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Case Study in Coke Oven Waste Heat Recovery Boiler PDF
Case Study in Coke Oven Waste Heat Recovery Boiler PDF
Photo 3 is on the performance of the screen tubes. The screen tubes can cause a temperature drop
of 30 deg C.
Photo 4 shows a program print out on how much would be the heat transfer coefficient to gas
radiation in the waterwall above the PSH. The HTC is around 36.35 kcal/hm2C.
Photo 5 shows the heat balancing and the resultant gas temperature at PSH inlet. The gas
temperature would be 844 deg C.
Photo 6 shows the PSH performance. The steam outlet temperature will be 422 deg C. This
matches with the present performance with inlet gas temperature of 840 deg C.
Photo 7 shows the cavity radiation performance in the waterwall space between PSH and SSH.
The HTC is estimated to be 24.11 kcal/m2hC.
Photo 8 shows that by heat balancing the inlet gas temperature to SSH would be 724.6 deg C.
Photo 9 shows the thermal performance of the SSH with inlet gas temperature of even 714 deg C.
The steam temperature that can be achieved is 515 deg C.
Practically after refractory lining the radiant waterwall section, the inlet gas temperature to PSH is
presently maintained at 840 deg C. The SSH outlet steam temperature is close to 505 deg C when the
steam generation is around 34 TPH.
Faster cooling
Faster cooling of boiler with air or cold water cause sticky deposits. This is seen with boilers
operating with sulfur containing gases. When the boiler is shut, it has to be allowed for natural
cooling only. Only when the boiler is depressurised by natural cooling, ID fan can be used for further
cooling. Pumping of cold water is not advised.
Section wise fouling monitoring
It is advised to monitor section wise temperature rise over a period. On shut down the deposits
should be photographed and samples have to be analysed. The alkali phosphates can work as glue.
Use of sonic horns / air blasters
Sonic horns / air blasters are used for loose dust. If the dust can be blown by compressed air, it can
be removed by sonic horns / air blasters.
Steam soot blowers
Steam operated soot blowers are not provided since the dust load is less than 50 mg/Nm3. It was
learnt that removal of the final layer of deposits was difficult even with high pressure water jet.
Steam operated soot blower cause erosion as well.
Fouling factor for superheater design
The trend of deposition is very slow. It is learnt that the deposition occurs very slowly. If the deposits
is adherent then the fouling factor has to be considered in sizing the superheater surfacing. There is a
space of 1.6 m between the two SH. It is possible to add one more loop to account for fouling.
4. DRAFT AND BOILER OPERATION
Draft effect and ID fan
A natural draft is created at coke oven stack because
of the hot gases. The coke oven stack is designed to
create the necessary draft by natural draft created by
the chimney. The height and diameter of the CO
stack are selected to create the required draft at Coke
oven. At the foot of the stack the draft is more. As
we go up in the height the draft available reduces.
Suppose at the foot of the stack the draft created is 40 mmWC at 31.5 m, the draft will be 40*31.5/54 =
-23.3 mmWC. As long as the draft maintained by ID
fan at boiler inlet point is -23 mmWC, the air would
not enter the stack. As the negative draft is increased, cold air would start coming in to the boiler.
We must maintain the same draft as the coke oven would have operated using natural draft. The
study conducted by SS energy shows that at an rpm of 780 and above, the ambient air is coming in to
the boiler. See the table above. The O2 was measured from a tapping made about 1 m above the
tapping in Coke oven stack. At 695 rpm, the gas had filled the stack above boiler tapping point. At
780 rpm, air has filled the space, which means beyond an rpm the air infiltration starts increasing.
See the figure below for the understanding.
Variation in gas flow and operators control
During the discussion it was informed that the kiln
gas flow remains constant. It is not the case at
present. This can be found that the ID fan rpm is
not kept constant by the operators as they were told
to maintain 40 mmWC at boiler inlet. As such the
ideal set point has to be -23 mmWC. When the gas
flow is less, the draft loss at stack is less. Then part
of the gas would leave the coke oven stack as the
available head is more. Operators have to find the
optimum rpm at which the oxygen in economiser outlet does not rise beyond 8.5%. This oxygen is
said to be 8.5% because the coke oven might be maintaining the same in order to maintain complete
combustion of the gases and at the same time they maintain Coke oven temperature at 1050 deg C or
so. Even if the gas temperature can be maintained higher it is good for boiler. But it may not be good
for the life of the refractory. Boiler can accept 1050 deg C.
