Indo German Energy Programme

Indo German Energy Programme
Page 1 of 1
Annexure IX Date 09.09.2008
Output 1.1
9. Basis for measurements and parameters to be monitored
9.1 Fuel
Coal is a natural product. For this reasons its chemical, physical and technological
properties depend on the herbal starting substances and the geometrical conditions during
carbonisation. The knowledge of chemical, physical and technological properties of coal is
of utmost importance for its use as fuel in combustion plants. A German Standard,
DIN 51700, defines the most important analysis procedures for the uniform description of
properties of solid fuels.
To assess the coal, a distinction is made between the pit coal as delivered and the water
and ash -free substance (waf). The moisture and ash -free substance contains only the
burnable parts of the solid and volatile elements. Prerequisite for smooth operation are the
knowledge of and information about these characteristics and properties.
The following overview shows the most important characteristics:
• Calorific value
• Ash content
• Water content
• Volatile elements
• Sulphur content
• Elementary analysis of the ash
• Melting behaviour of the ash
• Mineral size fraction of the pit coal
• Composition of the mixture
• Elementary analysis of the coal
• Apparent weight
• Grinding fineness of the pulverised fuel
• Grindability of the coal
If the fuel sample is taken from the material as delivered, it is called "raw". Water-free (waf)
is the term for the fuel dried at 106°C until reaching constant weight. The water- and ash-
free fuel results from deducing the ash content from the water-free fuel. This does not
correspond exactly to the ballast ratio, as during ashing the mineral portion may partly
change.
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Output 1.1
9.2 Heating value
To assess the heating value, the two terms upper heating value and lower heating value are
of importance. The upper heating value (Ho) is the amount of heat released during the
complete and perfect combustion of a certain amount of fuel. During the combustion, the
water content must be evaporated by the flue gases. For this reason, the water evaporation
heat must be deducted from the upper heating value (Ho) in order to receive the actual
lower heating value (Hu).
9.3 Water content
The moisture content of the coal, which is relevant for assessment and calculation, is
composed of the rough and the hygroscopic moisture. The rough moisture or surface
water is the moisture, which evaporates when the fuels are exposed to air at room
temperature.
The hygroscopic moisture is the moisture, which additionally evaporates during drying of
the fuels at 106 °C.
In order to determine the total moisture content, 100 g of coal is weighed accurately to
0.01 g in a shallow dish and dried until reaching a constant weight after about 3 hours.
a −b
Water content = ⋅ 100 [%]
c
a= dish and coal (moist) [g]

b= dish and coal (dry) [g]
c= coal (moist) [g]
9.4 Ash content
The determination of the ash content is supposed to provide information on the content of
inorganic (non-burnable) elements.

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Output 1.1
The term "ash" refers to the combustion residues of the solid elements obtained at a
temperature of 815°C. This residue is coadunate with the coal b ut a loosely mixed-in part
of the extracted material.
In order to determine the ash content according to DIN 51701, 1 g of processed coal is
weighed accurately to 0.0001 g. Together with the porcelain dish, the sample is inserted
into the cold muffler, and then it is slowly heated and completely burnt. After cooling
down it is weighed again and calculated as follows.
b−a
Ash (moisture free) = ⋅ 100 [%]
c
a= dish [g]
b= dish and ash [g]
c= coal (as weighed) [g]
Conversion of the ash content to the pit coal:
100 − Water content

Ash (raw ) = Ash (moisture free) ⋅ [%]
100
9.5 Volatile elements
Volatile elements are decomposition products of the organic fuel substance which leak out
as gases or vapours during the airtight heating of solid fuels up to around 900°C. The
remaining residue is called crucible coke.
According to their volatile elements, the coals are classified in grades.
To determine the volatile elements, 1.000g of analysis sample is degassed in a quartz

crucible covered with a loose cover at 900°C for 6 to 7 minutes. The degassed elements are
calculated as volatile elements in the following manner:
a −b
Volatile components (moisture free) = ⋅ 100 [%]
c

