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Nishat Dying and Finishing Unit#42: Presentation On Water Flow Process and Power House of NDF Unit#42

This document provides an overview of the water treatment process and power systems at Nishat Dying and Finishing Unit #42. It includes details on the raw water intake and storage, sand filtration, reverse osmosis treatment, demineralization plants, engine house, boilers, cooling towers, and regeneration processes. The key systems include intake of 300m3/hr of raw water, 168m3 of sand filtration capacity, 123m3 of reverse osmosis treatment, 900m3 of demineralized water storage, 9MW of power generation from Wartsilla engines and boilers, and regeneration of the demineralization beds and mixed bed polisher in multi-step processes.

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Naveed Ul Qamar
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65 views

Nishat Dying and Finishing Unit#42: Presentation On Water Flow Process and Power House of NDF Unit#42

This document provides an overview of the water treatment process and power systems at Nishat Dying and Finishing Unit #42. It includes details on the raw water intake and storage, sand filtration, reverse osmosis treatment, demineralization plants, engine house, boilers, cooling towers, and regeneration processes. The key systems include intake of 300m3/hr of raw water, 168m3 of sand filtration capacity, 123m3 of reverse osmosis treatment, 900m3 of demineralized water storage, 9MW of power generation from Wartsilla engines and boilers, and regeneration of the demineralization beds and mixed bed polisher in multi-step processes.

Uploaded by

Naveed Ul Qamar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPSX, PDF, TXT or read online on Scribd
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NISHAT DYING AND FINISHING UNIT#42

Presentation on Water flow Process and Power House of NDF


Unit#42

Prepared by:

Waqar Sajid Khan

ORICHEM

Today Major Areas to Discuss are:

Water Process Flow of Plant


Raw water
RO water
DM water system
Engine House
Boilers
Cooling Towers
Compressor

Total Raw Water Capacity


300m3/hr
No. of Turbines
3
Capacity
100m3/hr (Each)
Depth of well
150ft (Each)
Industrial Water Pool Capacity 600m3
Raw Water FRP Tank Capacity
30m3

SAND FILTERS

No. of Sand Filters


4
Sand Filter#01
32m3
Sand Filter#02
24m3
Sand Filter#05
32m3
Sand Filter#06
80m3
Total Sand Filters Capacity
168m3
Iron Filter
01
Capacity of Iron Filter
50m3
Sand Filter Vessel
Make
MS
Design Pressure
6bar
Operating Pressure
3-4bar
Inside Lining
Epoxy
Outside Protection
Enamel

Filling Media
Sand Filte r
Graded Sand
Iron Filter
Silica Sand

RO PLANT

Total RO Capacity
NO of ROs
4
RO#1
24m3
RO#2
15m3
RO#5
24m3
RO#6
60m3
Total RO Pool Capacity

123m3
Rejection:
Rejection:
Rejection:
Rejection:
900m3

8m3
5m3
8m3
20m3

DM PLANT

Total Treated Water Capacity


150m3
No of Demin Plant
2
Demin-A
30m3
Demin-B
30m3
No. of Mixed Bed Plant2
Mix-A
45m3
Mix-B
45m3
Total Treated Water Pool Capacity 900m3
Demin Plant & MBP
1-Cation Resin Amberlite IR-120 Na
2-Anion Resin Amberlite IR 402 CL
Regeneration Time
MBP
3Hours
Demin Plants
2 and Half Hours.

POWER HOUSE

WARTSILLA ENGINE:
Fuel: HFO (Furnace Oil), LFO (Diesel) and
Methane.
Total capacity: 9MW
Working Capacity: 8.6MW
HT: In 85C & Out 91C
LT: In 39C & Out 40C
Lube Oil Temperature: 58C
Exhaust Temperature: 430-440C
Engine Type: Low Speed Engine (750rpm)
Chemical Using: DG-4109
Residual Limit:

Wartsilla Boiler:
Total Capacity: 8Ton
Type: Fire tube Boiler/WHRB
Fuel: Waste gases of Wartsilla
Engine/ Methane Gas, HFO & LFO
Fuel Ratio: 4 Ton on Warsilla WHR
& 4 Ton on Gas Burner.
Purpose: Chillers,Dying, Finishing,
Printing
Chemicals Use: Adv-6445 and CS
Residual limit for Adv-6445:

Wartsilla Cooling
Tower:
System Volume:
Number of Circulating pump:
Flow rate of pumps:
Chemicals Use: 189C, DS747, BS-250 & Bs-3204
Residual limit for 189C:
Recommended COC :
Circulation Rate: 250m3/hr

Caterpillar Engines:

3520E (1.5 Years Old)


Capacity: 2025KW or 2MW
Fuel: Methane Gas
JW: 87C t0 90C
AC:
Lube Oil Temperature: 89C
Exhaust Temperature: 576C
Engine Type: High Speed Engine
(1500rpm)
Chemical Use: DG-4109

3520C (5-6 Years Old)


Capacity: 1950KW or 1.9MW
Fuel: Methane Gas
JW: 87C t0 90C
AC:
Lube Oil Temperature: 89C
Exhaust Temperature: 576C
Engine Type: High Speed Engine (1500rpm
Chemical Use: DG-4109
Residual Limit:

CAT Cooling Towers:


Caterpillar Boilers (WHRB):
System Volume:
Number of Boilers: 2
Number of Circulating pump:
Total Capacity: 3Ton (1.5 Ton each)
Flow rate of pumps:
Type: WHRB
Fuel: Waste gases of Caterpillar EnginesChemicals Use: DG-308, DS-747, BS-250
Residual limit for DG-308:
Purpose: Chillers, Dying, Finishing, Printing
Recommended COC :
Chemicals Use: Adv-6445 and CS
Circulation Rate: 250m3/hr
Residual limit for Adv-6445:
Residual limit for CS:

Regeneration of Separate Bed DM:


There are 4 Steps to regenerate the exhaust vessel of cation or
anion.
1-Back wash: Water use enter from bottom and discharge
from top for 2 to 3 min.
2-Chemical Injection: HCL and caustic is use with DM water to
regenerate resin for half an hour and drain the solution through
the center of the vessel and Injection of chemical through
bottom.
3-Slow Rinsing: It is same as chemical injection but here only
DM water is inject though bottom and drain from center for
45min.
4-Fast Rinsing: Here RO water is used to inject from top to
bottom for 25 to 30min until the conductivity becomes less than
1 in Anion vessel.

Regeneration of MBP:
There are 10 steps to regenerate the MBP.
1-Back wash: Bottom to Top to mixed resin for 2-3 min.
2-Settling-1: Settling time required 5min.
3-Chemical Injection: Hcl mixed with DM water enter trough bottom and
caustic
with Dm water inject through top and both are drain through the
center of the
vessel for 30-35min.
4-Slow Rinsing: Same as Chemical Dosing with DM water for 40-45min.
5-Rapid Rinsing: Same as slow rinsing but RO water is use.
6-Drain Down: For 10 min drain water through center.
7-Air Scoring: Airflow from bottom to top for 15min to mix.
8-Settling-2: For settling 5 min required.
9-Fast Rinsing: Inject RO water through top and drain from bottom for 2530min.
10-Final Rinsing: same as fast rinsing but in this step we check PH and
Conductivity. When conductivity become less than 0.3 than system

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