Residual Treatment Plant (RTP) is a part of Leaching and
Purification area in smelters. It is also called Jarosite Precipitation (JP)
area.
There are total of 5 Reactors having a capacity of 300 cubic
meters each at Zinc Smelter Debari. These reactors are equipped with agitators
and steam coil for heating process solution to 100 degree centigrade.
The challenge was that if the agitator of any reactor fails,
the steam would continue to flow through control valve to the reactor. As there
would be no mixing of solution due to failure of agitator, solution near steam
coils would heat rapidly and could lead to explosion of the reactor. The control
valve would only be closed manually and that involved great amount of risk as
well as process inefficiency.
A team consisting Mr. Vijay Kumar Rana (AM - Process), Mr.
Sanjay Kumar (AM - Instrumentation), Mr. Debasis Sahoo (Engineer - Process) and
Mr. Sandip Kanani (AM - Mechanical) felt the need for a change in this whole
process and automation with steam auto valve cut-off seemed to be the solution.
Once this modification was done, it is ensured that if
agitator of any reactor trips, the amperage of the reactor will drop down to no
load level and the valve will close automatically preventing the steam entrance
into the reactor.
This automation resulted in elimination of major hazard and
also eliminated man machine interaction in reactors. It also resulted in power
saving and increasing productivity.
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