Page 4 of 4
Output 1.1
a= quartz crucible and coal (moisture free) [g]

b= quartz crucible and residue [g]
c= coal as weighed (moisture free) [g]
9.6 Sulphur
Apart from waste material, the sulphur content in solid fuels ranges between 0.1% and 2 %.
Depending on the bond, a distinction is made between organic and mineral sulphur. The
absolute amount of sulphur content would not matter if the SO 2 emissions were not of
such importance today.
Organic sulphur is contained in the organic substance of the coal, whereas the mineral
sulphur derives from the ballast. The sulphur determination is effected according to
DIN 51724. The fuel analysis always specifies the total sulphur content.
9.7 Melting behaviour
The melting behaviour of the ash is an important indicator for the assessment of the
slagging behaviour of coal ashes. For the slagging of the heating surface, it is important to
know the softening temperature of the ashes for all coal boilers.
An important characteristic for melting boilers is the flow temperature. The analysis
described in the following is designed to offer a comparison between different ashes
concerning their melting behaviour.
A compact of fuel ashes is heated in a slightly reducing or oxidising atmosphere. The

deformations which occur at different temperatures are a characteristic for the melting
behaviour.
The most important deformations:
• Softening point (first indications for a deformation)

• Melting point (specimen is hemispherical)
• Flow point (ash becomes liquid)

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Output 1.1
The melting behaviour of the ash depends on its composition. Lime, iron oxide and
alkaline salts reduce the melting point. Alumina and silicic acid increase the melting point.
Typical characteristics of the melting behaviour:
• Short slags (little temperature difference between melting and flow

temperature)
• Long slags (big temperature difference between melting and flow
temperature)
9.8 Grindability
The grindability characterises the necessary energy input for grinding coal. A method
which is often used is the Hardgrove procedure. This method is based on the law as set up
by Rittinger according to which the effort necessary for grinding is proportional to the
newly created surface.
In this procedure developed in the USA, a coal sample with a set grain size (0.5 to 1.2 mm)
is ground in a determined time unit. The screening occurs with an R 0.075 screen and is
compared to a reference coal.
Particularly for dust firing, the grinding of coal is of importance. Coals with a longer
carbonisation time have a reduced content of volatile ingredients, and they are harder.
According to empirical assessments there is a connection between the volatile elements
and the grindability. A low index means higher effort for grinding than would be necessary
for coal with a higher Hardgrove index. The grindability also depends on the mineral
content (ash) and its composition.
9.9 Air flue gas
On the basis of a basic measurement, the efficiencies of the individual components and
eventually the overall efficiency of the plant are to be determined. This requires a whole
range of individual measurements. In some parts of the system continuous measurements
have to be carried out, while in other parts of the system all lines have to be measured at

Page 6 of 6
Output 1.1
the same time. The combustion system, i.e. the individual burner pipes, is an example of
this.
At this point, reference is made neither to the measurement set up not to the
measurement itself; only the measuring points shall be mentioned.
The fo llowing components of the air / flue gas system have to be measured:
• Life air fans,

• Induced draft fans,
• Fans of the flue gas desulphurisation (FGD fans),
• Flue gas return fans,
• Mill and exhaust vapour fans,
• Fans for pneumatic conveyance, i.e. carrying air for coal dust, air-borne
coke, ashes, shot beading etc.
• Air lock fans for Ljungström air preheaters,
• Fans for cooling towers and air condensators,
• Ventilation and deaeration fans,
• Air wheels for cooling the winding of electric motors and generators.
To determine the individual efficiency, the following parameters have to be measured in

individual systems: electrical power, pressure, temperature, mass flow, differential
pressure and oxygen content (O 2). When the measuring data are determined, wear,
pollution and leakages have to be taken into account; at least they should be documented.
9.10 Data required
The data required for assessing the efficiency, output, capacity, steam temperature
control, exist gas and air entering temperatures, water /steam pressure drops, air / gas
pressure drops, air infiltration, fuel, air and gas flows are given in the following tables.

Page 7 of 7
Output 1.1
Table 1: Parameters required for efficiency determination by energy balance method (Source
ASME PTC 4)
Parameter Typic al Typical

Influence [Note (1)] Influence [Note (2)]
DRY GAS LOSS PRI
Fuel Analysis PRI M
% O 2 in Flue Gas PRI M
Flue Gas Temperature PRI M
UNBURNED CARBON SEC M/E
% Carbon in Residue PRI M
Residue Split PRI C/M
Sorbent Analysis PRI M
Sorbent Rate PRI M
Fuel Rate PRI C/M
% CO2 in Residue PRI M
SO2/O 2 Flue Gas PRI M
WATER FROM H2 IN FUEL LOSS PRI M
Fuel Analysis PRI M
WATER FROM H2O IN FUEL LOSS PRI M
Fuel Analysis PRI M
MOISTURE IN AIR LOSS SEC M/E
Fuel Analysis PRI M
Flue Gas O 2 PRI M
Dry-Bulb Temperature PRI M
Wet-Bulb Temperature PRI M
Or Relative Humidity PRI M
Barometric Pressure SEC M
UNBURNED CARBON RESIDUE LOSS PRI M
Fuel Analysis PRI M
% Carbon in Residue PRI M
Residue Split PRI M
Sorbent Analysis PRI M
Sorbent Rate PRI C/M
% CO2 in Residue PRI M
SO2/O 2 in Flue Gas PRI M
UNBURNED H 2 IN RESIDUE LOSS SEC E
% H 2 in residue PRI M
CO IN FLUE GAS LOSS SEC M/E
Items for excess air PRI M
CO in flue gas PRI M

