431G 432G

Training Manual Green Anode Plant
Vedanta - Jharsuguda
14
138-02-043
Group 431/432 G
DE-060300
PROCESS GROUP 431/432 G - PITCH FUME TREATMENT -
Process Group 431/432 G - Pitch Fume Treatment -..................................................................1

14
14.1
Process .......................................................................................................................................1
14.1.1 Process Flow Sheets...................................................................................................................1
14.1.2 Brief Process Description ............................................................................................................2
14.1.3 Main Process Data & Process Highlights ....................................................................................3
14.2
Process Control...........................................................................................................................6
14.2.1 P&Id`s, Operator Screen Images ................................................................................................6
14.2.2 Control Logic Description ............................................................................................................7
14.3
Main Equipment ..........................................................................................................................8
14.3.1 Fresh Adsorbent Divider 431/432 G 013 .....................................................................................8
14.3.2 Air Heater Unit 431/432 G 050 ....................................................................................................8
14.3.3 Hot Air Dilution Chamber 431/432 G 055 ....................................................................................8
14.3.4 Knife Gate (pneumatic) 431/432 G 065.......................................................................................8
14.3.5 Throttle Flap (dead weight type-pneumatic) 431/432 G 080 .......................................................8
14.3.6 Vane Controller (pneumatic) 431/432 G 130...............................................................................8
14.3.7 Reactor-Filter-Unit 431/432 G 100/115/120 ................................................................................9
14.3.7.1 Technical Data ............................................................................................................................9
14.3.7.1.1 Reactor 431/432 G 100 .........................................................................................................9
14.3.7.1.2 Filter 431/432 G 115/120.....................................................................................................10
14.3.7.2 Drawings ...................................................................................................................................11
14.3.7.3 Equipment Description ..............................................................................................................12
14.3.7.3.1 Reactor 431/432 G 100 .......................................................................................................12
14.3.7.3.2 Filter Unit 431/432 G 115/120 .............................................................................................13
14.3.7.4 Regular Checks.........................................................................................................................37
14.3.7.5 Maintenance..............................................................................................................................40
14.3.7.6 Safety ........................................................................................................................................51
14.1
Process
14.1.1
Process Flow Sheets

(Work Copy)
Outokumpu Technology GmbH

file: 138-02-043_14_0.doc, Codeword: Vedanta
Revision: 0
Date: 29.09.2006
Page 1 of 53

14.1.2
138-02-043
Group 431/432 G
DE-060300
Brief Process Description

(Work Copy)

Page 2 of 53
Revision: 0
Date: 29.09.2006
CONTROL PHILOSOPHY
05.10.2006
1 (2)
Rev. 00
Vedanta Alumina Ltd.

Jharsuguda Green Anode Plant
Client ref.: VJ/SML/PO/032/1
OTK ref.:
DE-060300
Doc. No.:
133-50-071
Brief Process Description

of
Process Group 431-G
Pitch Fume Treatment Reference:
Process Flow Sheet
132-01-083 UB
P+I Diagram
168-01-063 UB
The process is described in order to the material flow whereas the control philosophy is written
in order to the signal flow, which is counter current to the material flow.
This Process Group 431 G collects pitch fumes from the following other Groups:
431 J Paste Mixing & Cooling

431 K Paste Weighing
431 L Anode Forming
431 N Vacuum System
431 P Green Anode Transport
An air heater (431 G 050) is used to keep the waste gas, collected from the paste cooler (431
J 200), above water dew point temperature to prevent condensation of evaporated cooling
water. To achieve the aforesaid, the complete pitch fume dry scrubbing system shall be
preheated to operation temperature before starting of anode production and sucking off pitch
fumes. The envisaged operating temperature, measured in the stack [431 G 135-TIR], has to
be varied from about 25C (winter) to about 65C (summer) with the actual ambient
temperature and humidity. The best operating temperature has to be found out during
commissioning. It is most important that at all points of high humidity like the duct work
downstream the hot air dilution chamber (431 G 055), the reactor (431 G 100), filter (431
G120), fan (431 G 135) and the stack the gas temperature is always at minimum 5C higher
as the water dew point in order to prevent clogging of ducts, the reactor fluid bed bottom and
of the filter bags.
As soon as the operating conditions (waste gas temperature, fluid bed height) are reached,
anode production may start while then pitch fumes are set free from hot anode paste. Because
all equipment for anode paste handling is covered or hooded the pitch fumes are collected and
sucked through a pipe work into the settling chamber (431 G 060), where a part of the anode
paste particles and pitch fume droplets, coming with the fumes, are separated.
From the settling chamber the fumes are sucked through a duct and a throttle flap (431 G
080), which is opened pneumatically and is closed by counter weight. If high temperature is
measured in certain ducts [431 G 055-TAHH; 431 G 060-TAHH; 431 G 080-TAHH] this Group
is shut down automatically and the throttle flap (431 G 080) closes.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
2 (2)
Rev. 00
Fresh adsorbent from the fresh adsorbent bin (431 F 450) is reclaimed by a rotary lock with
variable speed drive (431 G 010). Continuous discharge of fresh adsorbent is maintained by
an aeration unit (431 G 006), which is pulsing compressed air into the bin bottom. The two
hand-operated butterfly valves (431 G 020 / 025) and a bulker bag (431 G 030) are used to
calibrate the feed rate of the rotary lock.
The fresh absorbent is fed via an fresh adsorbent divider (431 G 013) to the suction points of
pitch fumes from the mixer unit (431 J 100), the vibrating feeder (431 K 005), behind the hot
air dilution chamber and to the main gas duct where pitch fume loaded waste gases are
intensively mixed with the injected adsorbent while gas and adsorbent are transferred into the
fluid bed reactor (431 G 100).
In the reactor the mixture of waste gas and adsorbent passes through perforated plates at a
velocity required to form a uniform fluid bed on top of the plates.
A multiple adsorption of condensed hydrocarbons takes place in the main raw gas duct, the
reactor hoppers, fluid bed and on the filter bag surface of the bag filter (431 G 120).
To achieve a maximum removal of the condensed and solid pitch particles from the waste gas
stream, the requested height of the fluid bed is automatically build up and maintained by
means of a control unit, which is measuring the differential pressure across the fluid bed and
so regulates the fluid bed height by starting and stopping the rotary locks (431 G 200 / 205),
which are discharging the reactor hoppers. The bag filter (431 G 120) above the fluid bed
recovers the dust from the gas flow drawn by a Fan (431 G 135).
Loaded adsorbent enriched with condensed pitch fumes will be periodically discharged from
the fluid bed by means of two rotary locks (431 G 200 / 205) and subsequently transferred by
screw conveyors (431 G 220 / 225) into the bin for "Loaded Adsorbent (431 G 300).
After the anode production has been stopped, only the fresh adsorbent feed (rotary lock 431 G
010) is shut off, while the rest of the Group (fan 431 G 135, dust collector 431 G 120, air
heater 431 G 050 is kept running and kept warm, being ready for the next start of anode
production. The rest of the discharge system for loaded adsorbent (screw conveyors 431 G
220 and 431 G 225) are kept running, the rotary locks (431 G 200 / 205) are still enabled to
run on request and the knife gates (431 G 210 / 215) are kept closed.
If the pitch fume dry scrubber system has to be shut down totally because of a longer stand
still, the fan (431 G 135), the dust collector cleaning system (431 G 120), the rotary locks (431
G 010 and 431 G 200 and 431 G 205) are shut off instantly, the knife gates (431 G 210 and
431 G 215) will open and a part of the fluid bed will be removed from the reactor. The screw
conveyors (431 G 220 and 431 G 225) will transfer the loaded adsorbent into the bin for
"Loaded Adsorbent (431 G 300) for storage. After run empty of the loaded adsorbent is
terminated, all equipment still running is shut off and the knife gate (431 065) opens to allow
the slurry of pitch condensates and anode paste fines to run down into the pitch barrel (431 G
075) located underneath the settling chamber (431 G 060). It is most important that the door
for removing the pitch barrel is closed tightly to prevent cold fresh air from coming in the
housing when the knife gate is open.

14.1.3
138-02-043
Group 431/432 G
DE-060300
Main Process Data & Process Highlights

Operating Principle of the OUTOKUMPU Dry Scrubber
To be treated in a dry scrubber gaseous pitch fumes have to be condensed first. Only
fumes with due points above the actual operating temperature (40 60C) are condensing
to small droplets normally visible as fume. Other components or so-called lighter
fractions will be removed (adsorbed) only in a very low percentage.
Most of the very small sized droplets of condensed pitch fumes are of less than 5 micron
diameter and so would pass the pores of a filter bag fabric in a high percentage. Because
they are organic liquids they would wet it and close the pores plugging the whole filter
bags.
The basic principle of this type of dry scrubber is as follows:
In a dry scrubber condensed pitch fume droplets have to pass zones of high adsorbent
dust concentration and get there in contact with relatively big grains of mainly 5 300
micron. If a droplet hits an adsorbent grain it is most likely that it sticks on the grains
surface. The higher the number of grains the higher is the chance of a droplet to be
caught. Very fine droplets, which are now sticking on the large adsorbent grains, are
held back by the fabric together with the grain and can be removed from the gas stream
so that the gas stream is now clean. The grainy material is commonly called Adsorbent.
It must be coarse enough to be collected in a filter bag but at the other hand it must be
small enough to be easily fluidized and transported by a gas stream. The most
advantageous aspect of this scrubbing principle for use in an anode plant is that a fraction
required in the anode production process can be used as the adsorbent, the Ball Mill
Product fraction.
In the OUTOKUMPU dry scrubber this effect takes place first in the collecting waste gas
pipe right after the points where fresh adsorbent (ball mill dust) is added. The dust
concentration at this point can be up to 50 g/m.
The second but main stage of the OUTOKUMPU scrubber is the Fluid Bed Reactor. The
advantage of this principle is that a droplet passes an approximately 250mm high fluidized
bed of adsorbent with millions of grains per cubic centimeter. The adsorbent concentration
is here so high (up to 250,000 g/m) that there is nearly no chance for a droplet not to be
caught.
The next scrubbing stage is the space above the fluid bed up to the filter bags. This is a
very dusty area with an adsorbent concentration estimated to be about 500-800 g/m.
The last barrier for the droplets is the adsorption layer on the filter bags. This layer is built
by ball mill dust and is relatively thin but compact with very small pores for the air to pass.
In total the OUTOKUMPU pitch fume scrubber has 4 adsorption zones and is therefore
most efficient.
Another advantage of this fluid bed type scrubber is the availability in case of a lack of
fresh adsorbent. If one of the fresh adsorbent feeding equipment, for instance one rotary
lock is out of order, the system is not to shut off. For the next 2 hours there is always
enough adsorbent in the scrubbers fluid bed available to maintain the scrubbing process
and to continue anode production or to shut down the system regularly if maintenance
needs longer time. It is only the fan and the bag cleaning mechanism, which is always
required to keep the system running. This gives more system availability and more
flexibility in operation.

