MillingPerformanceChallenges ALSTOM

Milling Systems
PRB Users Group
Milling System Performance Challanges

& Operational Safety
Pulverizer Performance
Pulverizers are Process MACHINES and Are used to :
Grind Fuel To Required Fineness

Dry Fuel According to the Fuels Drying Characteristics
Transport Fuel To Furnace
Pulverizer Throughput
Mechanical Capacity
– Throughput in Lbs/Hr that the pulverizer can mechanically grind
Thermal Capacity
– Throughput in Lbs/Hr that the pulverizer can dry
The Actual Capacity of a Pulverizer is the Lower of the Mechanical

or Thermal Capacity
Factors Affecting Pulverizer Mechanical

Capacity
Raw Fuel Grindability

Required Product Fineness
Fuel Moisture Content
Available Airflow
Available Power
Pulverizer Design
Mechanical Capacity Determination
Increasing Recirculation Load

– Lower HGI
– Higher Fineness
– Higher Moisture (High Rank Fuel)
Decreasing Recirulation Load
– Higher HGI
– Lower Fineness
– Lower Moisture (High Rank Fuel)
FINENESS CAPACITY FACTOR
Mechanical Capacity Determination HIGH
CAPACITY FACTOR
ALSTOM Applies Correction Factors For:
Hardgrove Grindabilty - HGI LOW HIGH
Product Fineness FINENESS (% THRU 200 MESH)
Moisture HGI CAPACITY FACTOR
– Eastern Bituminous HIGH
– Mid Western Bituminous
CAPACITY FACTOR
LOW
HARD SOFT
HGI (HARDGROVE GRINDABILITY INDEX)

Western Fuel (Sub C) Mechanical Capacity Adjustment
Hardgrove Grindabilty - Western Fuel Measured HGI Not An

Absolute Indicator of “Difficulty to Grind”
Product Fineness - Due to High Reactivity, Western Fuel Fineness

Levels Can Lower Than Eastern Coal With Low Unburned Carbon
Levels
Moisture - There Is No Capacity Correction For Western Fuels Due

to Drying Characteristics
Factors Affecting Pulverizer Thermal Capacity
– Fuel Rank
– Fuel Moisture Content
– Available Airflow
– Available Primary Airflow Temperature
– Desired Pulverizer Outlet Temperature
Coal Drying Characteristics
High Rank Fuels

Eastern Bituminous
– Raw Fuel Moisture Ranges 2% - 16%
– Pulverized Fuel Moisture Range 1% - 2 %
– Constant Outlet Moisture vs. Inlet Moisture
– Typical Pulverizer Outlet Temperature 180 oF
Mid Western Bituminous

– Raw Fuel Moisture Ranges 6% - 26%
– Pulverized Fuel Moisture Range 4% - 7.5 %
– Constant Outlet Moisture vs. Inlet Moisture
– Typical Pulverizer Outlet Temperature 170 oF
Coal Drying Characteristics
Low Rank Fuels

Sub Bituminous
– Raw Fuel Moisture Range 21% - 31%
– Pulverized Fuel Moisture Range 15% - 24%
– Outlet Moisture Varies With Inlet Moisture, Air Fuel Ratio, Outlet Temperature
– Typical Maximum Pulverizer Outlet Temperature 150 oF
Lignite
– Raw Fuel Moisture Up To 39%
– Pulverized Fuel Moisture Range 15% - 25 %
– Outlet Moisture Varies With Inlet Moisture, Air Fuel Ratio, Outlet Temperature
– Typical Maximum Pulverizer Outlet Temperature 150 oF
Pulverizer Thermal Capacity is Determined Using a Heat Balance

Mathematical Model
Required Heat = Heat Absorbed in Mill + Heat in Air Leaving

Available Heat = Primary Airflow x Air Temperature x Cp
To Increase Thermal Capacity

– Increase Mass Airflow
– Increase Air Temperature
Hot Air Dry Pulverized Coal
Seal Air Mill Water Vapor
Raw Coal
Air
Losses
Mill Thermal Prediction/Selection Using Heat Balance Algorithm
Inputs Outputs
Required Coal Flow - Given Inlet Temperature

Inlet Moisture - Analysis Relative Humidity
Outlet Moisture - Curves/Algorithm Dew Point
Available Airflow - Standard Coal Line Velocity
Outlet Temperature - Standard
The Actual Capacity of a Pulverizer is the Lower of the