Using difference between the coke oven gas temperature to boiler inlet gas temperature as a
control
At the time of visit, boiler 633 was at 971 deg C and boiler inlet gas temperature was at 930 deg C.
The difference was about 41 deg C. By decreasing the ID fan rpm, the boiler inlet gas temperature
could be raised to 937 deg C. This meant that the outside air infiltration is being minimised. The rpm
was at 830 and the steam generation was at 26.9 TPH. The economiser outlet gas temperature came
down from 181 deg C to 174 deg C. This means that the infiltration of air is reducing. Further
exercise is advised to narrow down the temperature drop. The steam temperature at PSH may go up
beyond 430 deg C. As such the PSH outlet steam piping and headers are of P11 material. There is
good margin available for PSH outlet header. The IBR calculation page was checked. Photo 16
shows the IBR calculation provided by the boiler maker.
Can the Oxygen in flue gas be used for control?
It is recommended to install oxygen analyser at boiler outlet. The operator can decide the ID fan rpm
based on the Oxygen level. The CO ppm level at the maximum can be 100 ppm. The oxygen at CO
oven inlet must be matched. It is advised to do sampling of the gas at CO duct when all the ovens are
operating at optimum point.
5. MEASUREMENT OF GAS FLOW AT ECONOMISER AND VARIATION IN STEAM
OUTPUT
Batch operation of the coke oven and variation in heat content
breaks down. It can develop air leaks. It is advised to seal weld the flanges. The fabric is replaced in
situ and never the flanges are required to be removed. The same is recommended in the other two
fabric joints.
Why the steam generated is reduced by air infiltration?
The heat provided by the Coke oven is unnecessarily used for heating the infiltration air from 30 deg
C to 180 deg C. If the infiltration air is reduced, the heat would be transferred to water to produce
steam. Infiltration air is the key for variation in steam to coal ratio.
Day generation versus coal consumed
The day steam generation is not uniform in a boiler. The heat input from the Coke oven is varying /
air infiltration levels are varying. Only then the steam flow every day from the boiler to boiler is
varying. Hence the gas flow must be varying over time. It is advised to generate trend graphs of the
steam generated to understand the steam generation cycles versus CO operation. Depending on the
number of charges at coke oven, there would be spikes of steam generation. Hence the steam
generation versus coal generation must be computed between cycles and not the days. Perhaps steam
generated per cycle (48 hrs / 44 hrs) must be compared.
6. LOSS OF HEAT FROM CASING AND EFFECTIVENESS OF INSULATION
Loss of heat from pressure parts and casings in boiler
It is advised to check the insulation condition by thermography camera. As long as the surface
temperature is less than 60 deg C, the losses of heat will hardly be 0.4% of the total heat.
Loss of heat from hot gas duct from coke oven to WHRB
The loss of heat from the 10 m hot duct connecting the boiler is expected to be 0.95%. See
calculation attached in annexure. Since the duct between CO outlet duct to boiler duct will be 40 m
long in total, we can say 4% of the heat is lost between the Coke oven and the WHRB. The gas
temperature drop between temperature measurement point at CO outlet and WRHB inlet should not
be more than 32 deg C. It is advised to optimise the temperature loss by reducing the rpm and
increasing the gate opening. This will reduce the air infiltration from cap. Infiltration flow is a
function of the cap sealing. This can vary from boiler to boiler. Hence best installation would be one
with smallest difference between CO oven & PSH inlet gas temperatures. Needless to say, that the
new thermocouple shall be provided close to boiler inlet.
7. CORROSION OF ECONOMISER
Operation at low economiser water inlet temperature
It is learnt that at one point of time low feedwater temperature was maintained between the
economiser inlet to reduce the boiler exit temperature. Since the gas contains sulfur, it is advised not
to reduce the water temperature below 135 deg C. Corrosion can be identified by pitting. Tubes at
cold end must be brushed and inspected for pits. Acid dew point is normally around 125 deg C.
8. TIME FOR START UP
Boiler with superheater in front
At present the radiation chamber is covered with refractory. Hence there is only superheater at first.
We need to restrict the gas inlet temperature to 600 deg C till steam pressure rises. If radiation
chamber was open to heat pick up, the steam generation would be faster.
Start with hot water
Always start with hot water. Steam generation will be instantaneous. It puts less strain to SH.
Circulation would develop immediately. After hydrotest water must be drained off to DM tank. Lay
required piping from boiler to DM plant for this purpose.
