May 3, 2023 1

SO2 Conc. Measurement Recorded as per PCB Limit

Noticeable Result

Measured –ppm

Date of Activity & Condition

Actual Condition No. of Observations

Total Slurry Flow –KL/Hr

B/H – I/L

Temp.

Gas Sample

Solid Sample

2

24/05/09 – Rajasthan Lime Quality - KF Feed Rate – 42 TPH

and Feed Sulfur -3.02% with Only GSA in Service

11.9 88 3 1

504/03/09 – Ash Recycling &

Feed Rate - 42 TPH with DTA Blend Only GSA in Service

9.97 95 3 1

3 11/02/09 – DTA Blend with FGD in Service – 42 TPH 8.5 95 3 0

13

11/11/08 – DTA Blend – 46 TPH FGD (3.5 KL) in Service and

GSA(7.7 KL) 11.2 95 2 0

9 ~ 13

11~14 July -2008 With GSA & FGD in service and 3.5 KL Water

in GSA .KF rate 46 & 44 tph, input Sulfur 2.12 ~ 2.60

9.3 ~ 9.6 80 6 4

May 3, 2023 2

MOL Solids Conc. at Normal Lime and High Pure Lime during various trial conditions.

Density Range

Solids (%) Measured at different Samplings with Normal Slaking conditions

1.070 14.74 15.03 17.13 13.96 17.67 14.23 14.58 14.44

1.075 12.0 14.8

1.080 16.84 16.14 15.92 16.01 15.89 17.07 15.75 17.34

1.085 15.30 16.85 17.9

1.090 17.59 16.20 18.12 17.86 19.4 18.7 19.3

1.095 16.25 19.5

1.10 23.10 21.08 20.72 20.20 19.54 20.33 19.10

1.105 19.98

1.11 21.29 22.0 22.15 20.50

1.115 20.38 19.77

1.120 23.10 21.32 20.32

1.125 25.49

1.130

1.135

1.140 21.85

May 3, 2023 3

SO2 Gas & Lime Load at FGD & GSA Combination Kiln-2

SO2 Measured-

ppm

BH Temp. Condition

Total Slurry + Water Flow –

KL/Hr

Lime Load –Kg/Hr

SO2 Load – Kg/Hr

SO2 On Line - ppm

11 78 9.4 + W 1795 511 155

11 80 9.3 + W 1832 573 148

36 85 10.8 + W 2116 671 132

268 90 13.8+0 2097 982 273

209 90 14.0+0 2483 744 211

41 95 (Raj . Lime) 9.8 +0 1772 826 106

486 95 11..2 1874 863 565

252 100 10.0 1674 370 447

339 105 10.0 1875 382 376

764 115 10.3 1284 666 805

May 3, 2023 4

SO2 Gas & Lime Load at only GSA –Kiln-2 Operation

SO2 Measured- ppm

BH Temp. Condition

Slurry Flow –KL/Hr / Type

Lime Load –Kg/Hr

SO2 Load – Kg/Hr

SO2 On Line - ppm

5 95 9.97 + Ash 2432 332 12

107 90 11.86+ Ash 2842 811 206

--- 90 10.18 + Ash 2416 477 1

364 91 10.9 1898 931 344

304 91 10.5 1828 690 331

557 102 10.1 + Imp. Lime 1389 829 408

330 90 10.77 + Ash 2968 802 332

276 91 10.5 + Hy. Lime 1728 694 294

72 91 11.9 + Ash 2775 695 100

36 91 11.5 + Raj. Lime 2382 799 61

2 88 12.0 + Raj. Lime 2429 702 32

228 89 12.0 + Ash 3507 761 251

114 95 12.0 + Ash 3955 859 340

0 100 10.1 + Ash 3269 440 104

May 3, 2023 5

Sampling & Activity During 2008~09 Month / Year Activity Carried out Gas Samples

AnalyzedSolid Samples

AnalyzedDuration

May & June - 08

Bag House –I/L temp. with 85 oC FGD GSA in Service

46 42 28 Days

July - 08 Bag House –I/L temp. with 80 oC FGD GSA in Service and Feeder Box Size distribution in varying rpm.