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Output 1.1

PULVERIZER REJECTS LOSS SEC E
Pulverizer Rejects Rate PRI M/E
Pulverizer Rejects Analysis PRI M/E
Pulverizer Outlet Temperature PRI M
Fuel Rate PRI C/M
Fuel Analysis PRI M
UNBURNED HYDROCARBONS IN FLUE SEC E
GAS LOSS
Hydrocarbons in Flue Gas PRI M
HHV of Reference Gas PRI M
Sensible heat of residue loss PRI M/E
Residue split PRI M/C/E
Temp of residue PRI M
Hot air quality control equipment loss PRI M
Flue gas temperature entering PRI M
Flue gas temperature leaving PRI M
%O2 in flue gas entering PRI M
%O 2 in flue gas leaving PRI M
Wet gas weight entering PRI C
Wet gas weight leaving PRI C
Air inflation loss SEC M
Inflation airflow PRI M
Inflation air temperature PRI M
Exit gas temperature PRI M
Formation of NO x loss SEC M/E
NO x in flue gas PRI M/E
Wet gas weight PRI C
Radiation and convention l0ss PRI M/E
Stream generator surface area PRI C
Local ambient air temperature PRI M/E
Local surface temperature PRI M/E
Local surface air velocity PRI E
Additional moisture loss SEC M/E
Mass flow of moisture PRI M/E
Flue gas temperature PRI M
Feed water pressure SEC M
Feed water temperature PRI M
Fuel flow PRI C/M
Calcination dehydration of sorbent loss PRI M
Sorbent analysis PRI M
Fuel rate PRI C/M
% carbon in residue PRI M

Page 9 of 9
Output 1.1

% CO2 in residue PRI M
Residue split PRI M/E
SO2/O 2 in flue gas PRI M
Water in sorbent loss SEC M
Flue gas temperature PRI M
Wet ash pit loss SEC E
Recycled streams loss SEC M
Recycled flow PRI M/E
Recycle temperature entering PRI M
Recycle temperature leaving PRI M
COOLING WATER LOSS SEC M/E
Cooling water Flow Rate PRI M/E
Temperature Water Entering PRI M
Temperature Water Leaving PRI M
Fuel Rate PRI C/M
Air preheat coil loss SEC M
(energy supplied from within boundary)
APC condensate flow rate PRI M/C
APCcondensate temperature PRI M
APC condensate pressure PRI M
Entering dry air credit PRI M
Entering air temperature PRI M
Excess air PRI M
Fuel analysis PRI M
Unburned carbon SEC M/E
Sulfur capture PRI M
Moisture in entering air credit SEC M/E
Moisture in air PRI M/E
Dry-bulb temperature PRI M
Wet- bulb temperature or relative humidity PRI M
Barometric pressure SEC M
Sensible heat in fuel credit SEC M
Fuel analysis PRI M
Fuel temperature entering PRI M/E
Sulfation credit PRI M
SO2/O 2 in fuel gas PRI M
Fuel analysis PRI M
Sorbent rate PRI M
Fuel rate PRI C/M

Page 10 of 10
Output 1.1

% Carbon in residue PRI M
% CO2 in residue PRI M
Auxiliary equipment power credit SEC M/C/E
Steam driven equipment
Mass flow of steam PRI M
Entering steam pressure PRI M
Entering steam temperature PRI M
Exhaust pressure PRI M
Drive efficiency PRI E/M
Electrical driven equipment
For large motors:
Watt- hour reading PRI M
Drive efficiency PRI E/M
For small motors:
Volts SEC M
Amps SEC M
Sensible heat in sorbet credit SEC M
Sorbent rate PRI M
Sorbent temperature PRI M
Energy supplied by additional moisture credit SEC M/E
Mass flow rate PRI M
Entering temperature PRI M
Entering pressure PRI M
NOTES:
(1) Typical influence: PRI = Primary, SEC = Secondary
(2) Typical Source: M = Measured, C= Calculated, E = Estimated.
Table 2: Parameters required for efficiency determination by input-output method
Parameter Typical Typical