9. OPTIMUM PARAMETERS FOR MAIN STEAM AT BOILER
Turbine heat rate
The turbine heat rate decides the optimum boiler pressure / temperature. Calculate turbine heat rate
for various conditions and decide. Each boiler will have its own back pressure based on the line
pressure losses. Steam temperature is decided by the gas inlet temperature to the WHRB and the gas
quantity. The superheater coils are widely pitched and is directly viewing the inlet hot gases. Hence
radiation pick up will be more as the inlet gas temperature is raised.
Steam pipe diameter
A steam pipe diameter is selected to keep the pressure drop optimum. Thus the material cost will be
less. If the diameter is on the higher side, the pressure drop will be lesser. There is no other effect to
turbine.
10. METHOD OF FLUE GAS MEASUREMENT
Gas flow measurement at CO outlet / boiler outlet
Ideally at both places it should be measured. Measuring at hot condition would not be practical as the
Pitot cannot be held due to heat conduction. At boiler outlet the gas flow can be measured. The gas
flow can be easily measured by averaging pitot at economiser outlet. As the small amount of dust is
likely to plug the port of averaging pitot tube, provision must be kept for easy withdrawal and
cleaning / compressed air cleaning on line. In case the gas flow is steady from CO, then this flow
reading will be steady.
deg C. There is no transmitter used. Directly cable is taken to DCS. There can be mV drop.
Disconnect the cable and measure mV at thermocouple. Measure the mV at cable end (before DCS)
and compare.
Local mercury in steel thermometer
Mercury in steel thermometers should be provided to measure the temperature locally. It is learnt that
new tapping has to be made. The range of the thermometer can be 600 deg C.
Steam loss in steam line
It is seen that the steam traps are kept in service in the main steam line. Superheated steam lines do
not cause condensation. It is the trap piping that condenses the steam and creates the trap action.
Heat being removed from the piping can cause temperature drop in main steam. In the case of black
out, drains shall be opened just prior to restarting. Drains shall be opened when the steam is first
charged to cold piping.
Heat lost in steam piping
The temperature of the insulating cladding of the piping is reported to be 55 deg C. The heat lost
over the entire steam piping is calculated and the revised steam temperature is found out. The
temperature drop in main steam piping is thus only 8 deg C.
16. REPLACEMENT OF INSULATION
This is not required as the skin temperature is reported to be 55 deg C. It is advised to measure the
temperature with IR camera to locate the sources of heat loss. Nowadays rigid insulation mattresses
are available either from mineral wool or from glass wool. One such product installed in another
plant for loss of temperature is shown in photo 16 of annexure. Similar products are available in LRB
mattress too.
17. IMPACT OF AIR INGRESS AT DIFFERENT ZONES OF BOILER
Air ingress is a heat loss. Instead of heating the water / steam the heat is transferred to air. Thus it is a
loss. It is seen that the all the air ingress points are already sealed. The oxygen mapping taken by SS
energy confirms that there is no air ingress. The oxygen levels are same right from the boiler inlet to
economiser outlet for all boilers.
provided here. It is learnt that spring supports are provided for one boiler only. See photo 22 in
annexure.
Hopper baffle plates
Evaporator hoppers and economiser hoppers can be provided with gas baffles to prevent gas by
passing at bottom. See photo 23 in annexure.
Roof for horizontal economiser duct
It was seen that roof cladding gets blown due to wind. A self (duct) supported light weight roof may
be provided to prevent rain water ingress to insulation. This area will collect rain and lead to
corrosion of economiser top casing.
Curved bends
The ducts in ID fan area are seen with abrupt 90 deg bend and abrupt Ts. Smooth bends will help in
reducing the power.
22. DIFFERENCES IN TOTALISED BOILER STEAM FLOW & TG STEAM FLOW
Range of calibration of transmitters
Range of calibration can be changed for sensitivity. If the steam generation of the boiler is not
exceeding 50 TPH, then calibrate to 55 TPH flow.
Correction for specific volume changes
Mass flow of steam is dependent on the steam pressure and steam temperature. When it varies the
mass flow needs to be corrected. Check if this is inbuilt in the indicated flow. The feed flow will be
fairly accurate as its specific volume does not change.
Arrangement of condensing pots for main steam line
Condensing pots for steam flow nozzles shall be located at the same level of the piping or above the
piping. It is learnt that at present the pots are below the steam lines.
