CAKING PLANT

AT NFL, PANIPAT
 CAKING PLANT FLOW DIAGRAM

NFL TANK Slurry CCIL Tank Slurry In Magnet

Carbon Traps
Carbon
Slurry Pipe line
Slurry
500 KL mounted
200 KL

Slurry In
NFL PIT Filtrate
No-114
Slurry
Filtrate Receiver Filtrate Out Dewatering
Tank Filter Press
Filtrate 10KL 2500 L
NFL Tank
No-112A
 CARBON SLURRY COLLECTION AT CAKING PLANT

@ 7-70 m³/hr (max)

From NFL
Slurry at 90°C To Circulation Pump
Carbon
slurry 20 m³/hr, Centrifugal,
transfer 3.5 -5.0 kg/cm²,
pump MOC-PP
500 KL Storage
Tanks (MS)

• Transfer of FDSK from NFL tank -200 KL and through (NFL) pump to 70% level of CCIL tank.
• Circulation pump run continuously and stop at low tank level.
• Pipe size is 100 mm, MOC-MS.
• Slurry has high foaming tendency due to high alkalinity and gases.
 MAGNETIC REMOVAL FROM SLURRY

To Circulation Pump
20 m³/hr , Centrifugal,
3.5 -5.0 kg/cm²,MOC-PP

Magnetic Trap 500 KL Storage

Tanks (MS)

• CB slurry at 3-5 kg/cm² pr. Parallel pass through 3 no’s of magnet traps in series
• of+ 10000 gauss field strength for removal of >1µm of magnetic impurities.
• Manual isolation & cleaning of each traps with water hourly after individual isolation &
bypass slurry.
 FILTER PRESS FEEDING

Feed Pump: Centrifugal,

20 m³/hr, 4.0-6.0 kg/cm²,
MOC-SS316L

500 KL Storage Filter Press

Tanks (MS)
• Filter press unit, 1 no., with 5-8 micron Filters and batch operation..
• Output cake 24 mm thick and CB content of 15% by wt .
• Sample Check and recording of cake moisture content.
• Batch time of 4 hr for 40 m³ slurry feed in 2 hr, cake squeezing 0.5 hr, cake discharge
and closing 1.5 hr.
 FILTER PRESS CAKING

Wet Carbon cake

2200 kg/Batch
To Belt conveyor

10 KL Tank Water
20 m³/hr Storage Tank
Feed Pump 2500 L
Pr. 8.0 kg/cm² Membrane
Filter Press
MOC-PP

• One Membrane Filter Press, Cap.2500 L of PP, High temp.>90°C,Chamber 32 mm,

batch time of 6hr.
• Manually release cake on batch completion ,1 plate/min.
• Data logging for field instruments and recording filter cloth condition.
• Maintain filtrate water clear of carbon by control on feed pr. and record hourly flow.
• Data logging for cake qty. released per batch along with batch time.
• cake feed to pre-crusher for size reduction.
 CLEAR WATER TRANSFER TO NFL

Centrifugal Pump
10 m³/hr, 3-5 kg/cm²,
10 KL Tank Water MOC-PP
Storage Tank

NFL’s Water storage tank

No. 112 A & 114 pit

• Pipe size of return water to NFL tank is 100 mm & MOC-MS.

• Pipeline laying in same rack & rout.
 CARBON CAKE SIZE REDUCTION

Cake size (max.)

500 x 500 x 32 Cake size
Cake from (max.) 10 x 10
mm
Filter Press x 10 mm
To 50 kg sacks
1200 mm 2000 kg/hr Bagging
Belt Conveyor Screen less
Pre Crusher

• One EPDM Belt conveyor, 1200 mm wide for feeding to pre crusher.
• One twin rotor screen less pre-crusher, 30 hp drive.
• Manual start up of pre crusher to be done before running of conveyor.
• Cake feeding to be done based on crusher load, manually.
• Manual bagging of 10 mm cake in 50 kg PE sacks (Dual bags) for transport.
• Data logging for no of bags packed and coding batch no. on sacks.
 CARBON CAKE TRANSPORT TO CCIL

Cake sample Cake Bag Transport

moisture test (By Road) to CCIL
at NFL lab in wt% Total-208 (10.4 MT)

Carbon Cake
50 kg PE bags
To Storage
Total No.-208/Day
Storage Shed Truck Weighment
Loading Bay
Capacity-20 MT At NFL Weighbridge

• Dust free warehouse shed area of 90 m² for 20 MT cake storage, 3 days inventory.
• Manual loading of bags for truck load of 10.4 MT at loading bay.
• Inventory of cake to be maintained for 3 days maximum.
• Test moisture through moisture analyzer (report to 0.1%) for out bound material.
• After loading of bags, final weighment to be done at NFL weighbridge.
• Data logging for daily truck load of material with moisture result.