10 10 5 Days

Aug ~ Sep - 08

Study with Corrosion Coupons @ 105 , 100 & 95 Deg.C

12 8 12 Days

Oct ~Nov - 08

Study with Corrosion Coupons after replacing with New Bags @ 98 7 95 Deg.C and .CaCl2 dozing study.

22 5 25 Days

Dec -08 & Jan-09

New Kit Set Up and Implementing ISO Method for SO2 Analysis.

9 0 7 days

Feb-09 High Pure Lime Development Samples

0 5 2 Days

Mar-09 Ash Recycling with MOL 12 11 25 days

May 3, 2023 6

Sampling & Activity During 2008~09 Month / Year Activity Carried out Gas Samples

AnalyzedSolid Samples

AnalyzedDuration

Mar - 09 Moisture and Bulk Density Measurement

--- 10 5 Days

Size Distribution of Ash Samples for Jams

0 10

Apr - 09 High Pure Lime Slaking and GSA Operation

22 7 3 Days

May - 09 Hydrated Lime Study and Monitoring and Ash Recycling

10 6 7 Days

June - 09 Comparing Kiln-1 and Kiln-2 Operation

10 7 Days

July-09 Ash Recycling in Kiln-2 5 3 Days

August-09 Ash Recycling in Kiln - 1 & 2Slaker Grit Analysis

19

--- 2

10 Days

5 Days

Sept-09 Ash Recycling in Kiln - 1 & 2

Slaker Grit Analysis

8

--- 2

5 Days

7 Days

May 3, 2023 7

Activity MonitoredRunning Condition - Fly Ash Size Distribution

Retained on Mesh Size /

Activity Type

Normal Lime Run – 2.0 TPH

Hydrated Lime – 1.7 TPH

Rajasthan Lime - 2.4 TPH

Ash + Slurry Mixing – 2.5 TPH

% Retained across each distribution

212 -Microns 0.1 0.08 0 0

106 Microns 0.8 1.50 1.26 0.5

53 microns 5.1 5.54 8.5 6.5

45 Microns 0.3 2.94 1.8 3.96

- 45 microns 93.8 89.94 88.38 88.98

May 3, 2023 8

Activity MonitoredRunning Condition - Fly Ash Size Distribution

Vimta Lab’s Particle Size Report

Retained on Mesh Size

MOL -117.5 % Solids

MOL -2 25.5 % Solids

Fly Ash Sample -1 Fly Ash Sample -2

30 Micron 0 0.1 0 0

20 Micron5.7 8.5 5.1 1.5

10 Micron39.6 40.1 33.5 35.3

5 Micron34.8 33.6 40.8 42.9

- 5 Micron 19.9 17.8 20.6 20.3

Sp. Surface Area ( m2 / cc )

