Flue gas de-sulphurized (FGD) gypsum – An Important By-product of cement industry

Role of gypsum in cement Industry:

Limestone, gypsum, slag & other additives are the most common raw materials used in cement production. Gypsum is a soft, transparent or translucent mineral composed of crystallised calcium sulphate (CaSO4), found naturally in sedimentary deposits. Gypsum is added to cement to regulate the extreme setting reaction which occurs in the presence of water. Besides influencing the setting time, gypsum also has an influence on other properties of cement such as strength development, volume stability etc.  

FGD storage sheds

Flue gas de-sulphurized (FGD) gypsum (An Important By-product of cement industry):

FGD gypsum results from the emissions cleaning process known as flue gas desulphurisation (FGD), at coal fired electricity generating stations. The cleaning of flue gases is carried out when finely ground limestone (or lime) reacts with sulphur dioxide emissions to produce a pure gypsum. In some cement industries, a multistep manufacturing process with electric utilities are carried out to meet precise product specifications for FGD gypsum. Followings are the importance of FGD gypsum, as by-product of cement industry:

• Contribution as an end product
• Environment Friendly
• Highly Economic
• Higher Purity Than Natural resources

 

Hindustan Alcox Limited take pride to be one of the top gypsum storage shed manufacturer  in India by offering world-class sheds in form of barrel vault structural sheds or gypsum domes. The Company has wide experience of about 30 years in building FGD sheds  with long span steel structure having span of up to 150 m & height of up to 40 m.

 

– Hindustan Alcox Limited, New delhi

(FGD Shed – Specialist)

 

 

Airport terminal Building: Engineered Steel Structure With Long Span Structure

Long Span Structure:

large span structures

Structure with span larger than 20m can be regarded as long span structure. Long Span Structures are today widely applied for sport, social, industrial, ecological and other activities. Structures with long span can be build with R.C.C Construction since design approach of long span structures results into flexible and column-free internal spaces. Many large span structures dictated by new design trends have the following features:

• Structural stability with technological astonishment.

• Capability to support considerable loads.

• Offers Economy in terms of steel weight.

Airport Terminal Building- A well-engineered steel structure with long span:

For building any Airport, the span & design of the Airport Terminal Building should be placed at high priority than material efficiency and ease of construction. All parts of the building utilize repetitive, modular designs that accommodate construction phasing and permit rapid construction. One of the primary design feature of the Airport Terminal Building is a long-span steel roof covering the check-in hall, security, and passport control functions.

As an experienced entity in building Airport terminal buildings with long span steel structures, Hindustan Alcox Limited had crafted many glorious examples of international airports & important gateway for national and International export like Vishakhapatnam airport, Chennai International Airport, Netaji Subhash Chandra Bose International Airport, Rajiv Gandhi International Airport, Gondia Airport – Maharashtra, Chandigarh international airport etc.

• Hindustan Alcox Limited, New Delhi

  (Airport Specialist in India)

Coal Storage Domes integrated with Coal Gasification: An Ideal Storage Solution

Coal Storage:

Spontaneous Combustion

For a fruitful outcome of thermal Power Plants, the business of industrial coal storage for large quantities is on top priority for maintaining the product Integrity. Open stockpiles leave materials subject to degradation during storage. In addition, there are environmental concerns with controlling dust and runoff from these coal stockpiles.

Coal Storage Domes integrated with Coal Gasification:

Coal storage

Conversion of coal by the chemical processes to produce a mixture of combustible gas or fuel gas or syngas is termed coal gasification Coal Gasifiers generally entails the controlled oxidation of the coal to convert it into desired gaseous products. The emphasis of coal gasification is to meet stringent emission control requirements.

Bulk storage dome structures are highly durable and strong. If we talk about strength and average building life of dome structures, then their life is longer and strength is more than any other type of stacker reclaimer sheds in Space frame industry. Coal storage domes with coal gasification has its own advantages. These include:

• Simple foundation requirements.

• Rapid construction regardless of weather.

• Condensation is virtually eliminated.

• Better environmental and fugitive dust control.

• Environment Friendly.