23. DRUM LEVELS ARE BEING MAINTAINED BY THE 30% FCV ITSELF
Specification of the feed pump
It is seen the FCV inlet pressure is around 105 kg/cm2 whereas the steam drum pressure is at 68
kg/cm2. The feed pump specification was not available for comments. Pressure developed by the
pump can be reduced by fluid coupling / VFD. VFDs are available nowadays for HT motors too. The
pump and motor suppliers concurrence is required for this. Fluid coupling is a good choice for power
saving as well. Stage removal is possible in the pump. KSB will ask for the pump to be sent to works
for this purpose. This will be the most economical solution. During the shutdown time, the pump
may be sent for changes. Or else procure one new pump and fit on the existing base and send
remaining pumps one by one for changes.
Valve specifications
The valves are seen with discharge pressure of 97 kg/cm2 as well. See photos 24annexure. At no
point of time this pressure is required in service. Due to this valve trim will not be suitable for higher
travel. Normally valves have pressure drop from 2.5 kg/cm2 to 12 kg/cm2 only, which is based on
the pump discharge pressure at various flows.
24. TEMPERATURE CONTROL FOR EXTRACTION LINE AND DESH
Specification of TCV
Extraction line TCV will call for larger pressure drop. It is to be given with multistage orifice by the
valve manufacturer. DESH TCV is wrongly specified. See specification attached in photo 25 in
annexure. This can be used once the pump discharge pressure is reduced.
25. WATER CHEMISTRY
Blow down
It is learnt that the CBD needs to be kept open continuously and thus HP dosing is continuous. CBD
is being given to control silica. Silica can be kept in boiler water at 2.5 ppm for this pressure. Silica
can rise due to chemicals. Please check this out. Steam loss out of the system will lead to
concentration of silica. Stopping of steam traps will considerably reduce the steam loss. It is seen that
the deaerator venting is already minimum. Any other passing of valves must be arrested.
PO4 and pH in boiler water
The PO4 level can be reduced to 4-5 ppm to avoid problems related to concentration of chemicals in
evaporator bundle, which has low flow circuits. The pH of the boiler water can be 9.4 to 9.6. Only in
the case of condenser tube failure we need to boost PO4 to avoid low pH situation.
Drum internal condition
It is required to observe the steam drum internal surface for magnetite layer formation. See photo 26
& 27 in annexure showing two steam drums. The best drum is shown in photo 26. If this surface is
not achieved, problems can develop at evaporator bundles. Corrosion products can accumulate at
evaporator bundles and its supply pipes.
Assess mechanical carry over
It is advised to check sodium in boiler water and in saturated steam. Even trace of PO4 found in
saturated steam is an indication of mechanical carry over. If mechanical carry over is present, the
boiler water silica has to be lowered and the blow down losses will be more.
CONCLUSION
1. The useful heat from Coke oven should not be diluted by excess air both and coke oven end and
at boiler end. Maintaining gas temperature close to 1050 is advised.
2. The gate at coke oven outlet shall be at the same level, when the CO stack is used for operation.
3.
4.
5.
6.
7.
8.
9.
Its opening can be increased step by step, if the temperature difference between the Coke oven
outlet and WHRB inlet is more than 40 deg C. By reducing the pressure drop at gate, natural
draft at WRHB inlet can be increased and thus infiltration can be reduced.
The draft at CO outlet and temperature indications shall be duplicated at boiler DCS for better
regulation of the ID fan rpm.
O2 analysers shall be added at boiler outlet and CO outlet. Maintaining a constant O2 will help in
achieving highest steam generation. Heat carried away by ambient air can be reduced. Once
installed O2 has to be minimised subject to gas temperature limit of 1050 deg C, which otherwise
can affect the refractory life.
Add thermocouples just after the screen tubes at mid point to know the gas temperature.
Coke oven outlet and boiler outlet temperature difference shall be minimised by the operators by
adjusting the ID fan rpm. If this helps to improve the steam temperature then consider partial
removal of refractory.
Add one loop of SSH coils to take care of fouling. This decision has to be taken after stabilising
the boiler operation as per point 6.
The coke oven cap design shall be good to minimise the ingress flow. The sealing detail of the
new cap and existing caps may be sent to undersigned for review.
Measure the draft above WHRB tapping at a time when Coke oven is operating with its stack.
This is the value to be maintained by ID fan to minimise the infiltration / loss of useful heat.
Feedback / complete log sheet may be sent to undersigned in a tabulated form giving the O2 at boiler
outlet, draft at WHRB inlet, temperature difference between Coke oven outlet and WHRB inlet. The
above three can be the control parameters. We have to find out which gives the best result.
