n d 3 in s ta nd b y. T h ere a re 2 d ryin g u n its o f w h ic h

b o th a re in s ta n d b y p res e n tly, g en era lly o n e w ill b e in w o rk in g c o n d itio n an d o th er in s ta n d b y m o d e.

39
Chilled Water Plant (CWP - 3&4):

C h ille d W a te r P la n t in u tilitie s d ep a rtm en t p ro v id es c h ille d w a te r fo r a ir c o n d itio n in g s y s te m s

th ro u g h o u t th e p la nt.

W a te r fro m p u m p h o u s e is c o o le d u s in g c h illers o f typ e Screw Chillers a n d Centrifugal Chillers.

T h es e c h ille rs u s e th e p rin c ip le o f a va p o r c o m p re s s io n re frig era tio n c yc le in th eir fu n c tio n in g .

W a te r a t a ro u n d 2 9 8 K (2 5 0C ) a n d retu rn w a rm w a te r a t a ro u n d 2 8 6 K (1 3 0C ) e n te rs in to c h ille rs ,

w h ic h is a s h e ll a n d tub e k in d o f a rra ng em e nt in w h ic h w a te r flo w s th ro u g h tu b e s id e. A re frig era n t

s u c h a s R -1 1 o r F re o n is u s ed in th e s h e ll s id e . T h e p ro p erty o f th is re frig era n t is s u c h th a t it ta k es th e

h ea t fro m th e ho t w a te r a n d g ets e va p o ra ted . Th is refrig e ra n t is a t a p re s s u re o f 1 .9 6 b a rg a n d in th e

va p o r fo rm is s e n t to a c o m p re s s o r w h ere fu rth e r c o m p res s io n ta k e s p la c e to a p p ro x im a tely a ro u n d

7 .8 4 b a rg p re s s u re a nd s im ila rly te m p era tu re o f re frig era n t g o e s to a p p ro x im a tely a ro u n d 8 0 0C . T h is

va p o r is no w fed in to a c o n d en s e r w h e re it is c o o le d b y u s in g c o o led w a te r at a ro u n d 1 .9 6 b a rg

p res s u re e n h a n c in g s u ffic ie n t te m p era tu re d ro p . It is s en t to th e s h ell in th e c h iller th ro u g h a n

ex p a n s io n va lv e, w h ic h e n h a n c e s th e d ro p in p re s s u re to th e in itia l p re s s u re o f a ro u nd 1 . 9 6 b a rg .

T h e w a te r th a t lo s es the h ea t in th e tu b e s id e c o m e s o u t a s c o o led w a ter a t a te m p era tu re o f a ro u n d

7 0C . T h is w a ter is p u m p ed b a c k to a ll a ir h a n d lin g u n its b y th e c e n trifu g a l c h illers . T o a vo id c o ld

lo s s es , a ll p ip e lin e s a re p ro p e rly in s u la te d .

9 n o s . o f 5 4 0 T o n R e frig era tio n (T R ) c a p a c ity c h illers a re p ro vid e d a t C W P-3 fo r c o o lin g a n d a ir

c o n d itio n in g req u ire m e n ts o f S M S & R o llin g M ills . O u t o f th e s e 9 , a s p e r d es ig n c a p a c ity 8 s h o u ld b e

in w o rk in g a n d 1 in s ta n d b y m o d e. T h e p res e n t u tiliza tio n is o f 7 to b e in w o rk in g c o n d itio n a n d 2 to

b e in s ta nd b y m o d e

3 n o s . o f 5 4 0 T o n R efrig e ra tio n (T R ) c a p a c ity c h illers a re p ro vid e d a t C W P -4 f o r a ir

40
c o n d itio n in g re q u irem en ts o f Q A T D , IT a n d C D S . In th e s e 3 , p res e n tly 1 is in w o rk in g m o d e an d 2 in

s ta n d b y m o d e.

R e c e n t d e ve lo p m e n ts in c lu d e re p la c in g 5 4 0 T R c a p a c ity c e n trifu g a l c h illers w ith 2 5 0 T R c a p a c ity

S c rew C h ille rs . A ls o re p la c em en t w ith m o re e c o frie n d ly re frig era n t c h illers is g o in g to b e

im p le m e n ted in C W P -4 w ith th e rev is io n in th e c ap a c ity a n d typ e o f th e c h ille rs o f C W P -4 .

R e c e n t u n its h a ve a ls o b e en d e ve lo p e d fo r m e etin g in c rea s in g re q u irem en ts .

41
C W P -5 w ith 5 c en trifu g a l c h illers o f 1 0 0 0 T R c a p a c ity a n d 5 s c rew c h ille rs o f 3 0 0 T R c a p a c ity a n d

2 1 5 0 m 3/ h r o f c a p a c ity, m e ets th e re q u irem en t in R o llin g M ills a rea .

C W P -6 w ith 3 c h ille rs o f 4 0 2 T R c a p a c ity a n d 3 0 0 m 3/h r o f c a p a c ity a n d C W P -7 w h ic h p ro vid es

th e re q u irem en ts a t S in te r P la n t – 3 , w ith 3 s c rew ty p e c h illers o f 3 5 0 T R c a p a c ity a n d a 2 6 0 m 3/ h r

c a p a c ity .

LPG and Acetylene Distribution Plant:

E a rlie r d a ys A c e tyle n e w a s g en e ra te d in A c e tyle ne g e n era to r fo r a p p lic a tio n in c u ttin g / w eld in g

p u rp o s es . P ro d u c tio n c a p a c ity w a s a ro u n d 3 0 N m 3/ h r.

A c etylen e a lo n g w ith o x yg e n is u s e d f o r c u tting / w e ld in g in m a c h in ery s h o p s , ro llin g m ills .

R e c e n tly LP G is b e in g im p o rte d a n d is s up p lied to th e a rea w h ere it is req u ired .