Mechanical or Thermal Capacity
80000
70000
60000
50000
40000
30000
20000
10000
0
C1 - EBit A - 25.5% B - 23.5% C - 27.2% D - 29.9% E - 31%
Required Coal Flow Mechanical Capacity

Thermal Capacity Maximimized Thermal Capacity
Pulverizer Performance Issues With PRB Switch
– 30% Increase in Required Coal Flow

• Loss of Spare Mill
– Adequate Available Milling Power
– Adequate Primary Airflow
– Adequate Primary Air Temperature
Suction Style Systems More Prone to Operational Limitations

– Lack of Fan Capacity Due to Higher Pressure Drop
– Lack of System Power w/Common Fan & Mill Motor
Typical Milling System Arrangements
Vertical Spindle Mills Horizontal Mills
ALSTOM Power (CE) Foster Wheeler

– RB, RS, RPS, RP, HP – Tube
– Suction & Pressurized – Suction & Pressurized
Babcock & Wilcox Babcock Borsig (Riley)
– EL, E, MPS – Tube, Atrita
– Primarily Pressurized – Suction & Pressurized
Foster Wheeler
– MB, MBF
– Primarily Pressurized
Babcock Borsig (Riley)
– MPS
– Primarily Pressurized
Potential Plant/Pulverizer Modifications For PRB

Switching
Mill Replacement
Classification Improvement
– Dynamic Classifier
– Wing Tip Vane Wheel w/Int. Deflector Liner
Increase in Primary Air Flow
– High Speed Exhauster Fan (Patented)
– PA Fan Modification
Increase in Primary Air Temperature
– Air Heater Upgrades
– Direct Fired Primary Air Heaters
Increase in Available Power
– Larger Mill Motor or Separate Exhauster Motor
High Speed Fan Arrangement
High Speed Motor With Direct

Coupling
– New High Speed Higher Capacity
Motor
– New Mill Gearing
– New Forced Cooled Fan Bearing
Assembly
– New Tungsten Carbide Lined High
Efficiency Fan
– New Fan Casing Liner System
Separate Motor With Gearbox

– New Exhauster Motor
– Variable Speed Available
– New Right Angle Gearbox
Efficiency Fan
Single Standard Speed Motor With

Gearbox
– New Higher Capacity Motor If
Present Motor Lacks Margin
– New Exhauster Gearbox
– New Forced Cooled Fan Bearing
Assembly
Efficiency Fan
Case Study - Modified ALSTOM 703 RS Milling System
Drivers Pre Mod Post Mod

Max. Coal Flow 60,000 84,000
Fuel Switch for MW 265 273
Emissions Fuel Type EBIT/Sub C Blend Sub C
Load Regain 200 Mesh Fineness 60 76
50 Mesh Fineness 4 0.1
Airflow 57,000 88,000
Modification Scope
Coal Spillage 50 0
Dynamic Classifier Underbowl Press. -1 -1.88
Power - Amps 54 121
1000 BHP High
Nox 0.45 0.15
Speed Motors
Mill Blue Print RESULTS
Direct Fired Primary Unit Currently Able To Attain

Air Heaters Boiler MCR On 100% Sub C
With 4 of 5 Mills In Operation
TFS2000R
Case Study - Tube Mill Replacement
Drivers Modification Scope RESULTS

Fuel Switch for (6) HP Mills For (3) Unit Currently At Boiler MCR
Emissions Suction Tube Mills On 100% Sub C With of 5 of 6
Mills In Operation
Load Regain Static Classifiers
Hot PA Fans
RSFC Low Nox
Burner System
200 Mesh
Mill Type MW Fuel Fineness NOX
Pre Modification Ball Tube 350 Illinois N/A 0.44
Pre Modification Ball Tube 250 Sub C 65% 0.15
Post Modification Vertical Spindle 360 Sub C 70% < .2
Case Study - Tube Mill Replacement

Fuel Switch for (6) HP Mills For (3) Unit Currently Under
Emissions Suction Tube Mills Construction
Load Regain Static Classifiers Expected MCR With
100% Sub C On 5 of 6
Hot PA Fans
Mills In Operation
200 Mesh
Mill Type MW Fuel Fineness NOX
Pre Modification Ball Tube 250 Illinois N/A 0.7
Pre Modification Ball Tube 175 Sub C 65% 0.4
Post Modification Vertical Spindle 230 Sub C 70% 0.4
Case Study - Vertical Spindle Mill Replacement