Revision: 0
Date: 29.09.2006
Page 3 of 53
138-02-043
Group 431/432 G
DE-060300

Main Technical Data of the Scrubbing System

Design capacity reactor/filter:
Design capacity fan;
Operating capacity:
Operating temperature:
Fresh adsorbent feed rate
Exhaust gas quality
Total scrubber pressure drop
Available under-pressure at reactor
inlet flanges:
Calculated under-pressure at reactor
inlet flanges with clean ducts:
Air heater design data:
Air heater expected operating data:
55,000 Acm3/h at 60C gas temperature and

1013 mbar
55,000 Acm3/h at 60C gas temperature and
1013 mbar
approx. 52,000 Acm3/h at approximate 45C
gas temperature, ambient pressure
30C to 60C, depending on the ambient
temperature in the anode plant.
1200 kg/h- normal operation
2400 kg/h start operation
10 mg/m3 particulates
5 mg/m3 - condensed pitch fumes
3.75 kPa - design
2.25 kPa - expected operating average
4.0 kPa
2.0 kPa
Flow rate: 4500 m3/hour
Temperature (design): 200C
Power (design): 220kW
Flow rate: 2500-4000 m3/hour
Temperature: 100C (depending on air inlet
temperature)
0.035% 0.1 % expected
Concentration of recycled condensed

tars from pitch fumes plus recycled
pitch from anode paste dust in ball mill
product
0.01% 0.035 % expected
Concentration of recycled condensed
tars from pitch fumes plus recycled
pitch from anode paste dust in green
anode paste
Items of Importance
Make sure the total flow rate through the scrubber is about 52,000 m3/h. Flow rate
shall never be less than 46,500 m3/h respectively 17.0 m/s in each hole of the
perforated plates of the reactor. If flow rate is getting too low there is a high risk of a
fluid bed break down. Loaded adsorbent contains pitchy matters.
When cleaning a pitch fume ducts the hot air dilution chamber, the main settling
chamber, the reactor, the filter and the fan, rotary locks, bins, the pitch barrel and
screw conveyors protect skin and eyes against dust and condensed pitch fumes. The
use of a mask with particle filter, gloves and further protective clothing is mandatory!
Note: Pitch dust and fumes are irritating (burning) the skin and if breathed
could cause cancer.

Page 4 of 53
Revision: 0
Date: 29.09.2006

138-02-043
Group 431/432 G
DE-060300
The airflow through both scrubber compartments should be equal to attain same
scrubbing conditions in each compartment. If in doubt please check the flow by a
portable flow meter. If required adjust the baffle at the Y-duct downstream the reactor
inlet.
Check regularly the time between two discharges of the fluid bed. If this interval is
shorter as normal this is a sign of too much adsorbent fed to the scrubber. In this case
check first the speed of the rotary lock (431/432 G 010). The normal speed has been
fixed and listed during commissioning. Readjust the speed to the listed set point or
make a calibration if required.
If the discharge interval is still too short then calibrate the rotary lock by feeding into
the bulker bag. If calibration shows that the feed rate is not too high then check the
clearance between rotary vanes and the housing of the rotary lock (431/432 G 010)
and adjust it because rotary lock was not gas tight.
If there is no material flow anymore detected by the flow detectors [431/432 G 025FAL] then please check the following:
- is the rotor of the rotary lock running?
is the fresh adsorbent bin empty?.
is the chute between rotary lock and fresh adsorbent bin clogged because the
aeration is not working or is a foreign body in the chute.
is the bin outlet plugged?
In case of High-High reactor bed level [431/432 G 100-PDSHH] check following:
are rotors of the rotary locks (431/432 G 200 /205) running?
is a chute clogged between reactor and rotary locks?
is a chute clogged between rotary locks and screw conveyor (431/432 G 220)?
are rotary locks (431/432 G 200/205) and chutes upstream air tight to ambient?
Check pitch fume ductwork regularly for deposits of pitch condensate and dust. Clean
duct segments as soon as deposits are more than 15mm thick.
Check main settling chamber (431/432 G 060) regularly for deposits of pitch
condensate and dust. Clean chamber as soon as deposits are more than 15mm thick.
Change barrel for pitchy matters (431/432 G 075) regularly.
Check hot air dilution chamber (431/432 G 055) regularly for deposits of pitch
condensate and dust. Clean chamber as soon as deposits are more than 30mm thick.
Check insulation of pitch fume pipe work, main settling chamber (431/432 G 060), hot
air dilution chamber (431/432 G 055), reactor (431/432 G 100), Filter (431/432 G
115/120), fan (431/432 G 135) and stack. If insulation is not tightly fixed to the
equipment, insulation is missing completely or partly, insulation cladding is bent then
condensation of water, plugging of pitch fume/dust and probably corrosion in this area
may occur. If insulation of a whole branch has been removed while the system is
running condensed water may clog this part and likely the filter bags.

Revision: 0
Date: 29.09.2006
Page 5 of 53

14.2
Process Control
14.2.1
P&Id`s, Operator Screen Images
138-02-043
Group 431/432 G
DE-060300
(work copies)

Page 6 of 53
Revision: 0
Date: 29.09.2006

14.2.2
138-02-043
Group 431/432 G
DE-060300
Control Logic Description

(Work Copy)

Revision: 0
Date: 29.09.2006
Page 7 of 53
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
1 (25)
Rev. 00
Control Philosophy
of
Process Group 431-G
Pitch Fume Treatment Reference:
Process Flow Sheet
132-01-083 UB
P+I Diagram
168-01-063 UB
Brief Process Description............................................................................................................ 2
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.5
2.6
2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
2.7
2.8
Control Logic Description ............................................................................................................ 3

Special Terminology for this Group............................................................................................. 3
Process Groups Linked with this Group...................................................................................... 3
Selections ................................................................................................................................... 4
Operation Mode of the Group (SE 1) .......................................................................................... 4
Heat-Up / Feed Adsorbent (SE 2) ............................................................................................... 4
Pitch Barrel Change (SE 3)......................................................................................................... 4
Hot Air Flow Rate (SE 4)............................................................................................................. 4
Group Start ................................................................................................................................. 5
Selections Prior to Start .............................................................................................................. 5
Start Preconditions...................................................................................................................... 5
Setpoints Prior to Group Start ..................................................................................................... 5
Group Start Sequence ................................................................................................................ 8
Restarting the Group................................................................................................................. 10
Normal Operation...................................................................................................................... 10
Group Shut Down ..................................................................................................................... 15
Normal Shut Down .................................................................................................................... 15
Shut Down by Other Groups ..................................................................................................... 16
Fast Shut Down......................................................................................................................... 16
Trip in Case of Faults ................................................................................................................ 17
Shut Down by Full Bins ............................................................................................................. 24
Local Operation of Special Equipment...................................................................................... 24
Signal Exchange with Sub-Groups of this Group and Other Process Groups .......................... 25
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
1
2 (25)
Rev. 00
BRIEF PROCESS DESCRIPTION

The process is described in order to the material flow whereas the control philosophy is written
in order to the signal flow, which is counter current to the material flow.
This Process Group 431 G collects pitch fumes from the following other Groups:

431 K Paste Weighing
431 L Anode Forming
431 N Vacuum System
431 P Green Anode Transport
An air heater (431 G 050) is used to keep the waste gas, collected from the paste cooler (431
J 200), above water dew point temperature to prevent condensation of evaporated cooling
water. To achieve the aforesaid, the complete pitch fume dry scrubbing system shall be
preheated to operation temperature before starting of anode production and sucking off pitch
fumes. The envisaged operating temperature, measured in the stack [431 G 135-TIR], has to
be varied from about 25C (winter) to about 65C (summer) with the actual ambient
temperature and humidity. The best operating temperature has to be found out during
commissioning. It is most important that at all points of high humidity like the duct work
downstream the hot air dilution chamber (431 G 055), the reactor (431 G 100), filter (431
G120), fan (431 G 135) and the stack the gas temperature is always at minimum 5C higher
as the water dew point in order to prevent clogging of ducts, the reactor fluid bed bottom and
of the filter bags.
As soon as the operating conditions (waste gas temperature, fluid bed height) are reached,
anode production may start while then pitch fumes are set free from hot anode paste. Because
all equipment for anode paste handling is covered or hooded the pitch fumes are collected and
sucked through a pipe work into the settling chamber (431 G 060), where a part of the anode
paste particles and pitch fume droplets, coming with the fumes, are separated.
From the settling chamber the fumes are sucked through a duct and a throttle flap (431 G
080), which is opened pneumatically and is closed by counter weight. If high temperature is
measured in certain ducts [431 G 055-TAHH; 431 G 060-TAHH; 431 G 080-TAHH] this Group
is shut down automatically and the throttle flap (431 G 080) closes.
Fresh adsorbent from the fresh adsorbent bin (431 F 450) is reclaimed by a rotary lock with
variable speed drive (431 G 010). Continuous discharge of fresh adsorbent is maintained by
an aeration unit (431 G 006), which is pulsing compressed air into the bin bottom. The two
hand-operated butterfly valves (431 G 020 / 025) and a bulker bag (431 G 030) are used to
calibrate the feed rate of the rotary lock.
The fresh absorbent is fed via an fresh adsorbent divider (431 G 013) to the suction points of
pitch fumes from the mixer unit (431 J 100), the vibrating feeder (431 K 005), behind the hot
air dilution chamber and to the main gas duct where pitch fume loaded waste gases are
intensively mixed with the injected adsorbent while gas and adsorbent are transferred into the
fluid bed reactor (431 G 100).
In the reactor the mixture of waste gas and adsorbent passes through perforated plates at a
velocity required to form a uniform fluid bed on top of the plates.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
3 (25)
Rev. 00
A multiple adsorption of condensed hydrocarbons takes place in the main raw gas duct, the
reactor hoppers, fluid bed and on the filter bag surface of the bag filter (431 G 120).
To achieve a maximum removal of the condensed and solid pitch particles from the waste gas
stream, the requested height of the fluid bed is automatically build up and maintained by
means of a control unit, which is measuring the differential pressure across the fluid bed and
so regulates the fluid bed height by starting and stopping the rotary locks (431 G 200 / 205),
which are discharging the reactor hoppers. The bag filter (431 G 120) above the fluid bed
recovers the dust from the gas flow drawn by a Fan (431 G 135).
Loaded adsorbent enriched with condensed pitch fumes will be periodically discharged from
the fluid bed by means of two rotary locks (431 G 200 / 205) and subsequently transferred by
screw conveyors (431 G 220 / 225) into the bin for "Loaded Adsorbent (431 G 300).
After the anode production has been stopped, only the fresh adsorbent feed (rotary lock 431 G
010) is shut off, while the rest of the Group (fan 431 G 135, dust collector 431 G 120, air
heater 431 G 050 is kept running and kept warm, being ready for the next start of anode
production. The rest of the discharge system for loaded adsorbent (screw conveyors 431 G
220 and 431 G 225) are kept running, the rotary locks (431 G 200 / 205) are still enabled to
run on request and the knife gates (431 G 210 / 215) are kept closed.
If the pitch fume dry scrubber system has to be shut down totally because of a longer stand
still, the fan (431 G 135), the dust collector cleaning system (431 G 120), the rotary locks (431
G 010 and 431 G 200 and 431 G 205) are shut off instantly, the knife gates (431 G 210 and
431 G 215) will open and a part of the fluid bed will be removed from the reactor. The screw
conveyors (431 G 220 and 431 G 225) will transfer the loaded adsorbent into the bin for
"Loaded Adsorbent (431 G 300) for storage. After run empty of the loaded adsorbent is
terminated, all equipment still running is shut off and the knife gate (431 065) opens to allow
the slurry of pitch condensates and anode paste fines to run down into the pitch barrel (431 G
075) located underneath the settling chamber (431 G 060). It is most important that the door
for removing the pitch barrel is closed tightly to prevent cold fresh air from coming in the
housing when the knife gate is open.
2
CONTROL LOGIC DESCRIPTION
2.1
Special Terminology for this Group

There is no special terminology for this group.
2.2
Process Groups Linked with this Group

The following Process Groups are linked with this Group 431 G:
431 C - Main Dust Treatment

431 H - Proportioning
The exchange of control signals is described in the following chapters and especially under 2.8
below.
CONTROL PHILOSOPHY
05.10.2006
4 (25)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-071
2.3
Selections
2.3.1
Operation Mode of the Group (SE 1)

The selection is made on the Operator Station located in the Central Control Room (CCR).
Selection and indication of the state of selection is on SCADA.
The operator has two options:
2.3.2
CENTRAL operation mode
CENTRAL operation mode can be started if all preconditions

(see 2.4.2) below are fulfilled.
LOCAL operation mode
(details please see under 2.7 below)
Heat-Up / Feed Adsorbent (SE 2)

Selection and indication of the state of selection is on SCADA and can be changed any time.
SE 2-1 - Heat-Up
This is the selection to start and run this Group in Heat-Up mode without feeding Fresh
Adsorbent to the system.
SE 2-2 - Feed Adsorbent
This is the selection to start and run this Group in Normal Operation Mode, feeding Fresh
Adsorbent to the system. Only if this Group is running under Feed Adsorbent selection, anode
paste production with Group 431 H is released.
2.3.3
Pitch Barrel Change (SE 3)

SE 3-1 - Pitch Barrel In
This is the selection used most of the time. At this selection the pitch barrel is located in the
barrel housing (431 G 075) and the door is closed.
SE 3-2 - Change Pitch Barrel
This selection is used if the pitch barrel has to be changed or emptied. At this selection the
knife gate (431 G 065) is kept closed [limit switch 431 G 065-ZL is activated].
2.3.4
Hot Air Flow Rate (SE 4)

SE 4-1 - Auto Flow
This is the selection used if the hot air flow shall be controlled automatically. At this selection
the position of the throttle flap (431 G 050) is controlled automatically by the measured flow
rate of hot air [431 G 050-FY].
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
5 (25)
Rev. 00
SE 4-2 - Manual Flow

This selection is used if the operator wants to control the position of the throttle flap (431 G
050] manually from SCADA [431 G 050-ZC].
2.4
Group Start
2.4.1
Selections Prior to Start

CENTRAL operation mode must be selected.
2.4.2
Start Preconditions
2.4.2.1 Process Group 431 C - Main Dust Treatment

The Group Main Dust Treatment must be running in CENTRAL operation mode prior to
start of this Group under selection SE 2-2 Feed Adsorbent. It must not be tripped and not
be in a stop (RESTOP or FASTOP) sequence.Air Heater 431 G 050
If there is no Air Heater Sub-Group Ready signal this Group 431 G does not start.
Note: This is a collective signal indicating that the heater, the fan and the throttle flap of
the package are healthy. For details please refer to the equipment documentation of
prepared by the SUPLIER.
2.4.2.2 Emergency stops
If the Emergency Stop of the Group has been activated it has to be RESET.
2.4.2.3 Alarms
If an Alarm of this Group has been activated it has to be RESET.
2.4.2.4 MCC`s of this Group
The MCCs signal of this group must be OK.
2.4.2.5 FASTOP Signal
If a FASTOP signal is valid this Group does not start.
2.4.2.6 RESTOP Signal
If a RESTOP signal is valid this Group can be restarted by overriding the RESTOP signal
by the Group Start signal.
2.4.2.7 Local Control Stations
Equipment selected to run the ON switches must be activated.
2.4.2.8 Loaded Adsorbent Bin (431 G 300)
If Feed Adsorbent (SE 2-2) is selected and if the bin is full (bin level is >/= 95% [431 G
300-LAH2] and/or >/= 100% [431 G 300-LAHH]) this Group does not start.
2.4.2.9 Compressed Air Pressure 431 G 120
Compressed air pressure in Group G [431 G 120-PAL] shall be higher than 6 bar (P>6
bar).
2.4.3
Setpoints Prior to Group Start

It makes sense to check and, if required, to readjust setpoints prior to a start of this Group.
CONTROL PHILOSOPHY
05.10.2006
6 (25)
Rev. 00

OTK ref.:
DE-060300
Doc. No.:
133-50-071
Actual Setpoint
The PLC program is storing all actually used setpoints as

Actual Setpoint The Actual Setpoint is automatically used
for the next start after the Group has been stopped or for a
restart after the Group has tripped. The Actual Setpoint is
displayed on SCADA.
New Setpoint
The operator has the opportunity to override the actual

setpoint by the New Setpoint any time Changing of setpoint
is on SCADA.
Previous Setpoint
Did the operator change an Actual Setpoint while the Group is

running in CENTRAL mode the previous one is also stored in
the PLC as Previous Setpoint for possible later use. The
operator may override the actual setpoint by the Previous
Setpoint at any time. Selection of the Previous Setpoint is on
SCADA.
Standard Setpoint
The operator may also override the actual setpoint by the

