Introduction:

Capacity enhancement is to increase the capacity of a plant by utilizing the hidden potential of all the major equipments through:

• Capacity evaluation, balancing and identifying the potential capacity of all the major equipments.
• Addition of minimum number of equipments for meeting the shortfall in capacity.
• Balancing of equipment by modifications as far as possible within the existing equipments only.
• Minimum modifications in the existing equipments to the extent possible.
• Minimum plant shutdown.
• All the essential performance improvement, safety, pollution control and infrastructure improvement measures to be included.

Coverage/ Methodology:

It covers:

• Collection of plant data and interaction with plant personnel.
• Carrying out process measurements during steady operation of plant covering temperature, pressure, flow & power.
• Analysis of plant design and operating data to identify the potential capacity major equipments.
• Carrying out capacity balancing of all the major equipments to identify the shortfall/ surplus.
• Situation analysis and formulation of various alternatives for upgradation of plant capacity.
• Carrying out mass gas and heat balancing of Pyro section.
• Finding out efficiency of all the process fans.
• Recommendation of measures for improvement of plant operations.
• Carrying out the Layout feasibility of the proposed addition/modifications.
• Preparation of General arrangement drawings for the proposed addition/modifications.
• Estimation of Capital Investments of the proposed capacity enhancement measures.
• Estimation of Return on investment in terms of Simple Payback period.

Benefits:

Plant Capacity enhancement study will lead to:

• Increased production capacity at the minimum cost.
• Increased market share of the company.
• Reduced cost of production.
• Increased profitability.