Dome Structural system provides a unique solution to the bulk storage industry. Remained committed towards sustainability and improving the local economies, the coal dome manufactured by Hindustan Alcox Limited are strong, durable, environmentally sound and adaptable. Over Last 20 Years, Our capabilities as a “prime industrial shed manufacturer” include building the Bulk storage dome shell for providing turnkey solutions all over the world.

• Hindustan Alcox Limited, New Delhi

  (Coal Storage Sheds Manufacturer in India)

Structural Technology of Space frame – The Reason Behind Popular Landmarks

Space structures:

Space Structure

The system of the space structure is a tetrahedron rigid structure constructed by interlocking struts in a specialized and well engineered three-dimensional geometric pattern. To utilize multi-directional and long span with a few supports, space frame structures or space structures are used, where flexing loads are transmitted as tension and compression loads along the length of each strut. These space frame structures are formed by assembling the pre-manufactured steel rods (linear elements) in such a way to uniformly distribute the overall load.

Features of a space structure are:

• High spanning capability
• Light In weight
• High resale value
• Greater safety factor
• Free forms
• Feasible 3-D Geometry
• Pre-assembly permits project acceleration

The Reasons behind popular landmarks (made by space frame technology):

1. Freedom of geometry: The first step in any form of structural analysis is the determination of degree of geometrical freedom in the space frame. A number of popular examples of landmarks have been proved to illustrate the freedom of geometry in structural framework comprises of space frames.
2. Highly Aesthetic View: Space structure system stands out as a superior aesthetic and architectural end product & present an aesthetic view for both indoors and outdoors.
3. Accuracy in Installation: Another essential feature of using Space frames is that there is a high degree of accuracy in the process of designing, fabrication and installation of space frames.
4. Versatile Structure: Possessing a versatility in shape & form, Space frame structure not only utilize a standard module to generate various free-form shapes but also exhibits its adaptability in accordance with the future trends.

 

Since last few decades the company, Hindustan Alcox Limited emerged as largest space frame manufacturer in india. Hindustan Alcox Limited pays special attention towards adhering to the highest standards of quality & sustain this growth to adapt with today’s emerging trends. Besides this, we are upgrading our services & technology and imperatively working towards creating well engineered and complex structures.

 

Hindustan Alcox Limited, New Delhi
(Space Frame Manufacturers In India)

Tensile Membrane Structures – A Highly Advantageous & Appealing Form of Membrane Structures

Tensile Membrane structures:
Membrane structures are widely popular in architectural design and are increasing in their abundance within Buildings, Sports Arena etc. These structures carry loads by membrane forces, with zero or insignificant bending. When tensile and compressive membrane forces are permitted within these structures, then the structures will be called as TMS or Tensile membrane structures.
Tensile Membrane structures are the exciting method of construction followed as new trend. Tensile Membrane Structures are characterized by having a negligible mass relative to the applied load, which is determined through an optimization process. In natural climate conditions the speed of ageing of these ETFE structures and the differences of their tensile strength under radiant energy over the course of time is regarded as an indicator of weather resistance. Blending aesthetic appeal with modern technologies, these structures are not only visually exciting, but also environmentally good and economically competitive as well.

Factors responsible to make tensile membrane structures an appealing and beneficial membrane structures:
Developments in material technology and the understanding of the structural behaviour TMS mean that it is now technically feasible to enclose very large spaces with a minimum of material. Followings are The factors that lead to a growth in the relevance of environmentally friendly architecture within which Tensile membrane structures have a useful role to play:

1. Excellent Optical Effects: Optical properties of the roofing structure offers a means of creating spaces where daylight levels are accentuated or creating more protected shaded spaces and night artificial lightening magnifies its elegance and creates ambient exterior luminescence. The Tensile membrane structures offer such optical properties to exhibit in the day and night which reduces the cost of interior lightening.
2. More Impressive Elegance: Tensile membrane structures can be easily manipulated into various types of shapes and are rich in color. Formation of Aesthetic night scenes with the coordination of light, gives membrane structures a competitive edge with today’s highly elegant modern buildings.
3. Outstanding Durability: Stability & durability are basic mechanical properties that all building structures must satisfy. Ranging from a frigid arctic climate to hot & scorching weather, membranes such as PTFE fiberglass, ETFE film and PVC  proved to be an excellently durable and long lasting fabrics used in the manufacturing of membrane structures.
4. Energy Conservation: High sun reflectivity and low absorption of sunlight by most of membrane structures, results in less energy used within a building and ultimately reducing electrical energy costs.