MOL Fly Ash

0.7564 0.7182 0.8393 0.8189

May 3, 2023 9

Activity MonitoredJam Condition Condition - Fly Ash Size Distribution

Retained on Mesh Size /

Activity Type

Normal Lime Run – 2.0 TPH

Hydrated Lime – 2.0 TPH

Rajasthan Lime - 2.4 TPH

Ash + Slurry Mixing – 2.7 TPH

% Retained across each distribution

212 -Microns 1.28 0.50 0 0.7

106 Microns 3.72 8.50 3.14 6.80

53 microns 14.62 17.5 13.7 10.4

45 Microns 2.8 1.2 1.7 3.96

- 45 microns 77.58 72.3 81.46 78.14

May 3, 2023 10

Activity MonitoredAsh Quality Range

Retained on Mesh Size /

Activity Type

Normal Lime Run – 2.0 TPH

Hydrated Lime – 2.0 TPH

Rajasthan Lime - 2.4 TPH

Ash + Slurry Mixing – 2.7 TPH

% Retained across each distribution

Moisture 1.05 1.29 1.08 1.37

LOI 21.0 24.3 23.8 27.6

CaO 44.2 49.35 54.39 41.7

CaSO4.2H2O 4.56 8.37 5.65 3.74

May 3, 2023 11

Activity MonitoredCaO Dilution & Slaker Grit Measurement

Retained on Mesh Size /

Activity Type

Normal Lime Run – 3.42 TPH April - 09

Hydrated Lime2.0 TPHMay-09

Rajasthan Lime - 3.8 TPH

May-09

Imported Lime - 2.85 TPH

April-09

Water / Lime Ratio

3.91 5.25 5.78 5.43

% Grit Generated

31.48 0 5.7 5.2

Water rate KL

13.4 10.5 22.0 15.5

Lime CaO(%) 72.0 66.0 89.0 92.0

Net CaO (%) in MOL with Zero Grit

37.0 39.5 41.49 51.19

MOL Density 1.10 1.095 1.095 1.072

MOL Solid Conc. (%)

21.42 19.5 19.5 14.8

May 3, 2023 12

Consistency of Wet Analysis with Online -ppmKiln-1 Kiln-2

Date Online Value-ppm

Wet Analysis - ppm

Date Online Value-ppm

Wet Analysis - ppm

Nov-08 640 842 Nov-08 803 653

Feb-09 521 547 Jan-09 651 606

Mar-09 565 631 Mar-09 7 9

Apr-09 460 489 Apr-09 185 178

Jun-09 130 112 May-09 100 72

Aug-09 40 14 Aug-09 415 381

Sep-09 69 45 Sep-09 75 152

Dec-09 205 180 Oct-09 256 140

Jan-10 159 140 Nov-09 530 454

Sep-10 76 77 Dec-09 280 254

Oct-10 78 74 Jan-10 390 349

May-10 235 209

Sep-10 400 1503

Oct-10 160 122

May 3, 2023 13

Training & Testing Review• Sample Collection and Analysis of Sample

was divided in to Cal. Process and WC Technicians.

• 10 No. of Technicians were trained from Cal . Process with improved ISO Method in Gas Sample collection and Trouble Shooting as well. All the WC Lab Technicians were able to analyze Gas Sample and Gypsum Sample.

• 5 No. of Technicians were able to do Lime Slaking Test , Size Distribution , Moisture and Bulk Density for review to ascertain problem.

• Total NO. of Gas samples of 143 and Solid samples of 114 was reviewed with the able support of Calcinations Process & Water Chemistry Departments.

• QC lab Collected MOL Samples during each Monitoring time to evaluate Solids which is more important parameter for the total review.

• QC Lab also carried out the Grit Samples Moisture and Size Distributions of Normal and High Pure Lime trials.

S.No. Cal. Process Technician

WC Dept. Technician

1 Rajasekhar (Late)

Chinnarao-Working

2 N.Rajasekhar-Working

B.Sriivas-Working

3 Satyanarayana-Working

P.Srinivas-Working

4 Sombabu-Working

Vasu-Working

5 Suresh-Left Trinadh-Left

6 Hemanth-Working

7 Mohan Krishna-Left

8 N.Prasad-Working

9 Ramanamurthy (Late)

10 Srinivas-Working

11 Mahesh -Working

May 3, 2023 14

Lime spray dryer process (LSD or Semi-dry process)

May 3, 2023 15

Lime spray dryer process (LSD or Semi-dry process)

• Main advantages of Lime spray dryer process • Dry process (> solid effluent easy to handle)

• Low Investment cost

 • Main disadvantages of Lime spray dryer process • Stoechiometric ratio (> more reagent is required to achieve the

removal of 1 ton of SO2)  • No easy by-product valorization (> effluent to be landfilled)

May 3, 2023 16

SO2 Gas & Lime Load during GSA operation in 2008-09 Kiln -1

SO2 Analyzed -ppm

BH-I/L Temp

Slurry KL/Hr

Water KL / Hr

Lime Kg/Hr

Total Solids (%) Conc.