Cylinder Filling Station (CFS):

P a rt o f th e Liq u id O xyg en (L O X ), L iq u id N itro g e n ( LIN ) a n d Liq u id A rg o n (L A R ) p ro d u c e d fro m a ir

s ep a ra tio n a re s to re d in ta n k s o f 5 to n c a p a c ity. T h es e a re p u m p ed u s in g rec ip ro c a tin g p u m p s to a

p res s u re o f a p p ro xim a te ly 1 4 7 b a r. T h en are p a s s e d th ro u g h a tm o s p h e ric va p o ris ers a n d v a p o rize d .

T h es e va p o rs a re fille d in to c ylin d ers th ro u g h th e c ylin d er m a n ifo ld s p res e n t.

T h ere a re 3 LO X p u m p s , 2 L IN p u m p s a n d 1 L A R p u m p s . M o re n um b er o f m a n ifo ld s o f o xyg en w h en

c o m p a re d w ith n itro g en a n d a rg o n a re p re s en t a s o xyg en c y lin d e rs a re q uite e s s en tia l in h o s p ita ls

fo llo w e d b y w eld in g ap p lic a tio n s .

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Air Separation Plant (ASU – 1,2,3 & 4):

F irs t o f its k in d Viz a g s teel c o m p ris e s o f a n in d iv id u a l a ir s e p a ra tio n p la nt w ith 4 u n its th a t re a d ily

s u p p lie s c o m p res s e d g a s e s s u c h a s O xyg en , N itro g en a n d A rg o n w itho u t b ein g d e p e n d en t o n o th er

in d u s tries .

43
A ir is a m ixtu re o f g a s es . A tm o s p h eric a ir c o n s is ts o f N itro g e n , O x yg e n , A rg o n , C a rb o n d io xid e, M o is tu re ,

H yd ro c a rb o n s , C h lo ro flu o ro c a rb o n s a n d In ert g a s es s u c h a s N eo n , X en o n a n d R a d o n e tc .

Table below gives the composition of air:

C o m p o ne n t P e rc en ta g e ( % ) b y vo lu m e.

N itro g en 7 8 .0 3

O xyg en 2 0 .6
A rg o n 0 .9 3

C a rb o n d io xid e

M o istu re

H yd ro c a rb o n s

(HC ’ s) 0 .9 8

C h lo ro flu o ro C a rb o n s (C F C ’ s)

In ert g a s es s u c h as N e o n , X e n o n ,

K ryp to n e tc .

T h e ind u s tria lly p ro d u c ed O xyg en , N itro g en a n d A rg o n h a ve a w id e ra n g e o f a p p lic a tio n in S te el

m a k in g p ro c e s s.

A tm o s p h e ric a ir is ta k en a n d is filtered a n d a fte r a s eries o f 4 -s ta g e c o m p re s s io n w ith in ter-s ta g e

c o o lin g (i.e . a fte r e ve ry s ta g e ) is s en t to a ir w a ter w a s h to w er f o r fu rth er c o o lin g a n d to a p a ir o f

a d s o rb en t b ed s w h e re c o m p o n e n ts s u c h a s c a rb o n d io x id e a n d w a ter m o is tu re a re rem o v ed a n d

fro m th ere to a p la te a n d fin typ e ex c h a n g er a n d is fu rth er c o o led b y h ea t tra n s fer w ith p ro d u c ts

c o m in g o u t fo r a c h iev ing th e a ir liq u e fa c tio n tem p era tu re o f ap p ro x im a te ly 9 9 K (-1 7 4 0C ) a t a

p res s u re o f a p p ro x im a tely 4 .9 b a rg ( 5 k s c g ). T h is liq ue fied a ir is s en t in to a d is tilla tio n c o lu m n

w h e re it is s ep a ra ted in to th e c o m p o n e n ts o f a ir.
44
T h is p la n t w o rk s o n th e b a s ic p rin c ip les o f liquefying a ir a nd s ep a ra tin g th e c o m p o n en ts b a s in g o n

th e ir boiling points, density differences a n d relative volatilities. Th is is fea s ib le o n ly a t n e g a tiv e

(lo w ) te m p e ra tu re s a n d th e p ro c es s th ro u g h w h ic h it is c a rrie d is c a lled Cryogenic Fractional

Distillation.

45
T h e d rie rs c o n s is t o f b e d s o f Activated Alumina a n d Molecular Sieves w h ic h a c t as th e a d s o rb en ts .

A c tiv ate d A lu m in a a d s o rb s m o is tu re w h erea s M o lec u la r S ie ve s a d s o rb s C a rb o n d io x id e a s w ell a s

M o is tu re. T h e s e a d s o rb e n ts a re u s e d a s th e y w o rk e ffic ie n tly a t lo w tem p era tu res a n d a s th is is a

c ryo g en ic p ro c e s s th e re is a re q u irem en t o f w o rk in g a t lo w tem p e ra tu res .

O u t o f th e 2 h o riz o n ta l d riers R 0 1 , R 0 2 o n e w o u ld b e in lin e (w o rk in g ) w h ile th e o th e r w o u ld in

re g e n era tio n . A ir is p a s s e d thro u g h a n y o f th e d rier a n d a lm o s t a ll th e c h e m ic a l p o llu ta n ts a re

a d s o rb ed a n d p u re a ir w ith les s th a n 1 p p m im p u rity c o m es o u t a t a ro u n d 5 .8 8 b a rg p res s u re a n d

2 8 3 K ( 1 0 0C ) – 2 8 6 K (1 3 0C ) tem p era tu re .

A fter a p e rio d o f tim e ( 5 h rs ) th e d rie rs g e t s a tu ra ted w ith th e s e c h e m ic a l p o llu ta n ts , s o th es e d riers

a re p u t to reg e n era tio n s o th a t th e b ed m a yb e re a d y fo r n e xt a ro un d o f a d s o rp tio n . T h e p ro c es s o f

re g e n era tin g th is b ed is c a lled Regeneration. A reg en e ra tio n c yc le is c a rrie d o u t u s in g w a s te

n itro g en s tre a m .

53
F ig u re : V ertic a l D rie rs in w o rk in g a n d in reg en era tio n

54
 7 . Is o la ted W ith o u t P res s u re: O n c e a g a in th e d rier is is o la te d fro m th e s ys tem , th is tim e w ith o u t

p res s u re fo r a b o u t 1 m in u te.