K.K.Parthiban
ANNEXURE
Photo 1: Steam generated with 93000 nm3/h considering 1.5% blow down.
Photo 2: The gas flow for 34 TPH steam generation is 81482 kg/h. This is about 70.9 % of the design
gas flow. The SH surfacing should be designed for this.
Photo 3: Performance of the screen tubes is predicted above for a gas flow of 81482 nm3/h 103042
kg/h.
Photo 4: The heat transfer coefficient at radiant chamber is expected to be 36.35 kcal/hm3deg C.
Photo 5: Radiant waterwall above the PSH will cool the gas to 844.34 deg C. There will be a steam
generation of nearly 6782 kg/h from radiant section.
Photo 6: The PSH outlet steam temperature should be 422 deg C for steam flow of 34000 kg/h.
Photo 6: The cavity above PSH would have a heat transfer coefficient of 24.11 kcal/hm2deg C.
Photo 8: The cavity between PSH and SSH would drop the gas temperature to 724.6 deg C.
Photo 9: The SSH will give main steam temperature of 519 deg C incase no DESH is envisaged.
Photo 10: Before shut down the screen drop is seen to be 946-821 = 125 deg C. After shut down the
temperature drop across screen is seen to be 939-800 = 149 deg C. First of all screen does not drop
the temperature this high. It can be the effect of air dilution. The above is for boiler no 633.
Photo 11: The above is the temperature profile of boiler 631 before and after shut down. The
temperature drop across screen before shut down is 1033-898.5 = 134.5 deg C. After shut down, this
is seen to be 966-833 = 133 deg C. Again screen does not drop the gas temperature this much. There
can be air dilution effect.
Photo 12: The above is the temperature profile of boiler 630 before and after shut down. The
temperature drop across screen before shut down is 956-832 = 124 deg C. After shut down, this is
seen to be 936-805 = 131 deg C. Again screen does not drop the gas temperature this much. There
can be air dilution effect. The dilution is governed by the draft at boiler inlet. Higher the draft higher
will be the dilution. Higher the ID fan rpm, higher will be the air ingress from CO stack cap.
Photo 13: The gas cooling due to present refractory lining in four walls except the roof will be to an
extent of 10 deg C only. At the time of visit the picture of gas temperature profile and ID rpm were
as below.
Photo 14: The above shows there is about 135 deg C to 154 deg C whereas it should be only 40 deg
C due to screen tube and the roof panel exposed to heat pickup.
Photo 15: The main steam line temperature drop can be around 8 deg C only if the surface
temperature is 55 deg C.
Photo 16: The O/L header of PSH and DESH are all of P11 material.
Photo 17: The failed roof tube shows long term overheating sign.
Photo 18: The failed location is shown. The swelling is at the beginning of the bend. It is localised
and hence it is not a complete starvation case.
Photo 19: The central tubes at manhole header would have less flow. Hence the construction dirt /
dirt ingress during shut down / corrosion products in boiler water can accumulate at the roof bends of
these tubes and cause over heating failure.
Photo 20: The riser at roof panel is made with a loop. This creates air lock and retard circulation.
Photo 21: Photo shows the rigid insulation used for steam piping at another plant. This will not sag
due to its weight. The product is sold by dynaweldindia.com.
Photo 22: boiler inlet gas duct is refractory lined and it is a cantilever duct. It should be supported by
springs to avoid tube / fin cracks.
Photo 23: Gas baffles are to be provided in ash hoppers for a depth of 1 m and to the full width. It is
to be welded to the hopper directly. This will prevent gas bypassing. Same is to be provided for
evaporator hopper.
Photo 24: The FCV and TCV are specified for a 3 kg/cm2 pressure drop as well. Up to 21% of valve
travel the control valve will work better. When the pump is provided with fluid coupling all FCV
and TCV would work better.
Photo 25: The above is the TCV specification. The outlet pressure for design is given as 97.44
kg/cm2. This is wrong. The inlet pressure also is 105 kg/cm2 actually. This will make the regulation
difficult. It is advisable to reduce the pump discharge pressure and go for lower DP valve to save
power.
Photo 26: The photo shows a good drum with the magnetite layer. This is what is to be achieved by
the proper pH.
Photo 27: The photo shows a bad drum with corrosion products in the boiler water. Take photograph
of the steam drums and compare the treatment effect.
The heat input considered here is corresponding to 36 TPH steam generation. At higher steam
generation condition the percentage heat lost will come down.