Standard Setpoint any time. Selection of the Standard
Setpoint is on SCADA. The Standard Setpoint can be edited
on the SCADA system any time but by a Shift Leader only,
after using his Password.
2.4.3.1 Rotary Lock 431 G 010 (Fresh Adsorbent)
(Setpoint SP 1)
This rotary lock is equipped with a variable speed drive.
Low Speed: The speed of the rotary lock can be varied between 20 % and 100 %
corresponding to a feed rate between 0.5 and 2.5 tons/hour. This feed rate can be varied
any time but requires the shift leaders password.
On SCADA the operator has the choice to select one of three options, New setpoint,
Previous setpoint and Standard setpoint all overriding the actual setpoint. The Standard
Setpoint has to be found out during commissioning.
High Speed: The speed of the rotary lock can be varied between 20 % and 100 %
Previous setpoint and Standard setpoint) all overriding the actual setpoint. The
Standard Setpoint has to be found out during commissioning.
2.4.3.2 Reactor 431 G 100 (Fluid Bed Height)
(Setpoint SP 2)
The fluid bed height is controlled by the differential pressure (431 G 100-PDY) across the bed.
The fluid bed height (expressed as differential pressure) setpoints can be varied any time
but require the shift leaders password.
Previous setpoint and Standard setpoint (first approach for Standard Setpoint is 50%)
all overriding the actual setpoint.
Low-Low Level [431 G 100-PDAL] {setpoint 9.5mbar}:
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
7 (25)
Rev. 00
If the differential pressure is below this value for more than 15 seconds an alarm is
initiated and the rotary lock (431 G 010) is switched to high speed (high feed rate) if it
is not already running at high speed.
Low Level [431 G 100-PDSL] { setpoint 10mbar}:
If the pressure has reached low level [431 G 100-PDSL] or is above this value for
more than 15 seconds the rotary lock is switched to low speed.
If the pressure has reached or is below low level [431 G 100-PDSL] (coming from high
or high-high fluid bed level) for more than 5 seconds after the rotary locks (431 G 200 /
205) were running to reduce the fluid bed height, the rotary locks are shut off.
High Level [431 G 100-PDSH] { setpoint 12mbar}: If the pressure has reached high level
[431 G 100-PDSH] (coming from low fluid bed level):
rotary locks (431 G 200 / 205) are both started to discharge loaded adsorbent from the
fluid bed in order to reduce the fluid bed height.
The rotary locks are running until low level [431 G 100-PDSL] is detected since more
than 5 seconds.
rotary lock (431 G 010) is restarted automatically, if the rotary lock has been stopped
previously by high-high pressure [431 G 100-PDAHH].
High-High Level [431 G 100-PDSHH] { setpoint 12.5mbar}: If the pressure has reached
high-high level [431 G 100-PDSHH] (coming from high fluid bed level):
rotary lock (431 G 010) is shut off
rotary locks (431 G 200 / 205) are both started (if they have not been already started
by high level see 2-3 above -) to discharge loaded adsorbent from the fluid bed in
order to reduce the fluid bed height.
The rotary locks are running until low level [431 G 100-PDSL] is reached and are then
stopped.
-
2.4.3.3 Air Heater 431 G 050 (Hot Air Temperature)

(Setpoint SP 3)
The hot air temperature may be changed at any time in a range of 4C to 200C but
requires the shift leaders password.
In case CENTRAL (SE 1-1) is selected setting [431 G 050-TC1] and display [431 G
050-TIR] of the actual temperature is on SCADA. On SCADA the operator has the
choice to select one of three options, New setpoint, Previous setpoint and
Standard setpoint ( first approach 115C) all overriding the actual setpoint.
In case LOCAL (SE 1-2) is selected setting is on the Local Operator Panel [431 G
050-LOP1] and display of the actual temperature is on SCADA [431 G 050-TIR] and is
locally [431 G 050-TI] but no shift leader password is required for changing the setting
in this operation mode.
The hot air temperature [remote 431 G 050-TIR (4 20 mA] and locally 431 G 050-TI] is
continuously measured in the duct between the air heater and the hot air dilution chamber
(431 G 055).
Air outlet temperature control is by the air heater unit using the 4 20 mA signal [431 G
050-TY] as control input. The outlet air temperature shall be kept within a range of +/- 1C
at all operation conditions (VEDANTA to check with supplier how temperature control
works in detail).
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
8 (25)
Rev. 00
2.4.3.4 Air Heater 431 G 050 (Hot Air Flow Rate) (Setpoint SP 4)
If Auto Flow (SE 4-1) is selected the operator may set the hot air flow rate at any time in
a range of 2000m3/hour to 4500m3/hour. Setting [431 G 050-FC] and display [431 G 050FIR] of the actual flow rate is on SCADA. On SCADA the operator has the choice to select
one of three options, New setpoint, Previous setpoint and Standard setpoint ( first
approach 4000m3/hour) all overriding the actual setpoint but this requires the shift
leaders password.
The hot air flow rate [431 G 050-FIR] is continuously measured in the duct between the air
heater and the hot air dilution chamber (431 G 055).
The flow is controlled by a PID-software-controller generated in the PLC program of this
Group (431 PLC 15). The controller opens and closes the throttle flap (with servo-drive
operating time between open and closed position shall be 60-80 seconds) of the air
heater to attain the set flow rate within a range of +/-50m3/hour.
If Manual Flow (SE 4-2) is selected the operator may set the hot air flow rate manually at
any time in a range of 50% to 100% (equal to about 2250m3/hour to 4500m3/hour).
Setting [431 G 050-ZC] and display [431 G 050-FIR] of the actual flow rate is on SCADA.
Previous setpoint and Standard setpoint ( first approach is 89 % (equal to about
4000m3/hour) all overriding the actual setpoint.
The flow is controlled by the operator by typing a flap opening percentage between 50%
and 100%. The servo drive opens / closes the throttle flap (with servo-drive operating
time between open and closed position shall be 60-80 seconds) until the set position is
reached. The positions (%) for 2000 m3/hour and 4500 m3/hour have to be found out
during commissioning.
2.4.4
Group Start Sequence

This Group requires a start command by the operator for each of the two operation selections:
Heat-Up (SE 2-1)

Feed Adsorbent (SE 2-2)
The operator has to start this Group always in the following sequence:
Step 1: Select SE 2-1 on SCADA and click START on SCADA (Start sequence 2.4.4.1
commences)
Step 2: This step requires Step 1 to be finished: Select then SE 2-2 on SCADA and click
START on SCADA (Start sequence 2.4.4.2 commences)
2.4.4.1 Heat-Up (Selection SE 2-1)
The operator is enabling Step 1 (selection SE 2-1) of this Group 431 G to start and to run the
selected equipment. To initiate the start he is using the SCADA system on the Operator
Station in the Central Control Room.
Signal from Group 431 C (Main Dust Treatment) is required (Group is running in CENTRAL
mode and is not in Group Start (START) or any Group Stop sequence (RESTOP or
FASTOP)).
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
9 (25)
Rev. 00
The horn starts to sound permanently for 15 seconds prior to start of the first equipment,
then it sounds intermittently until the last drive is running.
Screw conveyor (431 G 225) starts.
Screw conveyor (431 G 220) starts.
Aeration unit (431 G 105) is enabled.
Delay of 60 seconds to run empty the screw conveyors.
Knife gate (431 G 210) is closing until limit switch [431 G 210-ZL] is actuated.
Throttle flap (431 G 130) is closing until limit switch [431 G 130-ZL] is actuated.
Aeration unit (431 G 105) is disabled.
Fluid-bed height control loop (431 G 100-PDY; rotary locks 431 G 200 / 205; aeration unit
431 G 110) is enabled
Bag pulsing control loop (431 G 120-PDY; bag filter jet cleaning unit 431 G 120) is
enabled
Throttle flap (431 G 080) is opening until limit switch [431 G 080-ZH] is actuated.
Fan (431 G 135) starts, if
throttle flap (431 G 130) is closed [limit switch 431 G 130-ZL is actuated]
throttle flap (431 G 080) is open [limit switch 431 G 080-ZH is actuated].
knife gate (431 G 210) is closed [limit switch 431 G 210-ZL is actuated]
Delay of 30 seconds for fan impeller run-up.
Throttle flap (431 G 130) is opening until limit switch [431 G 130-ZH] is actuated.
Air heater fan (431 G 050) starts if:
throttle flap (431 G 130) is open [limit switch 431 G 130-ZH is actuated]
throttle flap (431 G 080) is open [limit switch 431 G 080-ZH is actuated].
Delay of 20 seconds for fan impeller run-up.
If SE 4-1 Auto Flow is selected, hot air flow control loop (431 G 050-FY; throttle flap 431
G 050) is enabled
If SE 4-2 Manual Flow is selected, jump to step 15.
Delay of 90 seconds for automatic throttle flap adjustment.
Hot Air Temperature control loop (431 G 050-TY; electric heater unit 431 G 050-E1) is
enabled.
Delay of 2 hours for heating up ducts, reactor, bag filter, fan and stack to temperature of
minimum 5C above the water dew point. During this delay time on SCADA the following
message is displayed: HEAT-UP.
It is possible to shorten the heat-up time by selecting SE 2-2 Feed Adsorbent on SCADA.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
10 (25)
Rev. 00
This override should only be used if this Group has been shut down for a very
Note:
short time and only if the operator is sure the ducts, reactor, bag filter, fan and stack is hot
(5C above water dew point).
Now this Group is running in heat-up mode.
2.4.4.2 Feed Adsorbent (Selection SE 2-2)

The operator is enabling Step 2 (select SE 2-2) of this Group 431 G to start and to run the
selected equipment. To initiate the start he is using the SCADA system on the Operator
Station in the Central Control Room.
The operator may click first the Feed Adsorbent button and then the START button on
SCADA any time the Group is running in Heat-Up mode.
Note: After a longer standstill period the operator should wait until the message HEAT-UP
has disappeared on SCADA before he clicks the FEED ADSORBENT and START button
because ducts and equipment have probably cooled down too much.
2.4.5
The horn starts to sound permanently for 15 seconds prior to start of the rotary, then it
sounds intermittently until the drive is running.
Aeration Unit of fresh Adsorbent Divider (431 G 013) is enable
Rotary lock (431 G 010) starts and runs at high speed (high feed rate), if low fluid bed level
[431 G 100-PDSL] or if no high fluid bed level1 [431 G 100-PDSH1 is detected.
Rotary lock (431 G 010) starts and runs at low speed, if fluid bed level2 [431 G 100PDSH2] or fluid bed level high [431 G 100-PDAH] is detected.
Rotary lock (431 G 010) does not start if fluid bed level high-high [431 G 100-PDAHH] is
detected.
This releases the signal Fume Scrubber on Service.
Now this Group is running in Normal Operation.
Restarting the Group