Fuel Switch for (8) HP Mills For (8) Unit Currently Has 8
Emissions Pressurized Mills Mills Installed With 8 Of
8 Mills Operational
Load Regain Dynamic Classifiers
Boiler MCR Expected On
PA Fans
100% Sub C With 7 of 8
Air Heater Modifications Mills In Operation After
Boiler Modifications
Boiler Modifications (Delayed
2007)
Coal Flow Mills in

MW Fuel Lbs/hr Service
Pre Modification 800 30% Sub C 92,000 7 of 8
Post Modification 800 100% Sub C 141,700 7 of 8
Case Study - Vertical Spindle Mill Modification 803 RS

Fuel Switch for New High Speed Fan w/Variable Unit Currently Operational
SOX Emissions Speed Control (Separate in SOX Compliance
Drive Motor)
Load Regain Boiler MCR On 100% Sub
Direct Fired Primary Air C With 5 of 5 Mills In
Heaters Operation
Dynamic Classifiers (1992)
TFS2000R (1992)
MW Fuel Year SOX

Pre Modification 390 Ebit. Compliance 1993 In Compliance
Pre Modification 280 Sub Bit C 2002 In Compliance
Post Modification 390 Sub Bit C 2003 In Compliance
Developing Technologies
Primary Air Flow Control

– Variable Speed Exhauster Fan
– Combustion Airflow Management
On Line Fuel Line Balancing

– Coal Line Distributors - Pressurized & Suction
– Pf Flo
Improved Operational Safety Systems

– Fog & Swirl
– Inerting
Pulverizer Operational Safety
Purpose
Minimize Risk of Pulverizer Explosions
Safely Control Pulverizer Fires
Design
Governed by NFPA Code Requirements
Various OEM Designs Using Different Interpretations of Code
ALSTOM Approach is Conservative Interpretation of Code/Conservative
Design
Design Not Affected by Coal Rank - i.e. Eastern Bit vs. PRB
NFPA Code
A pulverizer tripped under load shall be inerted and maintained

under an inert atmosphere until confirmation that no
burning/smoldering fuel exists in the pulverizer, or the fuel is
removed.
Hazardous Operating Conditions
Pulverizer Trip
Raw Fuel Feeder Trip - Interruption in Raw Fuel Feed
Restarting Hot Pulverizer With Charge of Coal
Explosion Mechanics
Oxygen
Combustion
Triangle
Pulverized Fuel Ignition Source

In Suspension
ALSTOM Approach
Standard Flow Through Steam Inerting/Clearing System

Currently Developing “Dust Suppression” System
Inerting Systems
Oxygen
Combustion
Triangle

In Suspension
Steam Inerting
Inerting - to establish an oxygen content of 7% or less inside an off line pulverizer in a

very short time period during conditions which are considered hazardous.
Maintenance Flow Inerting - maintain an oxygen content of 7% or less inside an off

line pulverizer after an inert atmosphere has been established. Low inerting flow is
approximately one quarter of inerting flow.
Clearing Flow- Coal transport flow rate - to safely transport the contents of the
pulverizer to the furnace while maintaining an inert atmosphere within the pulverizer.
This is used to safely remove the contents of the pulverizer prior to restarting or during
fire fighting procedures.
Steam Inerting Systems

25 40 S
T
M
20
30
M F
I L
15 O
L
L 20 W
10
0 K
2 L
10 B
5
S
/
0 0 H
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 R
TIME (SECONDS)
MILL 02 STEAM FLOW
Dust Suppression Systems
Oxygen
Combustion
Triangle

In Suspension
Dust Suppression Systems

With Inerting
Oxygen
Suppress Dust
Inert Mill
Cool Contents
Combustion
Triangle

In Suspension
Dust Suppression System

General Information
Developed and Patented by Westerns Farmers Electric Coop. (WFEC)

WFEC System Utilizes Water Fog, Water Swirl, and CO2
ALSTOM Power Has License Agreement With WFEC
WFEC Has Sold Licenses to Individual Plants
ALSTOM Experience Via. Western Farmers Electric Coop.
ALSTOM Has Been Working With WFEC For Over 3 Years
ALSTOM Optimized First System Fall 2001
Principle Of Operation - Inerting vs. Dust Suppression
Pulverizer Explosions Require