As a leading ETFE and PTFE manufacturer, Hindustan Alcox Limited specializes in creating customized membrane structures with sophisticated designed practices. The ETFE structures also includes tensile membrane structures, which require a prior understanding of shape and form, the behaviour of the materials used and the forces acting on it.

 

Hindustan Alcox Limited, New Delhi
(Membrane Structures manufacturers)

Role of Coal Gasification In various industries

Introduction to Coal Gasification / IGCC technology:

IGCC stands for “Integrated Gasification combined cycle”. The preliminary conversion into a gaseous fuel originated is named as SynGas / Synthesis Gas. Synthetic gas is an intermediate source for generation of hydrogen, ammonia, methanol, & other synthetic hydrocarbon fuels. For electricity generation, synthetic gas is not only used as fuel of internal combustion engines due to its combustible nature, but also plays an important role in keeping the plant eco- friendly.

During Coal storage at a large scale, for harnessing coal’s energy more cleanly and efficiently, a number of different ways attempted in order to motivate environmental concerns. Among them, the technology comes out to be most successful is coal gasification, where instead of burning the fossil fuel, it is chemically transformed into synthetic natural gas or syngas.

What is the Need:

Till now, the main objective of Conventional Thermal Power Plant was to increase the efficiency by means of increased temperature and pressure in the steam, which in turn generate an efficient power outcome. But today the need is to get more efficient power production along with keeping the outside eco friendly. With the technical advancement in working methodology, the upgraded thermal power plants are now capable to generate power using Coal Gasifiers in purpose to increase efficiency of the plant.

Coal Storage

Advantages of using the Coal Gasifiers:

• Clean Energy Conversion: From an economic and energy security perspective, coal gasification is proved the most successful process to dealt with clean energy conversion, since instead of opening the intermediate poisonous gases up to exploitation, coal gasification helps to access these resources cleanly.

 

• Environment Friendly: Addressing the atmospheric problems resulting from burning coal and getting least affected by these poisonous gases is one of the top priority objectives of coal gasification. This Environment friendly feature of coal gasification is also the key to achieve near-zero emissions from gasification-based power generation.

• Enhanced Power Generation & Reduced Resource Consumption:In coal based thermal power plants, synthetic gas collected during the coal gasification is used as fuel of internal combustion engines due to its combustible nature, which in turn not only participate in enhancing power generation but also reduces the resource consumption.

• Easy Installation and Maintenance: Coal Gasifiers, which are the main source to carry out coal gasification are installed in conjunction with coal bunkers. As far as their fixing and maintenance is concerned, these coal gasifiers are very simple to install and to maintain for the long term.

Coal Storage Shed

To supplement the eco friendly nature of the energy, Hindustan Alcox Limited provides world-class structures to cover spans up to 150m and any length. These sheds provide economical solution for such storage needs.

– Hindustan Alcox Limited, New Delhi

(Coal storage Shed Manufacturers in India)

Gypsum storage – Moisture Problem & Their Control Strategies

Gypsum Storage:

In cement producing plants, a widely used fine-grained calcium sulphate (CuSo₄) material used as binding agent is “gypsum”. In cement plants, gypsum is used as one of the prime materials to provide premium performance and superior aesthetics for a wide range of occupancies. Such material shall be stored in properly constructed sheds ensuring its storage without deterioration and without contact to ground and structural members, without exposure to moisture and heat, and away from direct sun.

Gypsum storage sheds

 

Moisture / Caking problem in Gypsum Storage

Materials required in construction operations shall be stored, and handled in a manner to prevent deterioration and damage to the materials, ensure safety of workmen in handling operations.

In context of gypsum storage in cement industry, Moisture control is one of the complex handling issues. Moisture ingress in gypsum stockpiles should be controlled not only to promote the well being of occupants but also the sustainability of a building to be constructed. Moisture Problem in gypsum storage not only linked to potential health problems, including increased risk of respiratory conditions resulting from exposure to mold, microbial agents, dust mites, but also can negatively impact durability, maintenance, aesthetics, and serviceability.