8 . B a la n c in g : In th is s te p th e reg en e ratin g d rie r is rea d ied to b e k ep t in lin e fo r w o rk in g . T h e

b a la n c in g v a lv e 1 1 is s lo w ly o p en e d s o a s to a llo w a ir fro m th e w o rk in g d rier to e n te r in to th e

re g e n era tin g o n e. T h is b a la n c in g en s u res th a t th e 2 d rie rs a re a t s a m e p re s s u re . O th erw is e ,

a ir a t a c erta in p re s s u re if it s u d d en ly e n te rs in to th e d rie r the re is a h ig h c h a n c e o f th e b e d

g e ttin g d is tu rb ed . T h is s lo w s tep is c a rrie d fo r a b o u t 2 0 m in u te s .

In a d d itio n to th is a c o o lin g p ea k a n d a h e a tin g p e a k a re to b e a c h ie ve d a s e ve n s m a ll a m o u n t o f

c h e m ic al p o llu ta n t g o in g in m ig ht c o s t h e a vily. S o , th is p u rific a tio n is d o n e w ith u tm o s t a tte n tio n .

F ig u re : D e p ic ts th e H e a tin g a n d C o o lin g Pea k

57
Air Cryo-Cooling Unit:

S in c e th is is a c ryo g en ic p ro c e s s , te m p era tu re s s ho u ld b e ve ry lo w . T o a tta in s u c h lo w te m p era tu re s

a ir is p a s s ed th ro u g h a b ra z ed a lu m in iu m Pla te a n d F in typ e h ea t ex c h a n g er fo r fu rth e r c o o lin g .

A ir a t a ro u n d 5 .8 8 b a rg p res s u re a n d te m p era tu re o f a ro u n d 2 8 3 K (1 0 0C ) – 2 8 6 K (1 3 0C ) is s e n t

in to th e ex c h a n g e r a n d h ea t tra n s fe r ta k e s p la c e in d ire c tly b e tw e en th e p ro d u c ts g a s eo u s n itro g en ,

g a s e o u s o xyg en c o m in g fro m th e c o lu m n . A n a ir s trea m fro m a ro u n d 1 5 3 K (-1 2 0 0C ) is ta k en a n d is

g ive n to tu rb in e D -0 1 a n d D -0 2 d ep en d in g o n th e re q u irem en t o f p ro d u c t p u rity.

T h is s trea m is e xp a n d ed in th e tu rb in e fro m 5 .8 8 b a rg p res s u re to a ro u n d 0 .3 9 2 b a rg p re s s u re a n d

a p p ro xim a te tem p e ra tu re o f 1 0 3 K (-1 7 0 0C ) . T h is s trea m fro m th e tu rb in e is g iv en to LP c o lu m n a n d

th e a ir fro m ex c h a n g er a ro u n d 4 .9 b a rg p res s u re a n d te m p era tu re a ro u n d 9 9 K (-1 7 4 0C ) is g ive n to

th e M P c o lu m n .

Main Distillation Column (Main Cold Box):

T h e d is tilla tio n c o lu m n c o n s is ts o f tw in c o lu m n c o n fig u ra tio n w ith a M ed iu m P re s s u re C o lu m n ( M P )

a n d a Lo w P re s s u re C o lu m n (LP ). T h e d is tilla tio n c o lu m n is c o m p o s e d o f a b u b b le-c a p s ie ve tra y

a rra n g e m en t. M e d iu m P re s s u re C o lu m n K -0 1 h a s a p res s u re o f a ro un d 4 . 9 b a rg p res s u re a n d h e n c e

th e n am e . It c o n s is ts o f 4 4 tray s . S im ila rly Lo w P res s u re c o lu m n K -0 2 d erive s its n a m e a s it o p e ra te s

a t lo w p re s s ure o f a ro u n d 0 .3 9 2 b a rg a n d it c o n ta in s 7 2 tra ys . A b o ve th e LP c o lu m n th e re is a Pu re

N itro g en to w er w ith 1 5 s ta g e s . T h e to ta l len g th o f th is d is tilla tio n c o lu m n is a ro u n d 3 3 m .

A ir fro m th e ex c h a n g e r is fe d to LP c o lu m n a n d o n e n terin g th e c o lu m n a ir liq u efie s a n d s ep a ra tes

in to c o m p o n e n ts . T h e b o ilin g p o in ts o f O xyg en , N itro g en a n d A rg o n a re 9 0 K (-1 8 3 0C ), 9 3 K (-1 8 6 0C )

a n d 7 7 K (-1 9 6 0C ) re s p e c tive ly.

B a s in g o n th e d e n s ity d ifferen c e O xyg en ten d s to s ta y a t b o tto m a n d s e ttles a s Rich Liquid (R L ) a t th e

59
th is un it. D u e to d en s ity d iffe ren c e a ll th e o xyg en p a rt s e ttles a s Oxygen Rich Liquid (O R L) a t th e

b o tto m . T h e o u tle t fro m th is u n it c o n s is t o f A rg o n a ro u n d 9 5 -9 8 % , O x yg e n 2 -3 % a n d rem a inin g 1 -2 %

o f N itro g en . S in c e p u rity o f a rg o n re q u ire d is o x yg e n a n d n itro g e n s h o u ld b e re m o ve d .

F o r rem o v a l o f o x yg en , th is m ixtu re is s en t to W a rm A rg o n U n it.

62
 F ig u re : B lo c k D ia g ra m fo r A S U 1 ,2 & 3

▶ A ir S ep a ra tio n U n it – 4 (A S U – 4):

A S U -4 is a n ew u n it w ith n e w te c h n o lo g ie s in tro d u c e d . T h e p ro c e s s in A S U -4 is s im ila r to th e 3 u n its

A S U - 1 , 2 & 3 b u t m o re p u rities a re ac h iev ed in th e la tes t o n e. O n ly th e e q u ip m e n t d iffe rs in A S U -4

a n d it is in th e fo llo w in g w a y:

● T h e d rie rs in th is u n it a re H o riz o n ta l u n lik e in th e p re vio u s u n its . T h is h e lp s in

re d u c in g p res s u re d ro p a n d s ig n ific a n tly o c c u p ie s le s s er a re a .