If the Group actually is in a run-empty stop sequence, (after Normal Shut Down (RESTOP)
has been initiated by the operator or the Group has been tripped after of an equipment fault)
and a part of the Group is still running it is possible to restart this Group by activating the
START button. Restarting is only possible after all faults have been eliminated and reset.
The Restart follows the same sequence like the normal Group Start including the horn
sequence as described above.
2.5
Normal Operation
Both Heat-Up operation (selection SE-2-1) and Feed Adsorbent operation (SE 2-2) is
Normal Operation because the only difference is the rotary lock (431 G 010), which is
running or is not running.
2.5.1
Aeration Unit 431 G 006

The aeration unit is equipped with a solenoid valve to open and close the compressed air
supply to the fresh adsorbent bin (431 F 450) according to a time interval, which is pre-set
in the PLC (431 PLC 15) program. If the rotary lock (431 G 010) runs, an air blast is
generated every 10 seconds for a duration of 1 second. The pre-set intervals are checked
and if necessary readjusted during commissioning.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
11 (25)
Rev. 00
If the rotary lock (431 G 010) runs and if after a delay of 20 seconds the flow switch [431 G
025-FAL] is not detecting fresh adsorbent flowing through the feed chute into the main
waste gas duct, the blasting time of the aeration unit is extended to 4 seconds as long as
the flow is interrupted or too low.
2.5.2
Rotary Lock 431 G 010 If the rotary lock is not tripped this Group is in normal operation.
Low Speed : The speed of the rotary lock can be varied between 20 % and 100 %
Previous setpoint and Standard setpoint all overriding the actual setpoint. The Standard
Setpoint has to be found out during commissioning.
High Speed: The speed of the rotary lock can be varied between 20 % and 100 %
Previous setpoint and Standard setpoint) all overriding the actual setpoint. The
Standard Setpoint has to be found out during commissioning.
Note:
In the past it turned out that the feed rate at high speed should be
approximately double of the rate fed at low speed. The best speed for both low- and high
speed has to be found out during commissioning.
2.5.3
Aeration Unit 431 G 013 for Fresh Adsorbent Divider 431 G 013
supply to the fresh adsorbent divider (431 G 013). If the rotary lock (431 G 010) runs, air
blast starts.
2.5.4
Air Heater Unit 431 G 050 Hot Air Temperature If the air heater unit is not tripped (fan, throttle flap, heater) this Group is in normal
operation
The hot air temperature may be changed at any time in a range of 4C to 200C but
requires the shift leaders password.
In case CENTRAL (SE 1-1) is selected setting [431 G 050-TC1] and display [431 G
050-TIR] of the actual temperature is on SCADA. On SCADA the operator has the
choice to select one of three options, New setpoint, Previous setpoint and
Standard setpoint ( first approach 115C) all overriding the actual setpoint.
In case LOCAL (SE 1-2) is selected setting is on the Local Operator Panel [431 G
050-LOP1] and display of the actual temperature is on SCADA [431 G 050-TIR] and is
locally [431 G 050-TI] but no shift leader password is required for changing the setting
in this operation mode.
The hot air temperature [remote 431 G 050-TIR (4 20 mA) and locally 431 G 050-TI] is
continuously measured in the duct between the air heater and the hot air dilution chamber
(431 G 055).
Air outlet temperature control is by the air heater unit using the 4 20 mA signal [431 G
050-TY] as control input. The outlet air temperature shall be kept within a range of +/- 1C
at all operation conditions (VEDANTA to check with supplier how temperature control
works in detail).
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
12 (25)
Rev. 00
2.5.5
Air Heater 431 G 050 -Hot Air Flow Rate If Auto Flow (SE 4-1) is selected, the operator may set the hot air flow rate at any time in
a range of 2000m3/hour to 4500m3/hour. Setting [431 G 050-FC] and display [431 G 050FIR] of the actual flow rate is on SCADA. On SCADA the operator has the choice to select
one of three options, New set point, Previous set point and Standard set point ( first
approach 4000m3/hour) all overriding the actual set point.
The flow is controlled by a PID-software-controller generated in the PLC program of this
Group (431 PLC 15). The controller opens and closes the throttle flap (with servo-drive
operating time between open and closed position shall be 60-80 seconds) of the air
heater to attain the set flow rate within a range of +/-50m3/hour.
If Manual Flow (SE 4-2) is selected the operator may set the hot air flow rate manually at
any time in a range of 2000m3/hour to 4500m3/hour. Setting [431 G 050-ZC] and display
[431 G 050-FIR] of the actual flow rate is on SCADA. On SCADA the operator has the
choice to select one of three options, New setpoint, Previous setpoint and Standard
setpoint ( first approach 4000m3/hour) all overriding the actual setpoint.
The flow is controlled by the operator by typing a flap opening percentage between 50%
and 100%. The servo drive opens / closes the throttle flap (with servo-drive operating
time between open and closed position shall be 60-80 seconds) until the set position is
reached. The positions (%) for 2000 m3/hour and 4500 m3/hour have to be found out
during commissioning.
2.5.6
Knife gate 431 G 065

If the knife gate is not tripped this Group is in normal operation
The slurry of pitch fume condensates and anode paste dust is automatically discharged
from the settling chamber (431 G 060). Discharge is controlled by opening the knife gate
(431 G 065) in regular time intervals.
The discharge sequence requires the selection SE 3-1 (Pitch Barrel In) and is like
follows:
Knife gate (431 G 065) is closed. Limit switch [431 G 065-ZL] is actuated.
Delay of 2 hours after knife gate (431 G 065) did close.
Knife gate (431 G 065) opens until limit switch [431 G 065-ZH] is actuated.
Delay of 120 seconds for pitch fume slurry run down into the pitch barrel (431 G 075).
Note:
During discharge time a pitch barrel must be inside the barrel housing and the
door of the barrel housing must be closed (both are manual operations).
Prior to changing / emptying the pitch barrel (431 G 075) the operator has to select SE 3-2
(Change Pitch Barrel).
With this command (SE 3-2) the knife gate closes until limit switch [431 G 065-ZL] is
activated if it is not already closed.
As long as SE 3-2 is selected the timer for the automatic discharge of the settling
chamber (see 5-2 of this chapter above) is interrupted.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
13 (25)
Rev. 00
2.5.7
Throttle flap 431 G 080

If the flap is not tripped this Group is in normal operation.
If the flap is open [limit switch 431 G 080-ZH is activated] this group is in normal operation.
2.5.8
Reactor 431 G 100 (Fluid Bed Height Control)

The fluid bed height is controlled by the differential pressure (431 G 100-PDY) across the bed.
While fresh adsorbent is fed continuously to the reactor the fluid bed is discharged
discontinuously as a function of the filter bed height (pressure). The bed height alters between
the high fluid bed low level [431 G 100-PDSL] and the fluid bed high level [431 G 100-PDSH]
limit.
2.5.9
The fluid bed height (expressed as differential pressure) set points can be varied any time
but require the shift leaders password.
Previous setpoint and Standard setpoint all overriding the actual setpoint.
Low-Low Level [431 G 100-PDAL] {set point 9.5mbar}:
If the differential pressure is below this value for more than 15 seconds an alarm is
initiated and the rotary lock (431 G 010) is switched to high speed (high feed rate) if it
is not already running at high speed.
Low Level [431 G 100-PDSL] { set point 10mbar}:
If the pressure has reached low level [431 G 100-PDSL] or is above this value for
more than 15 seconds the feeding rotary lock is switched to low speed.
If the pressure has reached or is below low level [431 G 100-PDSL] (coming from high
or high-high fluid bed level) for more than 10 seconds after the fluid bed discharging
rotary locks (431 G 200 / 205) were running to reduce the fluid bed height, the rotary
locks are shut off.
High Level [431 G 100-PDSH] { set point 12mbar}: If the pressure has reached high level
[431 G 100-PDSH] (coming from low fluid bed level) for more than 5 seconds:
rotary locks (431 G 200 / 205) are both started to discharge loaded adsorbent from the
fluid bed in order to reduce the fluid bed height.
The rotary locks are running until low level [431 G 100-PDSL] is detected since more
than 10 seconds.
rotary lock (431 G 010) is restarted automatically, if the rotary lock has been stopped
previously by high-high pressure [431 G 100-PDAHH].
Bag Filter 431 G 120

If the jet-type bag cleaning system [431 G 120-LOP1] is not tripped this Group is in normal
operation.
The jet-type pneumatic bag cleaning system is controlled by the actually measured
differential pressure across the filter bags. If the differential pressure measuring system
detects the differential pressure is above 12.5 mbar [431 G 120-PDH2], the Local Control
Panel [431 G 120-LOP1] gets a signal from 4 PLC 3 to start a bag cleaning cycle. The
bags are cleaned with a compressed air stream blown into the bags countercurrent to the
normal air flow. The cleaning cycle ends with a second signal from 4 PLC 3, if the
differential pressure did fall below 11 mbar [431 G 120-PDH1].
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
14 (25)
Rev. 00
Control of the bag cleaning sequence is done by a small sub-program in the

Note:
Local Operator Panel [431 G 120-LOP1], provided by the Dust collector supplier. It is part
of the sub-program that the next cleaning cycle starts with next un-cleaned row of filter
bags and not always with the same row.
2.5.10
Throttle flap 431 G 130

If the flap is not tripped this Group is in normal operation.
If the flap is open [limit switch 431 G 130-ZH is activated] this group is in normal operation.
2.5.11
Fan 431 G 135

If the fan is not tripped this Group is in normal operation.
2.5.12
Rotary Lock 431 G 200

If the rotary lock is not tripped this Group is in normal operation.
This rotary lock is started and stopped by the reactor fluid bed height control [431 G 100PDY] as described above (see 2.5.8 of this chapter).
2.5.13
Rotary Lock 431 G 205

If the rotary lock is not tripped this Group is in normal operation.
This rotary lock is started and stopped by the reactor fluid bed height control [431 G 100PDY] as described above (see 2.5.8 of this chapter).
2.5.14
Aeration unit (431 G 110)