– Pulverized Fuel in Suspension
– Sufficient Oxygen Intermixed With Coal Particles
– Sufficient Ignition Source
Steam Inerting Systems:
– Lower Oxygen To Prevent Particle to Particle Combustion
Dust Suppression Systems:
– “Knocks” Fuel Out Of Suspension
– Provide Some Degree of Fire Extinguishing
– Mill Cooling
Dust Suppression
System Schematic

Water Fog
Injected At:
– Classifier Approx. 7 Nozzles At 4 GPM/Nozzle
– Millside Approx. 6 Nozzles At 8 GPM/Nozzle
– Air Inlet Approx. 3 Nozzles At 10 GPM/Nozzle
Automatically Activated Upon Detection of Hazardous Condition
– Mill Trip
– Feeder Trip
– Interruption in Raw Fuel Feed
Can Be Manually Activated (Normal Starts and Stops)
Water Nozzles Kept Clean With Seal Air During Normal Mill Operation
Water Swirl
Safely Empties Contents Pulverizer To Pyrite System

Introduces Through (8) Nozzles Under Bowl Approx. 7 GPM/Nozzle
Used With Bowl Rotating
Manually Activated - Operator Visually Insures Mill is Empty by Inspecting
Pyrite Discharge
Water Nozzles Kept Clean With Seal Air During Normal Mill Operation

MillingPerformanceChallenges ALSTOM

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Milling Systems

PRB Users Group

Milling System Performance Challanges

Pulverizers are Process MACHINES and Are used to :

Grind Fuel To Required Fineness

The Actual Capacity of a Pulverizer is the Lower of the Mechanical

Factors Affecting Pulverizer Mechanical

Raw Fuel Grindability

Mechanical Capacity Determination

Increasing Recirculation Load

Mechanical Capacity Determination HIGH

Hardgrove Grindabilty - HGI LOW HIGH

Product Fineness FINENESS (% THRU 200 MESH)

Moisture HGI CAPACITY FACTOR

– Eastern Bituminous HIGH

– Mid Western Bituminous

HGI (HARDGROVE GRINDABILITY INDEX)

Western Fuel (Sub C) Mechanical Capacity Adjustment

Hardgrove Grindabilty - Western Fuel Measured HGI Not An

Product Fineness - Due to High Reactivity, Western Fuel Fineness

Moisture - There Is No Capacity Correction For Western Fuels Due

Factors Affecting Pulverizer Thermal Capacity

Coal Drying Characteristics

High Rank Fuels

Mid Western Bituminous

Coal Drying Characteristics

Low Rank Fuels

Pulverizer Thermal Capacity is Determined Using a Heat Balance

Required Heat = Heat Absorbed in Mill + Heat in Air Leaving

To Increase Thermal Capacity

Mill Thermal Prediction/Selection Using Heat Balance Algorithm

Required Coal Flow - Given Inlet Temperature

The Actual Capacity of a Pulverizer is the Lower of the

Required Coal Flow Mechanical Capacity

Pulverizer Performance Issues With PRB Switch

– 30% Increase in Required Coal Flow

Suction Style Systems More Prone to Operational Limitations

Typical Milling System Arrangements

Vertical Spindle Mills Horizontal Mills

ALSTOM Power (CE) Foster Wheeler

Potential Plant/Pulverizer Modifications For PRB

High Speed Fan Arrangement

High Speed Motor With Direct

High Speed Fan Arrangement

Separate Motor With Gearbox

High Speed Fan Arrangement

Single Standard Speed Motor With

Case Study - Modified ALSTOM 703 RS Milling System

Drivers Pre Mod Post Mod

Direct Fired Primary Unit Currently Able To Attain

Case Study - Tube Mill Replacement

Drivers Modification Scope RESULTS

Case Study - Tube Mill Replacement

Drivers Modification Scope RESULTS

Case Study - Vertical Spindle Mill Replacement

Coal Flow Mills in

Case Study - Vertical Spindle Mill Modification 803 RS

MW Fuel Year SOX

Primary Air Flow Control

On Line Fuel Line Balancing

Improved Operational Safety Systems

A pulverizer tripped under load shall be inerted and maintained