● R ed u c e d tim e in reg en e ra tio n o f d riers (3 h rs ) a n d a u to m a tic o p e ra tin g o f reg en e ra tio n

c yc le.

64
● Turbo-expanders E T0 1 a n d E T 0 2 a re p res e n t w h ic h a re e s s en tia lly tu rb in es E T 0 1 ,

E T 0 2 an d th e w o rk e xtra c ted fro m th e e xp a n s io n p ro c e s s is u s e d to tu rn s h a ft w h ic h

u s es it fo r c o m p res s io n in c o m p re s s o rs E T 0 1 C a n d E T 0 2 C .

● T h e im p o rta n t fea tu re in th is u n it is th e c o lu m n c o n s is ts o f structured packing u n lik e

th e b u b b le-c a p s iev e tra y c o m b in a tio n p re s en t in th e p rev io u s u n its . T h is he lp s in

re d u c ed p re s s u re d ro p s a nd a ls o th e a ltitu d e o f th e c o lu m n is g re a ter th a n th e p rev io u s

o n e s w ith a c o lu m n h eig h t o f 5 3 m , w h ic h h elp in a c h iev in g m o re liq u id s a n d p ro d u c t

p u ritie s .

● N o re q u irem en t o f H yd ro g en , as th e a rg o n f ro m th e c ru d e a rg o n u n it c o n ta in s v ery le s s

p p m o f o xyg en . A s a res u lt n o re q u irem en t o f W a rm A rg o n U n it.

● Exchanger is c a p a b le o f h a n d lin g m o re s trea m s a n d it is n o t u nlik e th e p rev io u s

exc h a n g er.

● P ro d u c ts o b ta in ed c a n b e in te rn a lly p re s s u rize d u s in g p u m p s a n d a fter p a s s ing

th ro u g h th e ex c h a n g e r G a s eo u s A rg o n (G A R ) a n d G a s e o u s O x yg e n c a n b e o b ta in ed .

● Y ield o f O xyg en is 1 9 .2 5 % in A S U -4 w h e n c o m p a red w ith 1 4 .2 6 % yield in p rev io u s u nits .

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F ig u re: B lo c k D ia g ra m fo r p ro c es s in A S U -4

67
Exchanger Cost:

D e p en d in g o n th e s u rfa c e re q u ired fo r h ea t tra n s fe r th e c o s t o f a h e a t e xc h a n g e r is d e p e n d en t. F o r a

s h ell a n d tu b e ex c h a n g e r, o n ly th e o u ts id e s u rfa c e a re a o f th e tu b es is s u ff ic ien t fo r th e c o s t c rite ria .

A s p la te fin h ea t e xc h a n g e r d o es n o t c o m e u n d e r th is c a te g o ry o f s h ell a n d tu b e, th e c o rre latio n s fo r

th is c o m p a c t h ea t ex c h a n g er rep o rt s u rfa c e a re a fo r e a c h p ro c e s s s tre a m fo r th e c o s t c riteria . T h e

n u m b er o f la yers a n d fin c h a ra c te ris tic s req u ire d f o r d iff eren t flu id s m a y re s ult in d ra m a tic a lly

d iffe re n t h e a t tra n s fe r a rea s . T h e to ta l s u rfa c e h e a t tra n s fe r s u rfa c e a re a in c a s e o f c o m p a c t

ex c h a n g ers is th e s u m o f th e a re a s o f a ll th e p ro c es s s trea m s .

F ro m res e a rc h a rtic le [6], a ro u nd 1 9 9 0 ’ s b y c o s t es tim a to rs , th e e s tim a te d c o s t fo r s h ell-tu b e

ex c h a n g er m a d e fro m c a rb o n s te el w a s a p p ro x im a tely a ro u n d 2 0 $ / ft 2 an d s ta in le s s s tee l c o m p a c t

ex c h a n g er w h en e s tim a te d u s in g s u c h c o rrela tio n s c a n g o u p to 1 0 0 $ /f t 2. C o m p a c t e xc h a n g e rs w ith

s m a ll c o re s ( < 1 0 0 0 0 ft 2), a lu m in iu m b ra ze d ex c h a n g ers c o s t b e tw e en 6 -1 5 $ / ft 2. L arg er c o re s

(> 1 0 0 0 0 ft 2) m a y c o s t b etw ee n 3 -8 $ / ft 2.

B ra z ed ex c h a n g er c o s ts va ry d e p e n d in g o n th e n u m b e r o f s tre a m s , d e s ig n p re s s u re s , typ e s o f

c o n n ec tio n s , s p ec ia l fe a tu res a n d te s tin g . D ep en d in g o n th e b ra zin g fu rn a c e d em a n d , m a n u fa c tu res

o f th is e xc h a n g e r a ls o a s s es s a b ra zin g c h a rg e s o m e tim es .

A c o s t es tim a te is c a rried o n fo r a p la te fin ex c h a n g er in a rec en t re s ea rc h p a p e r[9].

T h e to ta l a n n u a l c o s t w o u ld b e th e s u m o f c a p ita l c o s t, o p era tio n a l c o s t a n d th e m a in te n a n c e c o s t o f

th e s ys tem d u rin g a yea r. T h e c o s t c a n b e e s tim a te d a s

W h ere IC = C a p ita l C o s t $ ,

fc = F ixe d C o s t $ = 1 8 7 .5

A = H ea t tra n s fe r a re a

68
 F ig u re : A S U -4 E xc h a n g e r E -0 1

S trea m s d es c rip tio n :

In lets O u tlets

S trea m 1 G a s e o u s A ir (A G ) fro m B A C S tre a m 9 A G to E T0 1

CO5

S trea m 2 G a s e o u s A ir (A G ) fro m S tre a m 8 A G to K -0 1

R 0 1 /0 2

S trea m 3 A G fro m E T 0 1 C S tre a m 7 A L to V0 3

S trea m 4 A G fro m E T 0 2 C S tre a m 6 A G to E T0 2
S trea m 5 A G fro m E T0 2 S tre a m P 8 W N + A G to E -08

75
H ea t E xc h a n g er E ff ec tive n es s ≈ 0 . 9 2 3 o r 9 2 .3 %

A S U -1 , 2 & 3 E xc h a ng er

T h e 3 u n its o f A S P h a v e th e s a m e s e t o f c o n fig u ra tio n a n d th eir e xc h an g ers E -0 1 is a a lu m in iu m

b ra ze d p la te a n d fin typ e h e a t e xc h an g er.