Ash + Slurry kg / Hr

KF-Rate -MT/Hr

SO2 Load Kg/Hr

SO2 Online -ppm

13 93 8.66 5.69 4183 32.57 6038 46 816 45

--- 95 13.28 0 3046 20.85 3046 40 501 11

138 95 9.5 4.0 1875 31.55 4026 40 797 230

139 100 12.0 0 2369 18.11 --- 40 796 437

112 90 12.7 0 2280 17.95 --- 42 715 190

390 95-Raj 5.06 7.60 964 17.7 --- 48 925 371

768 97 7.09 7.82 1286 15.14 2879 48 1431 550

918 105 6.24 5.55 2642 35.86 3879 48 927 579

595 110 6.8 3.8 1578 21.11 ---- 48 927 489

765 115 3.4 6.7 482 13.12 --- 48 677 439

May 3, 2023 17

Some Measurements of SO2 Gas & Lime Load with Ash Recycling in GSA operation in Kiln -1 during 2010

Run Period

BH-I/L Temp

Total Slurry KL/Hr

Water KL / Hr

Lime Kg/Hr

Online T Slurry Density-g/cc.

Ash + Slurry kg / Hr

KF-Rate -MT/Hr

SO2 Load Kg/Hr

SO2 Online -ppm

Jan-10 105 11.16 3 . 2 1291 1.164 1830 48.2 950 308

Feb-10 89 14 . 0 4 . 0 1050 1.209 3030 47.9 719 16

Mar-10 90 13.11 5 . 5 754 1.125 1638 48.2 675 70

May-10 89 12 . 9 6 . 4 660 1.176 2270 46.45 1019 325

Jun-10 89 12 . 9 3 . 15 980 1.217 2799 44 . 8 758 63

Aug-10 88 13 . 3 4 . 6 870 1.205 2726 45 . 0 792 102

Sept-10 94 13 . 4 5 . 9 750 1.152 2036 42 . 0 870 235

Oct-10 101 11.3 3.4 790 1.134 1514 42 . 0 715 221

Nov-10 97 11.99 4 . 17 782 1.154 1846 42.1 881 304

Dec-10 89 14.80 2.8 1200 1.211 3122 46.1 841 32

May 3, 2023 18

Some Measurements of SO2 Gas & Lime Load with Ash Recycling in GSA operation in Kiln -2 during 2010

Run Period

BH-I/L Temp

Total Slurry KL/Hr

Water KL / Hr

Lime Kg/Hr

Online Slurry Density-g/cc.

Ash + Slurry kg / Hr

KF-Rate -MT/Hr

SO2 Load Kg/Hr

SO2 Online -ppm

Jan-10 89 14.11 6.11 800 1.181 2553 49. 2 962 70

Feb-10 90 13.42 6. 98 698 1.208 2719 46. 9 536 58

Mar-10 90 13.11 5 . 5 754 1.125 1638 48 . 2 675 70

May-10 89 10.40 5 . 7 470 1.188 1955 46 . 0 1058 260

Jun-10 89 12.35 4 . 65 770 1.191 2358 44 . 2 1487 703

Aug-10 89 12.04 3 . 64 840 1.219 2636 45 . 0 821 160

Sept-10 91 12.58 5 . 58 700 1.167 2100 42 . 0 907 255

Oct-10 90 11.50 4 . 5 700 1.218 2507 42 . 0 740 120

Nov-10 97 11.13 4 . 39 674 1.174 1936 42 . 0 790 160

Dec-10 89 12.0 2. 0 1000 1.218 2616 42.0 815 117

May 3, 2023 19

SO2 Gas & Lime Load during GSA operation during 2008-09 in Kiln -2

SO2 Analyzed -ppm

BH-I/L Temp

Slurry KL/Hr

Dill Water KL / Hr

Lime Kg/Hr

Total Solids (%) Conc.

