FUELS AND FUEL HANDLING SYSTEMS

A fuel is a substance composed mainly of carbon and hydrogen , which releases

heat energy on combustion.

Performance of heat energy is satisfactory only when the properties of fuel used is
ideal, and hence, a fundamental knowledge of type of fuel and their
characteristics is essential for an engineer.
ØThree types of fuels can be burnt in any type of steam generating plant:
Ø1. Solid fuel such as coal
Ø 2. Liquid fuel as oil
Ø3. Gaseous fuel as gas
Thermal power plants may use any type of fuel , but coal is the most used solid
fuel for generation of steam .The following systems are important in a steam
power plant
1. Fuel and Fuel handling system
2.Ash handling (Disposal) system
3.Flue gas system
4.Feed water System.
Supply of these fuels to the power plants from various sources is one of the important
considerations for a power plant engineer.

There are three types of fuels are available and these three types can be burnt in any type
of steam generating plant.
 Coal and Ash Circuit

•Coal Storage - Stores Coal from Mines.

• Coal Handling - Prepares, Conveys, Feeds Coal to
Boiler.
• Dust Collection- Separates Fly-Ash ,Dust from Flue
Gases.
• Ash Handling - Collected Ash and Dust are
Conveyed to Ash Storage.
The following important factors should be considered in selecting the fuel
handling system.
1.Plant Fuel rate
2.Plant Location
3.Storage area available.

Coal Handling System

A steam power plant of 400MW capacity requires about 5500 tons of coal per day
and produce 550 tons ash per day.
Mechanical handling of coal is preferred over manual handling due to following
reasons.
1.High reliability
2.Less labour
3.Ecominical for medium and large capacity plants
3.Operation is Easy and Smooth.
4.Losses in transport are minimized.
 MODE OF TRANSPORT

ØThe coal from coal mines to power stations is transported by road ,rail, sea or
river.
ØThe supply of coal by road is limited to small power plants
ØSupply of coal by rail to interior power plants is most common mode of
transportation.
ØCoal can be transported from mines to power plants by ships.
Ø unloading is easy if coal is delivered by trucks because they dump coal at the
storage
 EQUIPMENTS USED IN COAL TRANSFER
ØA very suitable means of Transporting. It can transfer large quantity of coal
ØOver a large distance economically –low initial cost ,low power consumption.
ØThey operate at a speed of 60-100m/min and handle 50 tones of coal per hour over
a distance of 400m

ØU s e o f l i f t t r u c k s i s
economical when the coal is
brought to the site by road. It
is suitable for small plants.
ØThe coal carried with rail
wagons or ships is unloaded
by means of cranes or grab
buckets at the site of the power
plant.
 Screw Conveyor

ØUsed to convey coal for only short distances.

ØThe movement of screw drives the coal from one end to other end of the
conveyor
ØSuitable for small plant applications and handles 125 tons per hour. It operates at
a speed of 70-120 RPM.
ØIt is compact and can be made dust tight.
 Bucket Elevator

Ø These conveyors are used for vertical lifts.

ØThe coal is loaded at the bottom and
discharged at the top.
ØBucket elevators are generally enclosed in a
casing in order to
get a dustless operation.
ØThey handle about 60 tons per hour at a
speed of 60 to 90m/min
ØExtensively used for vertical lift.
ØMaximum height is limited to 30m.
ØMaximum capacity 60 tones per hour.
 Belt Conveyor

Suitable for transporting coal in large quantities over long distances.

Ø Capacity 100tonnes per hour. A very suitable means of Transporting. It can
transfer large quantity of coal
ØOver a large distance economically –low initial cost ,low power consumption.
ØThey operate at a speed of 60-100m/min and handle 50 tonnes of coal per hour
over a distance of 400m.
 Grab Bucket

Lifts as well as transfers coal from

one point to another.
Ø Used with crane or tower. The grab
bucket is a device for lifting and
conveying operations.
Ø It is used with A crane , 23 cum
bucket operating over
ØA distance of 60 mm is Capable to
transfer 100 tons of coal per hour .
 COAL PREPARATION

 Coal delivered may not be suitable for feeding into combustion chamber
 Coal is sited and prepared at the preparation plant.

Crushing of Coal

ØBreaks large lumps of coal

into small pieces. Coal is
crushed in two stages in the
first stage the 300 mm size is
reduced to 100 to 75 mm and in
the second stage from 75 to 10
mm to below 6mm.

Coal Preparation Equipment

Vibrating separator : It is fitted after crusher to the screen the coal crushed
below set size. Oversize coal is returned to crusher for further proper crushing.
Generally it separates out over size coal of size >6 mm

Separator: Separates coal of required size, un sized coal is feed back to crusher.

Drier : Removes moisture from the coal. Hot flue gases are passed to remove
moisture.

Magnetic Separator :Removes iron particles from the coal, Otherwise they may
choke and increase wear of handling equipment.
 PULVERISED COAL SYSTEM

ØIn pulverized fuel firing ,the coal is

ground to a fine powder in a pulverised
mill and stored in a bunkers from where
it is fed into the combustion chamber by
means of stream of hot air.
ØThe air used to dry the coal and
conveying it to the furnace is called
primary air, and the air blown separately
to Complete the combustion is called
secondary air.
 Pulverizing Mills
The various types of mills used for pulverization of the coal are:-
• Ball Mill
• Ball and Race Mill
• Impact or Hammer Mill
• Bowl Mill

Advantages by pulverization of coal

ØRapid combustion without use of large quantity of excess
ØHigher boiler efficiency because of better combustion.
ØLow grade fuel can be used
ØAsh removal is easy
ØFluctuations of load can be easily used
ØGreater surface area of coal per unit mass.
ØFast response to load fluctuations.
Ø Free from clinker.
ØLarge amount of heat is released spontaneously.
 Disadvantages:

ØInstallation cost is high

ØRisk of explosions are more
ØSpecial equipment is required for
starting the system