Concept note for the conversion of 75 TPH IGNIFLUID Boiler An outline of existing process:

The IGNIFLUID Boiler consists basically of a travagrate where the bubbling action of the bed material along with the combustion process takes place. However, due to the high operating temperature of the fluidizing bed, the bed material or the burnt coal ash agglomerates to form bigger lumps and this will cause defluidisation of the bed. To avoid this, the grate is continuously in operation by which the agglomeration is taken out of the bed. Due to the absence of the bed coils in the combustion zone and the higher operating temperature of the bed, the bed floor plan area is comparatively lesser compared to a regular bubbling bed fluidized bed combustion boiler. The excess air level also will be high resulting in less boiler efficiency. It is, however, important to note that this type of boiler is taller than an FBC boiler of similar capacity.

Highlights of retrofit
1. During the retrofit, the travagrate will be totally removed. A static air box consisting of a distributor plate and fluidizing air nozzles fitted over this distributor plate will be introduced below the boiler. The combustion of the fuel will be taking place over this air box. The heat released by the combustion process will be continuously removed by what is known as bed coil tubes which will be located above the air box. These bed coils will continuously remove the heat from the combustion process and thereby act as steam generating coils. By this process the excess air level will be controlled within 20 % which is the optimum for a solid fuel fired boiler. 2. To provide these bed coils, suitable modifications in the existing furnace will be carried out. There is constraint in the lay out to achieve this increase in the floor plan area due to the presence of the boiler support columns. Hence the maximum possible increase in the floor plan area has been considered and based on the maximum bed coil area that can be accommodated in this available area, it is observed that the steam generation capacity of the boiler may reduce from the existing capacity of 75 TPH to 68-70 TPH. This figure is based on the details from the available drawings. However, only after exact detailing, it can be confirmed whether further increase in capacity beyond 68-70

TPH is achievable. Based on actual constraints, if any, observed during detailing, the boiler capacity could marginally drop also from 68-70 TPH (chances are rare). 3. By providing the bed coils, the temperature of the combustion zone is maintained within 900 Deg C. For this reason, the temperature profile of the boiler flue gases will come down resulting in lesser temperature at the existing superheater inlet zone. Hence to compensate this; additional super heater area may have to be provided in the existing super heater circuit. This aspect will be confirmed after detailed engineering. 4. The existing fuel feeding system will be modified. Present Single gravity feeder will change to six feeder system at lower location. There is space for that. 5. Due to the introduction of the air box with air nozzles, the pressure profile of the combustion air circuit will change requiring the replacement of the FD fan. Fuel will be fed to the boiler from the bunker through pneumatic arrangement for which a new fuel transport air fan will be introduced. 6. The existing ID fan may suit the requirements after conversion also. However the same can be confirmed upon receipt/verification of existing ID fan details. 7. The existing feed water pump will be retained. 8. The existing safety valves will be retained 9. The ESP data needs to be checked to find out the suitability of the existing ESP to meet the requirements after boiler conversion. 10. Ash handling system capacity and suitability needs to be checked and if necessary, may have to augmented or changed. 11. Fuel feed size to the boiler after conversion has to be less than 6 mm. The existing fuel handling system details are not available. If the existing coal crusher and screen are not selected for -6mm size, then the crusher and screen may have to be replaced retaining the conveyors.