Aeration unit (431 G 110) cycle is enabled as long as the rotary lock (431 G 200) is
running. When the rotary lock stops, the aeration unit is disabled.
The aeration unit is equipped with a solenoid valve [431 G 110-Y1] to open and close the
compressed air supply to the reactor discharge chutes according to a time interval, which
is pre-set in the PLC (431 PLC 15). If the rotary lock (431 G 110) runs, an air blast is
generated every 10 seconds for a duration of 1 second. The pre-set intervals are checked
and if necessary readjusted during commissioning.
2.5.15

If the knife gate is closed [limit switch 431 G 210-ZL is activated] this Group is in normal
operation
2.5.16

If the knife gate is closed [limit switch 431 G 215-ZL is activated] this Group is in normal
operation
2.5.17
Screw Conveyor 431 G 220

If the conveyor is not tripped this Group is in normal operation.
2.5.18
Screw Conveyor 431 G 225

If the conveyor is not tripped this Group is in normal operation.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
15 (25)
Rev. 00
2.5.19
Loaded Adsorbent Bin 431 G 300

If the bin level measurement is not tripped this Group is in normal operation.
If the Group is running in Heat-UP (SE 2-1) or Feed Adsorbent (SE 2-2) selection and if
the bin is not full (bin level is not >/= 95% [431 G 300-LAH2] and/or not >/= 100% [431 G
300-LAHH]) this Group is in normal operation.
If the Group is running in Heat-UP (SE 2-1) selection and if the bin is full (bin level is >/=
95% [431 G 300-LAH2] and/or >/= 100% [431 G 300-LAHH]) this Group is in normal
operation.
2.5.20
Heat-Up / Feed Adsorbent Selection (SE 2-1 / SE 2-2)

If this Group is running under Feed Adsorbent selection the operator may stop feeding of
fresh adsorbent any time. For this purpose he shuts down the rotary lock (431 G 010) by
clicking SE 2-1 - Heat-Up on SCADA From now this Group is running under Heat-Up
selection and is ready to be restarted for Feed Adsorbent operation.
Note:
The operator should be aware that if he selects Heat-UP and anode paste
production is running in Group 431 H that Group stops after a delay of 60 minutes by a
RESTOP automatically.
2.6
Group Shut Down
2.6.1
Normal Shut Down

This Normal Shut Down is only used, if this Group shall not run for a longer period because
of maintenance or during the weekend. Because of the relatively long heat up time (minimum
2 hours) this Group should not be shut down for a period less than 8 hours. For shorter
periods the system should be kept running under Heat-Up selection (SE 2-1) without adding
fresh adsorbent.
To initiate this sort of shut down the operator uses the RESTOP button on the SCADA
system
After a shut down of the Group or of a part of the Group all actual set points of this Group are
memorized as Actual Set Point.
The operator stops this Group using the RESTOP push button on SCADA.
Aeration unit (431 G 006) cycle is disabled and solenoid [431 G 006-ZY1] closes.
Rotary lock (431 G 010) stops
Aeration unit (431 G 013) is disabled and solenoid [431 G 013-ZY1] closes.
Air heater unit (431 G 050) gets a STOP signal.
Rotary locks (431 G 200 / 205) stop, if they are running.
Aeration unit (431 G 110) cycle is disabled and solenoid [431 F 110-ZY1] closes.
Fan (431 G 135) stops.
Throttle flap (431 G 080) closes until limit switch [431 G 080-ZL] is activated.
Knife gate (431 G 210) opens until limit switch [431 G 210-ZH] is activated.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
2.6.2
16 (25)
Rev. 00
Bag cleaning unit (431 G 120) is disabled.
Aeration unit (431 G 105) cycle is enabled.
supply to the reactor discharge chutes according to a time interval, which is pre-set in the
PLC (431 PLC 15). If the knife gate (431 G 210) is open, an air blast is generated every 10
seconds for a duration of 1 second. The pre-set intervals are checked and if necessary
readjusted during commissioning.
Delay of 10 minutes (run-empty time for screw conveyors)
Screw conveyor (431 G 220) stops.
Screw conveyor (431 G 225) stops.
Aeration unit (431 G 105) cycle is disabled.
The whole Group is stopped.
Shut Down by Other Groups

If this Group 431 G is running in CENTRAL mode it requires the following other Groups also
running in CENTRAL operation mode:
431 C Main Dust Treatment
After a shut down of the Group or of a part of the Group all actual setpoints of this Group are
2.6.2.1 Group 431 C Main Dust Treatment
Because a mayor part of equipment of this Group 431 G is connected to the Main Dust
Treatment it is essential that Group 431 C is running in CENTRAL control mode and is
not in a START or STOP sequence.
If this Group is running under selection SE-2-2 Feed Adsorbent and if Group 431 C is not
running anymore in CENTRAL mode because it has been stopped by a Normal Shut
Down (RESTOP), by a Fast Shut Down (FASTOP) or is tripped through a fault, shut down
of the rotary locks (431 G 200 / 205) and the screw conveyors (431 G 220 / 225) is
initiated and knife gates (431 G 210 / 215) do not open.
Rotary lock (431 G 010) is not shut down instantly, if the Group 431 C is shut
Note:
down or trips. The rotary lock is still feeding fresh adsorbent to the system until high-high
fluid bed level [431 G 100-PDAHH] stops the rotary lock.
2.6.3
Fast Shut Down

If this Group 431 G is running in CENTRAL mode and an operator has detected a serious
fault, which did not automatically trip this Group the operator is able to stop this Group as Fast
Shut Down (FASTOP).
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
17 (25)
Rev. 00
2.6.3.1 Fast Shut Down by the Operator (FASTOP)

The operator may initiate the Fast Shut Down of this Group at any time on the SCADA
system clicking the FASTOP button.
After the FASTOP button has been clicked, the following stop sequence does
commence:
All equipment of this Group stop instantly or keep the actual position except of the
throttle flap (431 G 080), which closes completely until limit switch [431 G 080-ZL] is
activated and the solenoid valves of the aeration units (431 G 006 / 013 / 105 / 110 Y1) are closing.
All actual set points of this Group are memorized as Actual Set Point
The whole Group is stopped now with full load of material in reactor, bag filter and
conveyors.
2.6.4
Trip in Case of Faults

If this Group 431 G is running in CENTRAL mode and an equipment or an instrument of this
Group fails this may cause an Alarm only and, if the fault is of the serious sort, this whole
Group or a part of this Group is stopped. Different faults may cause different stop sequences,
depending on the equipment and on the impact of this fault on the whole process of this
Group. In some cases a Normal Shut Down (RESTOP) will commence, in other cases a Fast
Shut Down (FASTOP) is the safer way and in few cases a special stop sequence may be
required.
Note: All instruments mounted on equipment or located somewhere in the field or anywhere
else are to be wired fail-safe.
2.6.4.1 Rotary Lock 431 G 010

[431 G 010-VFD] If there is a fault detected in the frequency controller or of the electric motor
-
cause an alarm
VFD-unit is shut down
[431 G 010-M1] If there is a fault detected in the MCC

-
cause an alarm
pertinent VFD-unit is shut off
[431 G 010-SAL] The rotary lock is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the rotor. If the frequency of the rotor is too
low or the switch fails
-
cause an alarm
equipment trips
If the rotary lock trips

-
alarm is generated
VFD-unit stops the motor automatically
solenoid of the aeration unit [431 G 006-Y1] closes
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
18 (25)
Rev. 00
2.6.4.2 Flow Switch 431 G 015-FAL

If the rotary lock (431 G 010) runs and if after a delay of 15 seconds the flow switch [431 G
025-FAL] is still not detecting fresh adsorbent flowing through the feed chute into the main
waste gas duct
-
causes an alarm
rotary lock (431 G 010) is shut off so that this group is running again in Heat-Up
selection.
2.6.4.3 Air heater 431 G 050 -VEDANTA to check with Supplier A collective fault signal initiated by the air heater package (resistance heating unit; fan; throttle
flap) [431 G 050-LOP1]
-
causes an alarm
Normal Shut Down is initiated automatically as described above (see 2.6.1).
[431 G 050-ZL / ZH] The throttle flap is equipped with two limit switches, incorporated in a
control box fitted to the drive unit. If a limit switch fails this
-
causes an alarm

[431 G 050-XAL / XAH] The throttle flap is equipped with two torque switches, incorporated in
a control box fitted to the drive unit. If a switch is actuated or a switch fails
-
causes an alarm
Normal Shut Down is initiated automatically as described
The maximum time required between start and stop of the actuator drive, which is tilting the
throttle flap, shall not be more than 90 seconds. If after 90 seconds the motor has not been
stopped automatically because the target position has not been reached
-
an alarm is initiated
[431 G 050-FAL] {set point ???? ask supplier - m3/hour} The flow rate of hot air is continuously
measured in the duct between the Air Heater and the Hot Air Dilution Chamber (431 G 055). If
the flow rate is below the set point
-
causes an alarm SCADA
[431 G 050-FAH] {set point 4500 m3/hour} The flow rate of hot air is continuously measured in
the duct between the Air Heater and the Hot Air Dilution Chamber (431 G 055). If the flow rate
is above the set point
-
causes an alarm on SCADA.
[431 G 050-TAL] {set point 80C} The temperature of hot air is continuously measured in the
duct between the Air Heater and the Hot Air Dilution Chamber (431 G 055). If the temperature
is below the set point
-
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
19 (25)
Rev. 00
[431 G 050-TAH] {set point 180C} The temperature of hot air is continuously measured in the
duct between the Air Heater and the Hot Air Dilution Chamber (431 G 055). If the temperature
is above the set point
-
causes an alarm on SCADA