U n lik e th e A SU -4 ’ s E xc h a n g e r E -0 1 , th is ex c h a n g er d o es n o t d ea l w ith m o re m u ltip le s tre a m s .

T h ere a re 6 c o res in th is e xc h a n g e r a n d te m p era tu re s o f ea c h c o re a re m e a s u red to d etec t a n y (if)

a b n o rm a l fu n c tio n o f the ex c h a n g er.

A ir fro m th e d rie rs is s e n t in to ex c h a n g e r w h ere o n e s trea m is ex c h a n g ed w ith p ro d u c ts a n d o n e

s tre a m is s e n t to tu rb ine s , w h ic h h elp in m a in ta in in g th e c o ld c o n d itio n o f th e c o lu m n .

A S U -1 :

81
 S trea m N o . P res s u re (b ar) T em p e ra tu re (K ) V o lu m e tric Flo w

ra te (N m 3/ hr)

1 6 .3 8 3 6 5 2 8 4 .1 5 8126 8

2 6 .1 0 9 2 5 1 5 5 .1 5 2570 0

P 1 (W N ) 1 .3 7 5 8 5 8 1 .1 5 4134 4

P 2 (N G ) 1 .3 7 5 8 5 9 0 .1 5 2475 7

P 3 (O G ) 1 .5 7 1 8 5 9 0 .1 5 1280 5

P 4 (W N ) 1 .2 7 7 8 5 2 8 7 .1 5 4134 4

P 5 (N G ) 1 .2 7 7 8 5 2 9 3 .1 5 2475 7

P 6 (O G ) 1 .3 1 7 0 5 8 0 .1 5 1280 5

T h e c a lc u la tio n s h a v e to b e d o n e in a s e ria l m a n n e r s o a s to a c h iev e p ro p er re su lts .

● Mass Balance:

W a s te N itro g e n f lo w ra te is o b ta in ed b y d o in g a o ve rall m a s s b a la n c e o n th e s ys tem .

F o r th e o v era ll m a s s b a la nc e,

T o ta l In let A ir flo w ra te = T o ta l O u tlet o f Pro d u c t flo w ra te c o m in g o u t o f th e ex c h a n g er + F lo w ra te

o f L iq u id N itro g e n + flo w ra te o f Liq u id O xyg en .

T o ta l P ro d u c t O u tlet flo w ra te = F lo w ra te o f O xyg en + F lo w ra te o f N itro g e n + F lo w ra te o f W a s te N itro g en .

A s s u m in g a L O X + L IN flo w rate o f 1 5 0 0 N m 3/ h r

 F lo w ra te o f W a s te N itro g en = T o ta l Inle t A ir flo w ra te – (F lo w ra te o f O xyg en +

F lo w ra te o f N itro g e n + T h e flo w ra te o f Liq u id N itro g e n + T h e flo w ra te o f Liq u id

O x yg e n )

 F lo w ra te o f W a s te N itro g en = ( 8 1 2 6 8 )-(1 2 8 0 5 + 2 4 7 5 7 + 1 5 0 0 ) = 4 1 3 4 4 N m 3/h r

82
 P 1 V 1 / T 1 = P 2 V 2 /T 2

P 1 is th e a tm o s p h e ric p res s u re ( 1 .0 1 3 2 5 b a r),

T em p e ra tu re T 1 is 2 7 3 .1 5 K a n d

V 1 is th e vo lu m etric flo w ra te a t th at tem p e ra tu re T 1 a n d P re s s u re P 1 .

S im ila rly P2 , T 2 a n d V2 d en o te th e p re s s u re (b a r) , te m p era tu re (K ) a n d V o lu m etric flo w ra te (m 3/ h r)

at P 2 and T2.

T a k in g P 1 = 1 .0 1 3 2 5 b a r a n d T 1 = 2 7 3 .1 5 K ,

V 2 = (P 1 V 1T 2)/ (T 1 P 2)

= [(T 2 V 1 )/( P 2 ) ]*[3 .7 0 9 5 *1 0 -3]

G ive s u s th e vo lu m e tric flo w ra te o f g a s in c u b ic m etre p er h o u r.

S a y, th e re is th e flo w ra te o f 1 st s tre a m a s V 1 = 8 1 2 6 8 N m 3/h r

Its eq u iva len t V o lu m e tric flo w rate a t P 2 = 6 .3 8 3 6 5 , T 2 = 2 8 4 .5 K is g iv en fro m th e fo rm u la a b o ve .

T h erefo re, V 2 = [(2 8 4 .5 *8 1 2 6 8 )/(6 .3 8 3 6 5 )]*0 .0 0 3 7 0 9 5

= 1 3 4 1 8 .7 9 5 m 3/ hr

● Conversion of Volumetric Flow rate to Mass Flow rate:

M a s s flo w ra te (k g /h r) = V o l. f lo w ra te (m 3/ h r) * D e n s ity (k g /m 3)

S trea P (b a r) T (K ) V o l. flo w D en s it M ass H Cp

ra te (k J/ kg ) (k J/ kg -
m y flo w ra te
(m 3/ h r K)
no. (kg /m 3 (h g / hr)
)

84
 )

1 6 .3 8 3 6 5 2 8 4 .1 1 3 4 1 8 .7 9 7 .8 4 6 1 0 5 2 9 5 .9 4 7 2 8 2 .9 9 1 .0 1 6

5 5
2 6 ..1 0 9 2 5 1 5 5 .1 6 6 8 2 .6 7 1 1 4 .2 0 2 9 4 9 0 7 .3 0 5 1 5 0 .4 1 1 .0 5 9