Heat input from fuel PRI M
Fuel rate PRI M
Heating value of fuel PRI M
Fuel analysis PRI M
OUTPUT PRI M

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Output 1.1
Table 3: Parameter required for capacity determination

Influence [Note (1)] Influence[Note (2)
Output PRI C
Saturated steam generator
Saturated steam flow PRI M
Feed water flow PRI M
Blow down flow PRI M/E
Extraction flow PRI M
Saturated steam pressure PRI M
Superheated steam generator
Main steam flow PRI M
Feed water flow PRI M
Blowdown flow SEC M/E
Desuperheating spray flow PRI C/M
Main steam temperature PRI M
Main steam pressure PRI M
Desuperheating spray water temperature PRI M
Desuperheating spray water pressure SEC M
Reheat steam generator
Reheat steam flow PRI C/M
Reheat desuperheating spray water flow PRI M
Feed water heater extraction flow PRI C/M
Feedwater heater extraction temperature PRI M
Feedwater heater extraction pressure PRI M
Feedwater heater entering water temperature PRI M
Feedwater heater leaving water temperature PRI
Feedwater heater water pressure SEC M
Feedwater heater water drain temperature PRI M
Turbine leakage SEC E
Steam extraction flow (other) PRI M
Reheat out steam temperature PRI M
Reheat out steam pressure PRI M
Reheat in steam temperature PRI M
Reheat in steam pressure PRI M
Reheat desuperheating spray water temp PRI M
Reheat desuperheating spray water pressure SEC M
Auxiliary steam

Page 12 of 12
Output 1.1

Influence [Note (1)] Influence[Note (2)
Auxiliary steam flow PRI M/E
Auxiliary steam temperature PRI M
Auxiliary steam pressure PRI M
Table 4: Parameters required for steam te mperature /control range determination
Parameter Typical Influence Typical Influence[Note (2)]

[Note (1)]
Superheated steam generators
Blowdown flow PRI M/E
Main steam temperature PRI M
Main steam pressure PRI M
Drum pressure (if applicable) PRI M
Drum level
Feedwater pressure SEC M
Desuperheated spray water flow PRI M
Desuperheated spray water temperature PRI M
Desuperheated spray water pressure SEC M
Other items required to determine output SEC M/C/E
Reheat steam generators
Reheat steam flow PRI M
Reheat out steam temperature PRI M
Reheat in steam temperature PRI M
Reheat desuperheating spray water flow PRI M
Reheat desperheating spray water temperature PRI M
Reheat desuperheating spray water pressure SEC M
Related parameters
Excess air M
Gas proportioning damper M
Flue gas recirculation flowBlowdown M

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Output 1.1
Table 5: Parameters required for excess air determination

Excess air M
Fuel analysis PRI M
Unburned carbon PRI C/E
% O2 in flue gas PRI M
O2 wet basis moisture in air PRI C/E
Dry-bulb temperature PRI M
Wet-bulb temperature PRI M
Or relative humidity PRI M
Barometric pressure SEC M
Additional moisture PRI M
Ca/s molar ratio PRI C/E
Sorbent rate PRI M
Fuel rate PRI C/M
Calcination PRI C/E
% CO 2 in Residue PRI M
Sulphur capture PRI C/E
SO 2/O2 in flue gas PRI M
Table 6: Parameters required for water / steam pressure drop determination

Super heater pressure drop M/C
Superheater outlet pressure PRI M
Superheater inlet (drum) pressure PRI M
Feedwater flow PRI M
Blowdown flow SEC M/E
Superheater spray flow PRI C/M
Superheater outlet steam temperatures SEC M
Superheater inlet steam temperature SEC M
Reheater pressure drop M/C
Reheater inlet steam pressure PRI M
Reheater outlet steam pressure PRI M
Reheater flow PRI C/M

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Output 1.1

Feedwater heater extraction flow PRI C/M
Turbine leakage SEC E
Steam extraction flow PRI M
Reheater spray water flow PRI M
Reheater inlet steam temperature SEC M
Reheater outlet steam temperature SEC M
Economizer pressure drop M/C
Economizer water inlet pressure PRI M
Economizer water outlet (drum) pressure PRI M
Feedwater flow PRI M
Superheated spray water flow PRI M/C
Economizer water inlet temperature SEC M
Economizer water outlet temperature SEC M
Table 7: Parameters required for air / flue gas pressure drop determination