[431 G 050-PAH] {set point 5mbar}The pressure in the duct between the Air Heater and the
Hot Air Dilution Chamber (431 G 055) is continuously measured. If the pressure is above the
set point
-
2.6.4.4 Hot Air Dilution Chamber 431 G 055

[431 G 055-TAH] {set point 190C} The temperature of waste gas is continuously measured in
the duct between the Hot Air Dilution Chamber (431 G 055) and the Settling Chamber (431 G
060). If the temperature is above the set point
-
causes an alarm
Fast Shut Down is initiated automatically as described above (see 2.6.3)
[431 G 055-TAHH] {set point 200C} The temperature of waste gas is continuously measured
in the duct between the Hot Air Dilution Chamber (431 G 055) and the Settling Chamber (431
G 060). If the temperature is above the set point
-
causes an alarm
Note: In case of high temperature or high-high temperature it is likely there is a fire in the duct
especially if welders are working in the field. The operator has to decide to open the pertinent
water valves of the sprinkler system in order to flood the pitch fume main duct and the hot air
dilution chamber.
2.6.4.5 Settling Chamber 431 G 060
the duct between the Mixer (431 J 100) and the Settling Chamber (431 G 060). If the
temperature is above the set point
-
causes an alarm
in the duct between the Mixer (431 J 100) and the Settling Chamber (431 G 060). If the
-
causes an alarm
dilution chamber.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
20 (25)
Rev. 00
2.6.4.6 Throttle Flap 431 G 080 pneumatic [431 G 080-ZH / ZL]: The flap is equipped with two proximity type limit switches. If one of the
switches fails
-
causes an alarm
equipment trips
The maximum time required by the pneumatic drive for tilting the flap blade from one limit
switch to the other one shall not be more than 10 seconds. If after 10 seconds the limit switch
is not reached
-
causes an alarm
equipment trips
If the flap trips

-
an alarm is generated
Normal Shut Down of this Group (see 2.6.1 above), which is initiated automatically.
the duct between the Settling Chamber (431 G 060) and the reactor (431 G100). If the
-
causes an alarm
Fast Shut Down is initiated automatically as described above (see 2.6.3).
in the duct between the Settling Chamber (431 G 060) and the reactor (431 G100). If the
-
causes an alarm
Fast Shut Down is initiated automatically as described above (see 2.6.3).
dilution chamber.
2.6.4.7 Reactor 431 G 100
[431 G 100-PDALL] {< 9.5mbar} If low-low differential pressure is detected across the reactor
filter bed and if SE 2-2 Feed Adsorbent is selected and if this signal [431 G 100-PDALL] is
valid for more than 15 minutes or if the measuring unit fails for more than 5 seconds
-
cause an alarm
Group is switched to Heat-Up mode automatically.
[431 G 100-PDAHH] {> 12.5mbar} If high-high differential pressure is detected across the
reactor fluid bed and this signal is valid for more than 10 minutes or if the switch fails for more
than 5 seconds
-
cause an alarm
Group is switched to Heat-Up mode automatically.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
21 (25)
Rev. 00
2.6.4.8 Bag Filter 431 G 120

[431 G 120-LOP1] If the bag cleaning device trips
-
Normal Shut Down (see 2.6.1 above) will be initiated automatically.
[431 G 120-PDAL] {< 2.5mbar} If low differential pressure is detected across the filter bags or
if the measuring unit fails for more than 5 seconds
-
cause an alarm
NOTE: During Start or Restart of this Group there is an override of this function of 20 seconds
to allow the fan to run up.
[431 G 120-PDAH] {> 13mbar} If high differential pressure is detected across the filter bags or
if the measuring unit fails for more than 5 seconds
-
cause an alarm
[431 G 120-PDAHH] {> 15mbar} If high-high differential pressure is detected across the filter
bags or if the measuring unit fails for more than 5 seconds
-
cause an alarm
[431 G 120-PAL] {< 6 bar} If low pressure is detected for more than 15 seconds in the
compressed air service line to the pneumatic service unit (431 G 120-PSU) or if the switch fails
for more than 5 seconds
-
cause an alarm
2.6.4.9 Throttle Flap 431 G 130 pneumatic [431 G 130-ZH / ZL] The flap is equipped with two proximity type limit switches. If one of the
switches fails
-
causes an alarm
equipment trips
The maximum time required by the pneumatic drive for tilting the flap blade from one limit
switch to the other one shall not be more than 10 seconds. If after 10 seconds the limit switch
is not reached
-
causes an alarm
equipment trips
If the flap trips

-
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
22 (25)
Rev. 00
2.6.4.10 Fan 431 G 135

[431 G 135M1] If there is a fault detected in the electric motor or in the MCC of this motor
-
cause an alarm
equipment trips
[431 G 135-SAL] The fan is equipped with a proximity type low-speed switch measuring the
frequency of a target rotating with the impeller shaft. If the frequency of the rotor is too low or
the switch fails
-
cause an alarm
equipment trips
[431 G 135-VAH] The fan is equipped with a vibration switch. If vibration is too high
-
fan trips
If the fan trips

-
fan (431 G 135) is shut down instantly.
This initiates a Normal Shut Down of this Group (see 2.6.1 above).
2.6.4.11 Rotary Lock 431 G 200

-
cause an alarm
equipment trips
-
cause an alarm
equipment trips

-
2.6.4.12 Rotary Lock 431 G 205

-
cause an alarm
equipment trips
-
cause an alarm
equipment trips

-
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
23 (25)
Rev. 00
2.6.4.13 Screw Conveyor 431 G 220

[431 G 220-SAL] The screw conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the screw. If the frequency of the screw is too
-
cause an alarm
equipment trips
-
cause an alarm
equipment trips
If the conveyor trips

-
rotary locks (431 G 200 / 205) are shut off.
2.6.4.14 Screw Conveyor 431 G 225

[431 G 225-SAL] The screw conveyor is equipped with a proximity type low-speed detector
measuring the frequency of a target rotating with the screw. If the frequency of the screw is too
-
cause an alarm
equipment trips
-
cause an alarm
equipment trips
If the conveyor trips

-
rotary locks (431 G 200 / 205) and the screw conveyor (431 G 200) are shut off.
2.6.4.15 Fresh Adsorbent Bin 431 G 300

[431 G 300-LY] The bin is equipped with a continuous level measurement (load cell system). If
the level measurement fails
-
cause an alarm
rotary locks (431 G 200 / 205) are shut off automatically
screw conveyors (431 G 200 / 205) are shut off automatically
or if the Group is just running empty after the Normal Shut Down has been initiated
-
knife gates (431 G 210 / 215) close

aeration unit (431 G 105) stops
[431 G 300-LAHH] The bin is equipped with a level probe. If the level measurement fails
-
cause an alarm
rotary locks (431 G 200 / 205) are shut off automatically
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
24 (25)
Rev. 00
-
2.6.5

Shut Down by Full Bins
2.6.5.1 Loaded Adsorbent Bin 431 G 300

If the bin is full (bin level is >/= 95% [431 G 300-LAH2 and/or bin level >/= 100% [431 G 300LAHH])
-
cause an alarm
rotary locks (431 G 200 / 205)
-

2.7
Local Operation of Special Equipment
2.7.1
Fan 431 G 135

Starting the fan requires the throttle flap (431 G 130) to be closed previously so that limit
switch [431 G 130-ZL] is activated.
2.7.2
Knife Gates 431 G 200 / 205

It shall not be possible to open a knife gate by Local Control Station as long as the fan (431 G
135) is running
2.7.3
Air Heater 431 G 050

It shall not be possible to start and run the air heating unit by Local Control Station as long as:
the fan (431 G 135) is not running

the throttle flap (431 G 130) is not open [limit switch 431 G 130-ZH must be activated]
the throttle flap (431 G 080) is not open [limit switch 431 G 080-ZH must be activated]
the knife gates (431 G 210 / 215 /065) closed [limit switches 431 G 210 / 215 /065-ZL
must be activated].
Safety Note: If there is not enough negative pressure in the pitch fume ducts hot air
could be blown out to ambient and could injure people.
CONTROL PHILOSOPHY
05.10.2006
OTK ref.:
DE-060300
Doc. No.:
133-50-071
2.8
Rev. 00
Signal Exchange with Sub-Groups of this Group and Other Process Groups
Signal
Description
Sort of Signal
from Group 431 C to Group 431

G
Group 431 C is running in

CENTRAL mode and is not in any
Group START or STOP sequence
Group 431 G is running under
selection SE 2-1 Heat-Up
Group 431 G is running under
selection SE 2-2 Feed
Adsorbent.
Sub-Group 431 G 050 is ready to
be started
Sub-Group 431 G 050 is running
in CENTRAL mode.
Sub-Group 431 G 050 is shut
down completely
Sub-Group 431 G 050 is tripped.
Digital signal from PLC Number

431 PLC 12 to PLC Number 431
PLC 15
Digital signal within PLC Number
431 PLC 15
Digital signal within PLC Number
431 PLC 15
from Group 431 G to Group 431

J and to Group 431 H
from Group 431 G to Group 431
J and to Group 431 H
from Sub-Group 431 G 050 to
Group 431 G
Group 431 G
Group 431 G
Group 431 G
from Group 431 G to Sub-Group
431 G 050
431 G 050
431 G 050
431 G 050
431 G 050
Group 431 G
Group 431 G
Group 431 G
Group 431 G
Group 431 G
Group 431 G
START Sub-Group 431 G 050

STOP Sub-Group 431 G 050
actual temperature in hot air duct
[431 G 050-TY]
temperature set point in hot air
duct [431 G 050-TC1]
air flow rate in hot air duct [431 G
050-FY]
actual position of throttle flap
blade [431 G 050-ZT1]
actual current of air heater
resistances [431 G 050-LOP1]
end position of throttle flap blade
[431 G 050-ZSL1]
end position of throttle flap blade
[431 G 050-ZSH1]
no torque of throttle flap blade
[431 G 050-XSL1]
no torque of throttle flap blade
[431 G 050-XSH2]
??Digital?? signal within PLC