P1 1 .3 7 5 8 5 8 1 .1 5 9 0 4 4 .5 4 5 6 .0 2 7 5 4 5 1 1 .4 7 7 8 0 .1 6 7 1 .2 9 0

(W N )

P2 1 .3 7 5 8 5 9 0 .1 5 6 0 1 6 .5 7 7 5 .3 3 7 3 2 1 1 1 .0 7 4 9 0 .6 2 5 1 .1 0 3 9

(N G )
P3 1 .5 7 1 8 5 9 0 .1 5 2 7 2 3 .8 9 9 1 1 4 1 .5 3 1 0 9 3 3 1 .0 4 -1 3 3 .4 1 .6 9 9

(O G ) 9
P4 1 .2 7 7 8 5 2 9 3 .1 3 5 1 7 8 .6 6 1 .4 6 9 5 1 6 8 0 .9 7 5 304 1 .0 4 1

(W N ) 5 4

P5 1 .2 7 7 8 5 2 8 7 .1 2 0 6 3 4 .0 1 1 .5 3 0 9 5 1 .0 2 6 2 9 7 .7 5 1 .0 4 1

(N G ) 5 7

P6 1 .6 0 1 2 5 2 8 6 .1 8 4 8 7 .3 2 8 2 .1 5 6 3 1 8 3 0 1 .2 2 6 2 5 9 .8 3 0 .9 1 9

(O G ) 5

S a y fo r e xa m p le e n erg y o f a n ind ivid u a l s tre a m is g ive n b y,

T o ta l In p u t E ne rg y o n w a rm -e n d (k J /h r) = S u m o f E n e rg y o f In d iv id u a l in let S trea m s = 2 9 7 9 7 7 0 0 .2 6
k J/ hr

85
T o ta l O u tp u t E n e rg y o n w a rm -e n d (k J / h r) = S u m o f E n erg y o f In d iv id u a l O u tlet s tre a m s =

(5 1 6 8 0 .9 7 5 *3 0 4 )+ (3 0 5 9 1 .0 2 6 *2 9 7 .7 5 )+ (1 8 3 0 1 .2 2 6 *2 5 9 .8 3 ) =

1 5 7 1 1 0 1 6 .6 5 + 9 2 1 5 6 6 8 .0 4 + 4 7 5 5 2 0 7 .7 9 7 = 2 9 6 8 1 8 9 2 .4 9 k J /h r

D iffe re n c e in E n e rg ie s = In p u t – O u tp u t = 2 9 7 9 7 7 0 0 . 2 6 – 2 9 6 8 1 8 9 2 . 4 9 = 1 1 5 8 0 7 . 7 7 6 k J/ hr

Calculating Warm-end ΔT:

86
F o r c a lc u la tin g th e w a rm -en d ΔT,

m *C p * Δ T = D iffe re n c e in E n erg ie s

F ro m w h ic h , Δ T = D iffe re n c e in E n erg ies / (m *C p )

H ere, m = T o ta l In le t m a s s flo w ra te a ir,

C p = W eig h te d a ve ra g e o f C p o f in let a ir stre am

T o ta l M a s s flo w ra te m = 1 0 5 2 9 5 .9 4 7 8 kg /h r

T o ta l (m .C p ) = 1 0 5 2 9 5 .9 4 7 8 *1 . 0 1 6 1 = 1 0 6 9 8 0 .6 8 2 9

C p = S u m o f (P ro d u c t o f in d ivid u a l m a s s f lo w ra te o f ea c h s trea m a n d C p o f th a t s trea m )/( To ta l

M a s s flo w ra te)

=(1 0 5 2 9 5 .9 4 7 8 *1 .0 1 6 1 )/(1 0 5 2 9 5 .9 4 7 8 )

= 1 .0 1 6 k J / k g -K

 Δ T = 1 1 5 8 0 7 .7 7 6 / (1 0 6 9 8 0 .6 8 2 9 ) = 1 . 0 8 2 5 K (1 . 0 8 2 5 0C )
ΔT = 1.08250C

T h e w a rm -en d Δ T is 1 . 0 8 2 5 0C a n d a s n o ex c h a n g er is c o m p le tely effic ie n t i.e ., z ero Δ T , th is d ro p is

o b s erved .

S im ila r c a lc u la tio n s a re c a rried o n fo r A S U -3

E x c h a n g e r A SU -3 *:

S trea m N o . P res s u re (b ar) T em p e ra tu re (K ) V o lu m e tric Flo w

ra te (N m 3/ hr)

87
 1 37.99845 3 1 6 .3 3 0 ,7 0 0

2 6 .5 9 8 5 2 9 4 .5 9 3 8 ,3 0 0

P4 19.02565 2 9 5 .3 5 706
P5 38.44925 2 9 9 .9 5 1730 0

P6 1 .2 2 2 9 7 3 0 6 .3 5 3250 0

P1 19.02565 1 0 3 .1 5 706

P2 38.44925 9 6 .1 5 1730 0

P3 1 .3 1 7 0 5 8 0 .1 5 3250 0

T h e c a lc u la tio n s h a v e to b e d o n e in a s e ria l m a n n e r s o a s to a c h iev e p ro p er re su lts .

● Mass Balance:

W a s te N itro g e n f lo w ra te is o b ta in ed b y d o in g a o ve rall m a s s b a la n c e o n th e s ys tem .

F o r th e o v era ll m a s s b a la nc e,

T o ta l In let A ir flo w ra te ex c e p t E T 0 2 s tre a m = T o ta l O u tle t o f P ro d u c t flo w ra te c o m in g o u t

o f th e ex c h a n g e r + F lo w ra te o f L iq u id N itro g en + T h e flo w ra te o f L iq u id O x yg e n .

T o ta l P ro d u c t O u tlet flo w ra te = F lo w ra te o f O xyg en + F lo w ra te o f N itro g e n + F lo w ra te o f W a s te N itro g en

+ F lo w rate o f A rg o n .

