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01 Boiler Design General (Compatibility Mode) PDF
01 Boiler Design General (Compatibility Mode) PDF
Dr V T Sathyanathan
Retired General Manager
Bharat Heavy Electricals Ltd;
Tiruchirappalli
Arrangement
Introduction
Coal Property Variations & Design Issues
Grouping of Indian Coals for Boiler Design
Boiler Efficiency
Effect Of Ash On Boiler Design
Conclusion
Points to Ponder
Introduction
Emerging Market
Challenges and Demands
Scenario
Continual Reduction in Delivery time
Coal will remain as the fuel of future
Affordable cost of generation
Higher Efficiency
Optimal Aux Power Consumption
Higher Unit Sizes
Use of large varieties of fuel for BFBC
/ CFBC Boilers
Scenario
Suitability for differing modes of
operation, and grid conditions
Free Governance Mode, Availability Based Tariff
Increasing environmental control
norms
High Reliability & Availability
Optimal life cycle cost
Leveraging IT
Life Extension of Power Plants &
capacity upgrades
Mankind is in pursuit of truth, let us work towards this
Dr V T Sathyanathan
Impact
Shorter Engg & manufacturing
time
Advanced planning of materials
Expectations to erect and
commission in short cycle
Weight reduction measures
Elimination of non value added
activities and process at all levels
Impact (Cont)
Very high availability & PLF to be
achieved
Better heat rate and low cost
power
Lower pollution levels
Better position in ABT
Low gestation period
Better MTBF & MTTR
Many OEM boilers addressed
Mankind is in pursuit of truth, let us work towards this
Dr V T Sathyanathan
Concern
Making the optimal plant heat
rate
Handling the fuel quality change
Operational deviations
Reducing the damage
mechanisms
Increasing MTBF
Addressing old power plants
Mankind is in pursuit of truth, let us work towards this
Dr V T Sathyanathan
Operational
feedback
Design
improvements
Design
Feedback
New
Design
The Facts
4000
3500
3000
Billion kilowatthours
2500
2004
2000
2030
1500
1000
500
0
Coal Nuclear Natural Gas Renewables Petroleum
Gas
Coal 10.7%
59% Diesel
1.1%
Nuclear
2.5%
Wind
1.7%
Hydro
25%
Fuel wise Installed Capacity
Focus
Customer
Needs
Realized
Performance
Specified
Requirements
(Design)
Missing
Customer Needs
Zero RH Spray
Accidental Un-realized
Boiler efficiency? Keeping high
excess air
Running
unit with
Excellent
high APH
outlet temp
Redundant
Wasted Ineffective SB
Specified Requirement
Realised Performance (Design)
Mankind is in pursuit of truth, let us work towards this
Dr V T Sathyanathan
boiler 210
T
MW 200 MW
120.7 t/h auxpower 10 MW
4000 kcal/kg
Coal Petrography
The Emerging Tool – Mainly Trouble shooting
110
100
% HEAT RELEASE
Heat from FC
90
80 Heat from VM
70
60
50 2
40
30
0 2 4 6 8 10 12
TIME IN MINUTES
Coal 2 Coal 1
Ash Analysis
Provides indicators to
Slagging / fouling / deposition
potential
Erosion potential
Corrosion potential
Slagging/deposition
Slagging /deposition indices
Ash deformation temperatures
Lower the number, higher the tendency for deposition
Base/ Acid Ratio
In certain ranges the combinations have low melting
temperatures, resulting in higher deposition
Iron/ Calcium ratio
lower fusiblity temperatures in certain ranges
Iron Content in Ash
Higher the content , more the propensity for deposition
Silica / Alumina Ratio
Lower fusiblity temperatures at higher ratios
Viscosity Index
Mankind is in pursuit of truth, let us work towards this
Dr V T Sathyanathan
Slagging Indices
( based on a typical design stage input)
Worst Coal