 

 

Moisture Control Strategies for Gypsum storage:

Many factors must be considered to ensure no moisture in gypsum stockpiles.

• The foremost step regarding moisture control strategies for gypsum storage is to address all potential sources of water intrusion and then to offer all viable solutions for its prevention from moisture.

 

• Materials subject to loss of quality through moisture should be kept within impermeable wrapping, if not used within a reasonable period.

 

• Integrating the air and /or vapor retarder with the penetrations helps to restrict air and vapor flow, resulting in reduced moisture problems. Air control highly need to have structural continuity, while vapor control can be accomplished using a variety of other materials.

 

• Dehumidification involves the withdrawal of moisture from the air to lower its relative humidity. This generally becomes necessary during wet monsoon months to facilitate production processes and prolonging storage life of gypsum and other additives in bulk.

 

• The roofing system is a vital part of the exterior weatherproofing envelope and is comprised of a multitude of steel materials and components. It is crucial that ceiling and penetration of roofing systems be properly designed & installed to provide better performance. Therefore, Gypsum stockpiles should be stored at the work site in a building or a storage shed which is dry, leak proof and moisture proof.

Gypsum storage

Gypsum storage sheds engineered by Hindustan Alcox Limited is the most advisable choice to cover gypsum stockpile for the adverse environment conditions. We, at Hindustan Alcox Limited provide storage solution for gypsum with long span steel structure having span of up to 150 m & height of up to 40 m. Besides barrel vault structure, Gypsum dome also provides an opportunity to achieve good plant efficiency by maximum space utilization and hasty operational works.

 

 – Hindustan Alcox Limited, New Delhi

(Gypsum Storage Shed Manufacturer)

Airport Terminal Building: Key Planning Issues& Resolution

Need for Airport Terminal Building:

An Airport Terminal building is the most significant interface between ground access and the aircraft. Growth in aircraft traffic and the introduction of larger aircrafts have influenced the service life of airports.

Space frame structures

In the context of the robust growth of the country economy, the need for Airport terminal buildings is felt to keep pace with the rapid increase in air travel and development in the infrastructure of airports as well.

 

Objectives of an Airport Terminal Buildings:

The four basic objectives of airport terminal building are as follows:

• Operational efficiency for processing of passengers and their baggage
• Providing Ample Parking space for aircraft
• Adaptability to implement innovations in aviation technology
• Security

 

Key Planning Issues in building an Airport Terminal Building:

Depending upon the ongoing trend analysis and survey, followings are the Key Planning Issues in building an Airport Terminal Building:

 

• Growth Rate for Traffic at Terminal buildings:Passenger traffic is the key parameter, which needs to be estimated or forecast appropriately for capacity planning.

 

• Peak Hour Projections:An Airport Terminal building and its facilities therein should have sufficient space to cater to peak hour passenger traffic at the airport.

 

• Level of Services in Target Year:Level of Service Standards and associated criteria to evaluate the level of service is a rather complex issue. Passengers are concerned with completion of air journey at a reasonable cost, with minimum delay, and inconvenience.

 

• Cost of Construction:The design and approach towards Airport Terminals have undergone a radical change. Earlier, a terminal was a building where a passenger commenced and concluded an air journey. Currently, a lot more is expected from an airport terminal building – not only it should be functionally efficient, it should also be aesthetically and architecturally appealing to view.

large span steel structures

Airport space frame structures are planned for maximum efficiency, convenience and economy. The main objective is to impart space for line operations, facilities for passenger’s convenience, office for the airport management as well as non-aeronautical functions.Since 30 years, the company Hindustan Alcox Limited emerged as leading airport steel structure manufacturer in producing well engineered and aesthetically appealing airport terminal buildings.

 

 

– Hindustan Alcox Limited, New Delhi

(Airport Terminal Buildings Manufacturer)

Gypsum storage sheds: In-plant Handling & Service

Gypsum storage:

Gypsum storage

Gypsum is fine-grained calcium sulphate (CuSo₄) material industrially used as binding agent and a prime consumer in the cement industry. Gypsum is produced from open-cast mines, or underground mines using pillar and stall mining methods. For cement manufacturing process, Gypsum is supplied in crushed form for further fine grinding with clinker.