Ash + Slurry kg / Hr

KF-Rate -MT/Hr

SO2 Load Kg/Hr

SO2 Online -ppm

100 89 12. 0 0 2527 31.55 4806 40 785 180

0 108 5.32 4.8 1289 49.55 3269 42 440 104

228 89 10.4 3.57 1201 29.32 3507 47 761 251

364 91 10.9 0 1898 21. 0 --- 42 931 344

242 90-Spl 9.38 0 1897 20.2 ---- 38 648 251

294 91-Hy 10.5 0 1590 15.5 --- 42 693 310

440 91-Hy 10.5 0 1040 14.6 --- 42 693 510

313 105 10.3 0 1771 15.92 --- 48 842 434

557 102-Imp L

10.1 0 1901 19.1 --- 48 829 408

31 91-Raj. 11.5 0 1986 19.0 --- 42 796 61

2 88-Raj. 11.9 0 2055 18.6 --- 42 821 31

May 3, 2023 20

MOL Solids Concentration at Specific Density Measurement before and after Mixing Ash ( Aug -09)

MOL Slurry Quality from Slaker Slurry after Mixing Ash – Kiln-2

Density Range

Solid Concentration (%) Density Range

Solid Concentration (%)

1.04 11.08 6.66 1.13 24.22 25.88 24.941.05 11.0 13.65 1.14 26.521.06 12.36 15.0 14.28 1.15 29.32 28.55 26.421.07 14.01 14.35 15.56 1.16 31.58 29.1 28.661.08 16.22 1.17 31.8 29.66 29.871.09 18.54 19.28 19.65 1.18 34.32 32.331.10 18.99 20.66 20.14 1.191.11 20.85 20.18 22.31 1.20 36.791.12 23.30 1.211.13 25.55 26.12 26.85 1.23 38.73

May 3, 2023 21

MOL Solids Concentration at Specific Density Measurement before and after Mixing Ash ( Sep -09)

Density Range

Solids Conc. – Slaker

Ash Mixing for Kiln-1 Tank

Ash Mixing for Kiln-2 Tank

1.04 1.10 19.3 20.04 22.01 23.06

1.05 10.06 1.14 26.13 24.76

1.06 10.20 1.15 28.96

1.07 15.08 1.16 27.84

1.08 16.69 17.24 17.11 1.17 33.11

1.09 17.55 17.89 1.18

1.10 1.19. 33.99 36.58 35.55

1.11 21.55 20.52 1.20 35.43 37.78

1.12 24.55 23.08 1.21>

49.99

May 3, 2023 22

Back Ground Results of SO2 Without Ash Recycling in Kiln-1

Period F/R-MT/Hr

Slurry Flow –KL/hr

Lime Load-kg/Hr

Bag House-I/L Temp.

Slurry Density-g/cc

SO2 Load-Kg/Hr

SO2 by Analysis -ppm

On Line Emission of SO2 - ppm

Nov-2008

46 3.5 210 115 1.060 1252 1219 617

26/12/08 48 6.2 248 115 1.040 1192 928 514

Apr-09 48 6.8 680 105 1.100 927 595 489

Jun-09 42 10.5 945 105 1. 090 752 244 270

Jun-09 42 12.7 952 90 1 . 075 711 112 130

May 3, 2023 23

Back Ground Results of SO2 Without Ash Recycling in Kiln-2

Period F/R-MT/Hr

Slurry Flow –KL/hr

Lime Load-kg/Hr

Bag House-I/L Temp.

Slurry Density-g/cc

SO2 Load-Kg/Hr

SO2 by Analysis -ppm

On Line Emission of SO2 - ppm

Jun -2007

52 11.7 784 115 1.067 1365 795 915

Mar -2008

48 9.1 1064 105 1.117 678 48 144

Aug-2009

47 12.3 1845 89 1.150 761 239 450

May 3, 2023 24

Latest Results of SO2 for comparison Analysis Vs Online – Kiln-1

Period F/R-MT/Hr

Slurry Flow –KL/hr

Total Lime Load-kg/Hr

Bag House-I/L Temp.

Slurry Density-g/cc

SO2 Load-Kg/Hr

SO2 by Analysis -ppm

On Line Emission of SO2 - ppm

21-Dec-10

42 13.5 2835 89 1.210 854 6 72

23-Dec-10

42 13.5 3213 89 1.238 845 72 160

28-Dec-10

46 14.8 3108 89 1.210 841 3 30

31-Dec-10

47 16.5 3036 89 1.184 873 34 90

21-Jan-11

39 13.0 89 1.158 612 43 67