Best Coal
Furnace Design
Impact of Coal& Ash variations
Large furnace required for
High ash, low grade coal
Coals with slagging / deposition tendency
Low reactive coals
Smaller furnace required for
Low ash, high calorific value coals
Non slagging coals
Highly reactive coals
Furnace performance depends on the sizing basis
and the coal being fired
Mankind is in pursuit of truth, let us work towards this
Dr V T Sathyanathan
Additional Mills –
Implication on Boiler
Bigger Primary air Fans
Bigger Primary airheaters
Increased boiler height
Additional ducting & dampers
Complicated fuel pipe routing
Additional space, Cramped layouts
Additional Coal Bunkers
Coal handling system enhancement
Additional C&I
Additional equipment for maintenance
Mankind is in pursuit of truth, let us work towards this
Dr V T Sathyanathan
Additional Mills –
Implications on Performance
Normal design for optimum performance with middle
mills operation
Furnace & SH/RH performance depends on the
elevations in service – wider variations with more
number of mill elevations
Top mills in service result in more heat to the SH&RH
Bottom mills in service result in lesser heat to the
superheater & reheater
Increased SH / RH spray or short fall in temperatures
when firing coals with extreme properties
Duct Sizing
Sizing for all the worst conditions –
leads to large size ducts
Operate at much low velocity at rated
load with normal coals
Low flue gas velocity often leads to ash
settlement in the ducts.
Dust Collector
70
60
50
40
30
20
10
0
0.0-0.2 0.2-0.4 0.4-0.6 0.6-0.8 0.8-1.0 1.0-1.2 1.2-1.4 1.4-1.6 1.6-1.8 1.8-2.0 2.0-2.2 2.2-2.4 2.4-2.6 2.6-2.8
Range of Fuel Ratio
Distribution of Ash
Per Million Kcals
Number of Coals
70
60
50
40
30
20
10
0
20-40 40-60 60-80 80- 100- 120- 140- 160- 180-
100 120 140 160 180 200
Ash Range (Kgs)
0
20
40
60
80
10 -10
2 0 20
10 -10
4 0 40
10 -10
6 0 60
10 -10
8 0 80
11 -11
0 0 00
11 -11
2 0 20
11 -11
4 0 40
11 -11
6 0 60
11 -11
8 0 80
12 -12
0 0 00
IDT Range (Deg.C)
12 -12
2 0 20
12 -12
4 0 40
12 -12
Distribution of Initial
6 0 60
Mankind is in pursuit of truth, let us work towards this
12 -12
8 0 80
Deformation Temperature
-1
30
0
Dr V T Sathyanathan
Dr V T Sathyanathan
160
144
140
120
101
100
No. of Coals
80
60
40 33
20
0
1 2 3
Coal Group
160
148
140
120
100
N o. of C oals
88
80
60
42
40
20
0
1 2 3
Coal Group
180
161
160
140
120
No. of Coals
100 93
80
60
40
24
20
0
1 2 3
Coal Group
250
223
200
150
No. of Coals
100
50
30
16
0
1 2 3
Coal Group
Boiler Efficiency
Boiler Efficiency
This is influenced by coal properties,
ambient temp. & relative humidity,Boiler
exit gas temp.
Determines the heat input to the boiler
efficiency by 0.04%
VM % 22 22 25
M % 12 13 14
Ash % 42 34 24
%Ash 42 34 24
Conclusion
Conclusion
Steam generator performance greatly
influenced by the coal/ash properties
Special design considerations required to
ensure satisfactory performance for the
range of coals
Trade offs required to accommodate wide
bands- increases the cost and at times
compromises the equipment performance.
The design of a modern day power plant is a
synthesis of thermal performance criteria with
economic considerations.
Mankind is in pursuit of truth, let us work towards this
Dr V T Sathyanathan
Points to Ponder
Coal Properties
Possibility of narrowing the variation band
Specification for the Very Worst coal
Should we consider all the worst factors
occurring simultaneously?
Equipment sizing criteria
Scope for a revisit based on the operating
experience