Number 431 PLC 15
Number 431 PLC 15
Number 431 PLC 15
Number 431 PLC 15
Number 431 PLC 15
Number 431 PLC 15
4-20mA signal within PLC
Number 431 PLC 15
??4-20mA or digital?? signal
within PLC Number 431 PLC 15
Number 431 PLC 15
Number 431 PLC 15
signal within PLC Number 431
PLC 15
PLC 15
PLC 15
PLC 15
PLC 15
25 (25)

14.3
Main Equipment
14.3.1
Fresh Adsorbent Divider 431/432 G 013
14.3.2
Air Heater Unit 431/432 G 050
14.3.3
Hot Air Dilution Chamber 431/432 G 055
14.3.4
Knife Gate (pneumatic) 431/432 G 065
14.3.5
Throttle Flap (dead weight type-pneumatic) 431/432 G 080
14.3.6
Vane Controller (pneumatic) 431/432 G 130

Page 8 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006

14.3.7
138-02-043
Group 431/432 G
DE-060300
Reactor-Filter-Unit 431/432 G 100/115/120
14.3.7.1 Technical Data

14.3.7.1.1 Reactor 431/432 G 100
Design:
Manufacturer:
Humboldt Wedag India Pvt. Ltd.
The reactor is designed for:

Feed material:
air, pitch fumes, water steam, calcined petroleum coke

dust
Design flow rate:
55,000 Am3/hour, 60C, 1013mbar
Operating flow rate:
52,000 Am3/hour, 45C, 1013mbar
Minimum flow rate:
46,500 Am3/h, 1013mbar
Dry adsorbent feed size:
0-0.3 mm, 55-70% < 0.075mm
Fluid bed bottom :

8 segments; total length
7408 mm
5 segments; total width
4354 mm
perforation of bottom plates
6 mm dia
air velocity through perforation
17 m/s minimum
19.5 m/s maximum
Fluid bed:
average height
150 mm approx.
total adsorbent weight:
2800 kg approx.

Revision: 0
Date: 29.09.2006
Page 9 of 53
138-02-043
Group 431/432 G
DE-060300

14.3.7.1.2 Filter 431/432 G 115/120
Design:
INTENSIV FILTER GmbH & Co KG / Germany
Manufacturer:
INTENSIV FILTER / McNally Bharat Engineering Co.

Ltd
The filter is designed for:

Feed material:
air, pitch fumes, water steam, calcined petroleum

coke dust
Design flow rate:
55,000 Am3/hour, 60C, 1013mbar
Operating flow rate:
42,000 Am3/hour, 45C, 1013mbar
Minimum flow rate:
46,500 Am3/h, 1013mbar
Dry adsorbent feed size:
0-0.3 mm, 55-75% < 0.074mm
Technical data
Filter type:
IFJN 80/5-3 BX
Expected pressure difference:
app. 1200 1500 Pa
Operating pressure:
- 80 hPa
Filter surface area:
700 m2
Filter sleeves:
Nominal diameter
Nominal length
Material
Total number
Number in 1 row
Rows
Division of supporting cages
160 mm
3375 mm
PE-V 610
400 pieces
16
25
1 x 2250mm; 1 x 1125
Cleaning cycle:
120 s
Cycle time:
12 s
Pulse time:
0.05 s
Compressed air consumption:
80 Nm3 /h

Page 10 of 53
Revision: 0
Date: 29.09.2006

138-02-043
Group 431/432 G
DE-060300
14.3.7.2 Drawings
Pitch Fume Dry Scrubber

Revision: 0
Date: 29.09.2006
Page 11 of 53

138-02-043
Group 431/432 G
DE-060300
14.3.7.3 Equipment Description

14.3.7.3.1 Reactor 431/432 G 100
The reactor is divided into three sections, the lower section, the middle section and the top
section.
The lower section is a pyramidal shaped sheet steel structure with horizontal and vertical
bracings. Because of the relatively high raw gas flow rate this reactor consists of two
pyramidal bottom parts with one raw gas inlet and one discharge flange for each part.
The middle part is a rectangular steel sheet housing, which is flanged to the bottom parts.
The middle part has a steel frame which is carrying the perforated plates on which top the
adsorbent fluid bed builds up. At the side(s) of the middle part adsorbent discharge
flanges are bolted through which loaded adsorbent is withdrawn by rotary locks working in
on/off sequence, controlled by differential pressure across the fluid bed.
The top section is also a rectangular sheet steel construction and features the inspection
doors.
In the reactor the mixture of waste gas and adsorbent passes through the perforated
plates at a velocity sufficient to form a uniform fluid bed on top of the plates.
To achieve a maximum removal of the condensed and solid pitch particles from the waste
gas stream, the requested height of the fluid bed is automatically build up and maintained
by means of a control unit, which is measuring the differential pressure across the fluid
bed and so regulates the fluid bed height by starting and stopping the rotary locks
(431/432 G 200 / 205), which are discharging the reactor hoppers.

Page 12 of 53
Revision: 0
Date: 29.09.2006

138-02-043
Group 431/432 G
DE-060300
14.3.7.3.2 Filter Unit 431/432 G 115/120

Revision: 0
Date: 29.09.2006
Page 13 of 53

138-02-043
Group 431/432 G
DE-060300
Gas Cleaning Operation

Page 14 of 53
Revision: 0
Date: 29.09.2006

138-02-043
Group 431/432 G
DE-060300
Filter Bag Cleaning

Revision: 0
Date: 29.09.2006
Page 15 of 53


Page 16 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 17 of 53


Page 18 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 19 of 53


Page 20 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006

138-02-043
Group 431/432 G
DE-060300
Filter Bag Support Cages

Revision: 0
Date: 29.09.2006
Page 21 of 53


Page 22 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006

138-02-043
Group 431/432 G
DE-060300
Compressed Air Supply

Revision: 0
Date: 29.09.2006
Page 23 of 53


Page 24 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 25 of 53


Page 26 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006

138-02-043
Group 431/432 G
DE-060300
Measuring of the Differential Pressure

Revision: 0
Date: 29.09.2006
Page 27 of 53

138-02-043
Group 431/432 G
DE-060300
Electrical Equipment

Page 28 of 53
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 29 of 53

138-02-043
Group 431/432 G
DE-060300
Differential Pressure Control Unit DE 21

Page 30 of 53
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 31 of 53


Page 32 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 33 of 53


Page 34 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 35 of 53


Page 36 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006

138-02-043
Group 431/432 G
DE-060300
14.3.7.4 Regular Checks

Revision: 0
Date: 29.09.2006
Page 37 of 53


Page 38 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 39 of 53

138-02-043
Group 431/432 G
DE-060300
14.3.7.5 Maintenance

Page 40 of 53
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 41 of 53


Page 42 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 43 of 53


Page 44 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 45 of 53


Page 46 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 47 of 53


Page 48 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 49 of 53


Page 50 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006

138-02-043
Group 431/432 G
DE-060300
14.3.7.6 Safety

Revision: 0
Date: 29.09.2006
Page 51 of 53


Page 52 of 53
138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006


138-02-043
Group 431/432 G
DE-060300
Revision: 0
Date: 29.09.2006
Page 53 of 53

431G 432G

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

431G 432G

Hochgeladen von

Copyright:

Verfügbare Formate

Training Manual Green Anode Plant

PROCESS GROUP 431/432 G - PITCH FUME TREATMENT -

Process Group 431/432 G - Pitch Fume Treatment -..................................................................1

Process Flow Sheets

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Brief Process Description

Outokumpu Technology GmbH

Vedanta Alumina Ltd.

Brief Process Description

431 J Paste Mixing & Cooling

Outokumpu Technology GmbH

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Main Process Data & Process Highlights

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Main Technical Data of the Scrubbing System

55,000 Acm3/h at 60C gas temperature and

Concentration of recycled condensed

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Outokumpu Technology GmbH

Training Manual Green Anode Plant

P&Id`s, Operator Screen Images

Outokumpu Technology GmbH

Training Manual Green Anode Plant

Control Logic Description

Outokumpu Technology GmbH

Brief Process Description............................................................................................................ 2

Control Logic Description ............................................................................................................ 3

Outokumpu Technology GmbH

BRIEF PROCESS DESCRIPTION

431 J Paste Mixing & Cooling

CONTROL LOGIC DESCRIPTION

Special Terminology for this Group

Process Groups Linked with this Group

431 C - Main Dust Treatment

Outokumpu Technology GmbH

Vedanta Alumina Ltd.

Operation Mode of the Group (SE 1)

CENTRAL operation mode

CENTRAL operation mode can be started if all preconditions

LOCAL operation mode

(details please see under 2.7 below)

Heat-Up / Feed Adsorbent (SE 2)

Pitch Barrel Change (SE 3)

Hot Air Flow Rate (SE 4)

Outokumpu Technology GmbH

SE 4-2 - Manual Flow

Selections Prior to Start

2.4.2.1 Process Group 431 C - Main Dust Treatment

Setpoints Prior to Group Start

Outokumpu Technology GmbH

Vedanta Alumina Ltd.

The PLC program is storing all actually used setpoints as

The operator has the opportunity to override the actual

Did the operator change an Actual Setpoint while the Group is

The operator may also override the actual setpoint by the

2.4.3.1 Rotary Lock 431 G 010 (Fresh Adsorbent)

This rotary lock is equipped with a variable speed drive.

2.4.3.2 Reactor 431 G 100 (Fluid Bed Height)

Outokumpu Technology GmbH