AIR SIDE RESISTANCE M/C
Forced draft fan discharge pressure PRI M
Air heater inlet pressure PRI M
Air heater outlet pressure PRI M
Winbox pressure PRI M
Furnance pressure PRI M
Air flow PRI C
Main steam flow SEC M
Air temperature SEC M
GAS SIDE RESISTANCE M/C
Furnance pressure PRI M
Super heater inlet pressure PRI M
Superheater outlet pressure PRI M
Reheater inlet pressure PRI M
Reheater outlet pressure PRI M
Generating bank inlet pressure PRI M
Generating bank outlet pressure PRI M
Economizer inlet pressure PRI M
Economizer outlet pressure PRI M
Air quality control equipment inlet pressure PRI M
Air quality control equipment outlet pressure PRI M
Air heater gas inlet pressure PRI M
Air heater gas outlet pressure PRI M

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Output 1.1

Flue gas flow rate PRI C
Main steam flow SEC M
Flue gas temperature SEC M
Table 8: Parameters required for air infiltration determination

Infiltration based on measured o 2
Excess air entering component PRI C
Flue gas O2 entering component PRI M
Excess air leaving component PRI C
Flue gas O2 leaving component PRI M
Infiltration by energy balance C
Flue gas rate entering air heater PRI C
Flue gas O 2 entering air heater PRI M
Fuel analysis SEC M
Flue gas temperature entering air heater PRI M
Flue gas temperature leaving air heater PRI M
Air temperature entering air heater PRI M
Air temperature leaving air heater PRI M
Moisture in air SEC M/E
Table 9: Parameters required for fuel, air and flue gas flow determination
Parameter Typical Influence [Note (1)] Typical Influence Note (2)]

Input from fuel
Fuel rate (measured) PRI M
Fuel rat (calculated) PRI C
Output PRI M
Fuel efficiency PRI C
Fuel analysis PRI M
Wet air flow rate C
Excess air PRI C
Moisture in air PRI C
Wet gas flow rate C
Fuel analysis PRI M
Unburned carbon PRI M/E

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Output 1.1
Parameter Typical Influence [Note (1)] Typical Influence Note (2)]

Excess air PRI M/E
Moisture in air PRI M/E
Additional moisture PRI M/E
Ca/S MOLAR RATIO PRI M/E
CALCINATION PRI M/E
Sulpher capture PRI M/E

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9. Basis for measurements and parameters to be monitored

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9.2 Heating value

9.3 Water content

a= dish and coal (moist) [g]

9.4 Ash content

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Conversion of the ash content to the pit coal:

100 − Water content

9.5 Volatile elements

According to their volatile elements, the coals are classified in grades.

To determine the volatile elements, 1.000g of analysis sample is degassed in a quartz

D:\Guptha\Steag \GTZ\Output 1\Output1.1\Final report 23 July 08\Annexures\NEW AnnexureIX.doc

a= quartz crucible and coal (moisture free) [g]

9.7 Melting behaviour

A compact of fuel ashes is heated in a slightly reducing or oxidising atmosphere. The

• Softening point (first indications for a deformation)

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Typical characteristics of the melting behaviour:

• Short slags (little temperature difference between melting and flow

9.9 Air flue gas

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• Life air fans,

To determine the individual efficiency, the following parameters have to be measured in

9.10 Data required

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Parameter Typic al Typical

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Parameter Typic al Typical

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Parameter Typic al Typical

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Parameter Typic al Typical

Table 2: Parameters required for efficiency determination by input-output method

Parameter Typical Typical

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Table 3: Parameter required for capacity determination

Parameter Typical Typical

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Parameter Typical Typical

Table 4: Parameters required for steam te mperature /control range determination

Parameter Typical Influence Typical Influence[Note (2)]

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Table 5: Parameters required for excess air determination

Parameter Typical Typical

Table 6: Parameters required for water / steam pressure drop determination

Parameter Typical Typical

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Parameter Typical Typical

Parameter Typical Typical

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Parameter Typical Typical

Table 8: Parameters required for air infiltration determination

Parameter Typical Typical

Parameter Typical Influence [Note (1)] Typical Influence Note (2)]

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Parameter Typical Influence [Note (1)] Typical Influence Note (2)]

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