 F lo w ra te o f W a s te N itro g en = T o ta l Inle t flo w ra te – (F lo w ra te o f O xyg en + F lo w ra te o f

N itro g en + F lo w ra te o f A rg o n + T h e flo w ra te o f Liq u id N itro g e n + T he flo w rate o f Liq u id

O x yg e n )

 F lo w ra te o f W a s te N itro g e n = (3 0 7 0 0 + 3 8 3 0 0 + 2 8 4 0 0 ) -(1 7 3 0 0 + 3 2 5 0 0 + 7 0 6 + 1 0 0 0 + 1 1 0 0 ) = 4 3 7 9 4
N m 3/ hr

88
 ● Conversion of Flowrate:
F o r g a s es th e flo w ra te is g ive n in n o rm a l c u b ic m etre p er h o u r (N m 3/h r).

T h is is th e flo w rate o f g a s a t 1 a tm o s p h e re ( 1 .0 1 3 2 5 b a r) o f P re s s u re a n d Te m p era tu re o f 2 7 3 .1 5 K

(0 0C ). S o th is f lo w ra te is n e ed ed to b e c o n ve rte d to c u b ic m e tre p er h o u r.

T h e c o n v ers io n is a s fo llo w s :

A p p lying th e C o m b in ed Id ea l G a s E q u a tio n

P 1 V 1 / T 1 = P 2 V 2 /T 2

P 1 is th e a tm o s p h eric p res s u re (1 .0 1 3 2 5 b ar),

89
T em p e ra tu re T 1 is 2 7 3 . 1 5 K an d

V 1 is th e v o lu m etric flo w ra te a t th a t te m p era tu re T 1 a n d P re s s ure P1 .

S im ila rly P2 , T 2 a n d V2 d en o te th e p re s s u re (b a r) , te m p era tu re (K ) a n d V o lu m etric flo w ra te (m 3/ h r)

at P 2 and T2.

T a k in g P 1 = 1 .0 1 3 2 5 b a r a n d T 1 = 2 7 3 .1 5 K ,

V 2 = (P 1 V 1T 2)/ (T 1 P 2)

= [(T 2 V 1) /(P 2 )]*[3 . 7 0 9 5 *1 0 -3]

G ive s u s th e vo lu m e tric flo w ra te o f g a s in c u b ic m etre p er h o u r.

S a y, th e re is th e flo w ra te o f 1 st s tre a m a s V 1 = 3 0 ,7 0 0 N m 3/ h r

Its eq u iva len t Vo lu m e tric flo w ra te a t P2 = 3 7 .9 9 8 4 5 , T 2 = 3 1 6 .3 K is g iv en fro m th e fo rm u la a b o v e.

T h erefo re, V 2 = [(3 1 6 .3 *3 0 7 0 0 )/(3 7 . 9 9 8 4 5 )]*0 .0 0 3 7 0 9 5

= 9 4 7 .9 5 3 m 3/h r

● Conversion of Volumetric Flow rate to Mass Flow rate:

M a s s flo w ra te (k g /h r) = V o l. f lo w ra te (m 3/ h r) * D e n s ity (k g /m 3)

S trea P (b a r) T (K ) V o l. flo w D en s it M ass H Cp

ra te (k J/ kg ) (k J/ kg -
m y flo w ra te
(m 3/ h r K)
no. (kg /m 3 (h g / hr)
)
)

1 6 .3 8 3 6 5 2 8 4 .1 1 3 4 1 8 .7 9 7 .8 4 6 1 0 5 2 9 5 .9 4 7 2 8 2 .9 9 1 .0 1 6

5 5

90
 2 6 ..1 0 9 2 5 1 5 5 .1 6 6 8 2 .6 7 1 1 4 .2 0 2 9 4 9 0 7 .3 0 5 1 5 0 .4 1 1 .0 5 9

P1 1 .3 7 5 8 5 8 1 .1 5 9 0 4 4 .5 4 5 6 .0 2 7 5 4 5 1 1 .4 7 7 8 0 .1 6 7 1 .2 9 0

(W N )

P2 1 .3 7 5 8 5 9 0 .1 5 6 0 1 6 .5 7 7 5 .3 3 7 3 2 1 1 1 .0 7 4 9 0 .6 2 5 1 .1 0 3 9

(N G )
P3 1 .5 7 1 8 5 9 0 .1 5 2 7 2 3 .8 9 9 1 1 4 1 .5 3 1 0 9 3 3 1 .0 4 -1 3 3 .4 1 .6 9 9

(O G ) 9

P4 1 .2 7 7 8 5 2 9 3 .1 3 5 1 7 8 .6 6 1 .4 6 9 5 1 6 8 0 .9 7 5 304 1 .0 4 1

(W N ) 5 4

P5 1 .2 7 7 8 5 2 8 7 .1 2 0 6 3 4 .0 1 1 .5 3 0 9 5 1 .0 2 6 2 9 7 .7 5 1 .0 4 1

(N G ) 5 7
P6 1 .6 0 1 2 5 2 8 6 .1 8 4 8 7 .3 2 8 2 .1 5 6 3 1 8 3 0 1 .2 2 6 2 5 9 .8 3 0 .9 1 9

(O G ) 5

S a y fo r e xa m p le e n erg y o f a n ind ivid u a l s tre a m is g ive n b y,

T o ta l In p u t E n e rg y o n w a rm -e n d (k J /h r) = S u m o f (M a s s F lo w ra te *E n th a lp y) o f In d iv id u a l in le t S tre a m s =

12 320 22 6+ 14 558 15 2+ 11 396 62 8+ 271 78 46 +1 176 71 1= 42 16 95 64 kJ/hr

T o ta l O u tp u t E ne rg y o n w a rm -e n d (k J / h r) = S u m o f (M a s s F lo w ra te*E n th a lp y) o f In d ivid u a l O u tlet s trea m s

= 1 9 1 0 6 8 + 6 6 5 6 4 6 6 + 1 2 9 8 0 8 0 2 + 1 7 3 3 7 5 9 1 = 4 1 8 0 0 9 3 5 k J /h r
91
D iffe re n c e in E n e rg ie s = In p u t – O u tp u t = 4 2 1 6 9 5 6 4 – 4 1 8 0 0 9 3 5 = 3 6 8 6 2 8 .7 0 k J /h r

Calculating Warm-end ΔT:

F o r c a lc u la tin g th e w a rm -en d ΔT,

m *C p * Δ T = D iffe re n c e in E n erg ie s

92
F ro m w h ic h , Δ T = D iffe re n c e in E n erg ies / (m *C p )

H ere, m = T o ta l In le t m a s s flo w ra te a ir,

C p = W eig h te d a ve ra g e o f C p o f in le t a ir s trea m

m = 3 9 8 0 1 .7 3 + 4 9 5 9 3 . 4 3 + 3 6 7 5 2 .6 5 + 8 6 7 3 .5 1 6 + 8 7 4 8 . 7 8 3 = 1 4 3 5 7 0 .1 k g / h r

C p = S u m o f (P ro d u c t o f in d ivid u a l m a s s f lo w ra te o f ea c h s trea m a n d C p o f th a t s trea m )/( To ta l

M a s s flo w ra te)

=(3 9 8 0 1 .7 3 *1 .0 5 9 3 + 4 9 5 9 3 .4 3 *1 .0 1 5 8 + 3 6 7 5 2 .6 5 *1 .0 8 4 3 + 8 6 7 3 .5 1 6 *1 .0 2 4 1 + 8 7 4 8 .7 8 3 *1 .0 1 8 6 )/(1 4 3 7
0 .1 )

= 1 .0 4 6 0 6 7 k J /k g -K

 Δ T = 3 6 8 6 2 8 .7 /(1 5 0 1 8 3 .9 ) = 2 .4 5 4 5 1 5 K (2 . 4 5 4 5 1 5 0C )
ΔT = 2.4545 0C

93
Efficiency of heat exchanger :

The efficiency of a heat exchanger can fall due to several reasons, including ¹ ² ³:
- *Fouling*: Accumulation of deposits on heat transfer surfaces, such as mineral scaling, biological
growth, or corrosion, which reduces heat transfer efficiency.
- *Improper Maintenance*: Failure to regularly clean and inspect heat exchangers can lead to reduced
performance and increased energy costs.
- *Operating Conditions*: Deviating from optimal temperature, pressure, and flow rates can significantly
impact heat exchanger performance.
- *Material Selection*: Using materials with low thermal conductivity or poor corrosion resistance can
reduce efficiency.
- *Fluid Quality*: Contaminated fluids can lead to scaling, corrosion, and other forms of fouling.

To raise the efficiency of a heat exchanger:

- *Regular Cleaning and Maintenance*: Schedule periodic inspections and cleaning to prevent fouling
and maintain optimal performance.
- *Optimize Operating Conditions*: Monitor and maintain optimal flow rates, temperatures, and
pressures to ensure effective heat transfer.
- *Use Advanced Materials*: Consider upgrading to materials with higher thermal conductivity or
corrosion resistance.
- *Implement Heat Recovery Systems*: Recover waste heat to improve overall efficiency and reduce
energy costs.
- *Utilize Advanced Monitoring Technologies*: Install sensors and data analytics to monitor
performance and identify areas for improvement.
- *Improve Fluid Quality*: Use filtration systems and monitor fluid composition to prevent scaling and
corrosion.

Additionally, consider the following strategies ⁴ :

- *Increase Fluid Velocity*: Boost turbulence to enhance heat transfer coefficients.
- *Use Enhanced Tube Surfaces*: Implement low-finned tubes or twisted grooved tubes to promote
turbulence and fluid mixing.
- *Install Tube Inserts*: Strategically place wire matrix or coiled wire inserts to generate turbulence and
improve heat transfer.
- *Vibration Equipment*: Use vibration equipment to dislodge fouling deposits and maintain clean tube
94
surfaces.
References:

1 . w w w .v iza g s te el.c o m ||D a te o f A c c e s s ed 0 2 / 0 6 / 2 5

2 . h ttp s :/ / en .w ik ip ed ia .o rg / w ik i/ V is a k h a p a tn a m _ Ste el_P la n t ||D a te o f A c c e s s ed 0 1 / 0 6 /2 5

3 . h ttp s :/ / en .w ik ip ed ia .o rg / w ik i/ H ea t_e xc h a n g e r# P la te_ fin _h e a t_e xc h an g er||D a te o f

A c c e s s ed 0 3 /0 6 /2 5

4 . h ttp :/ / w w w .th erm o p e d ia .c o m /c o n ten t/ 1 0 3 6 / ||D a te o f A c c e s s ed 0 2 / 0 6 / 2 5

5 . h ttp :/ /eth es is .n itrk l.a c .in / 2 9 7 / 1 /D E SIG N _ O F_ C O M PA C T_ PL A TE _F IN _ H E A T _E X C H A N

G E R 2 . p d f ||D a te o f A c c es s e d 0 3 / 0 6 / 2 5

6 . A d va n ta g e s o f B ra z ed H ea t E xc h a n g e rs in th e G a s P ro c e s s in g In d u s try, K ev in

M . Lu n s fo rd , B rya n R es e arc h & E n g g . , In c . , B rya n , T e xa s .

7 . h ttp :/ /w w w .lin d e-

en g ine erin g .c o m /in tern et. g lo b a [Link] d e en g in ee rin g .g lo b a l/ en /im a g e s/ P_ 3 _2 _e_ 1 2 _1 5 0

d p i1 9 _ 5 7 7 2 .p d f ||D a te o f A c c e s s ed 0 4 /0 6 / 2 5

8 . S im u la tio n o f m u lti s tre a m p la te-f in h ea t ex c h a n g ers o f a n a ir s e p a ra tio n p la n t, R B o eh m e,

J .A . R . P a ris e , R Pita n g a M a rq u es , C ryo g en ic s 4 3 (2 0 0 5 ), 3 2 5 -3 3 4

9 . E n e rg y a n d C o s t O p tim iza tio n o f a p la te a n d f in h ea t e xc h a n g e r u s in g G en e tic

A lg o rith m , H a m id rez a N a ja fi, B e h za d N a ja fi, Po o ya H o s e in p o o ri, A p p lie d T h erm al

E n g in e erin g , 3 1 (2 0 1 1 ), 1 8 3 9 -1 8 4 7

95