 

The Gypsum Industry is consistently working towards its building value for society by offering creative, safe, recyclable & economic products for the homes. Moreover, the cement industry is using gypsum storage in controlled composition as additives to improve cement’s inherit qualities, performance and efficiency.

 

FGD or Flue Gas Desulphurization is another application of Gypsum storage in which the desulphurization process takes place when the flue gases are brought into contact with an aqueous suspension containing powdered limestone or quicklime. The SO2 is washed out by the water and oxidized to SO3 in the aqueous solution, and precipitated to get gypsum.

 

In-plant Handling of Gypsum storage:

Stockpiles of gypsum are very heavy and can become unstable if proper stacking and handling procedures are not followed. Special care must be taken while loading, securing shipments, warehousing, or handling gypsum. Heavy equipment are generally used to move, stack, load, stock, or handle gypsum storage. A large machine that is used in performing almost all in-plant handling operations, is Stacker or Reclaimer. The stacker is mainly used to produce efficient industrial outcome by avoiding problems like increase in moisture, caking, oxidation etc. In addition to stacker or reclaimer, Lift trucks are also used to move heavy stacks of gypsum.

 

Exposure of gypsum stockpiles to rain and other high moisture levels may result in water stains, discoloration, particle segregation & sag. To evade such problems, Hindustan Alcox Limited provides gypsum stockpile sheds with highest quality standards ensuring safety and reliability which ensures the safety of stored resources.

 

Services We Provide:

Hindustan Alcox Limited offer the gypsum storage solutions with economical and ecological aspects which will also comply with future demands. Along with Best possible safety standards in all functions, we provide storage solution with worldwide proven technology, reliability & quality. We provide –

• Highest quality standards ensuring safety and reliability
• Efficiency and profitability
• Intra-plant quality assuring systems
• Commissioning with highly qualified supervisors
• Worldwide After-Sales Services

 

 

• Hindustan Alcox Limited (Gypsum storage shed manufacturer in India)

Impacts on Public & Environment by Coal Storage & Handling

Coal storage

Nowadays, Intermediate coal storage or lignite storage is common practice with indirect coal preparation systems. A constant feed from coal mines either to the coal mill or to the burners of a kiln system is a prerequisite for safer coal operations. The captive thermal power plants where coal is kept before burning also emit large quantities of carbon dioxide (CO₂ ), the “greenhouse gas” which are largely responsible for climate change. Depending on different factors like geology, demographics & climate, the public health and environmental effects caused by power plant may also vary from place to place. Followings are the major impacts on public & environment by coal storage & handling:

• Respiratory Effects: Inhalation effect from coal storage & handling is the biggest concern, which causes breathing problems not only to the people at the site but also to people living nearby the coal-based power plants.

 

• Impact on water bodies: At the coal-based thermal power plant, screening of coal is done to remove the impurities from the coal and the waste is placed in waste piles. If rain comes, rain percolates through these waste piles containing harmful soluble components and elevates Total Dissolved Solids (TDS) in local water bodies. This runoff is also acidic and contains heavy metals. In this way, Coal storage harms land, surface waters, groundwater and even air.

 

• Impact to the land:  Affect to the land from coal storage and handling cause drastic changes in the local area nearby by deteriorating land fertility and inculcating harmful chemicals. Damage to plants, animals and humans occurs from the destruction and removal of habitat & environmental contamination.

 

 

Using coal storage sheds over open stockpiles will be very much beneficial in reducing the above mentioned impacts on public & environment by coal storage & handling. We at Hindustan Alcox Limited specializes in manufacturing coal storage sheds with long span steel structure having span of up to 150 m & height of up to 40 m. Along with these longitudinal sheds, we also built dome type structural storage sheds. These coal dome and lignite dome, engineered by Hindustan Alcox Limited is one of the best choices to cover stockpile for the purpose to benefit the environment.

 

 

• – Hindustan Alcox Limited, New Delhi (Coal Storage Sheds Manufacturer India)