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Coal Mill & Fan Performance
Coal Mill & Fan Performance
Coal Mill & Fan Performance
Performance Management
Manohar Tatwawadi
Director, TOPS
mtatwawadi@gmail.com
SCOPE
• Various types of Coal mills can be found in the
Power Industry. The type of Coal mill under
discussion within this Presentation is a “Bowl
Mill” (Bowl and Rollers), typically used by the
power industry.
Identification of
Performance
Requirements
Maintenance
Maintenance
Improvement
Strategy
Plan
Maintenance
Management Finalise the
and Maintenance
Maintenance Plan
Operations Plan
Transport air (mill inlet) Measure air temperature and A/F (air
to fuel) ratio inside mill.
The profile of
the roll should
be parallel with
the grinding ring
profile.
A classifier
recirculates
coarse coal in
the grinding
zone and
balances the
flow of coal to
each burner
line to the
furnace.
22/11/2012 Manohar Tatwawadi
Classifiers
• The flow of coal particles through a classifier is
several times the amount of coal flowing to the
burners because of the large amount of coal
recirculated within a pulverizer. For example, if a
pulverizer is operating at 100,000 lb/hr coal feed to
the burners, as much as 300,000 lb/hr or more may
be flowing through the classifier for regrinding. For
this reason the surface smoothness and inverted
cone clearances or discharge doors of the MPS
original design mills are extremely important for
acceptable pulverizer performance and of course,
optimum furnace performance.
22/11/2012 Manohar Tatwawadi
Pulverisers
• Coal pulverizers are essentially volumetric devices, because the
density of coal is fairly constant, are rated in mass units of tons/hr.
• A pulverizer accepts a volume of material to be pulverized which is
dependent on the physical dimensions of the mill and the ability of
coal to pass through the coal pulverizing system.
• The furnace volume and mill capacity in a specific power station
may dictate the need to purchase coals which are reactive and
easily grind.
• The common measure of mass in tons enables matching of energy
requirements with available coal properties and mill capacity.
• Increased combustible loss can occur if the furnace volume or mill
capacity is less than desirable for a particular coal.
• There are a number of possible remedial actions.
• Operators can correct some deficiencies in the combustion system :
• Biasing the performance of the coal pulverizing for variable coal
qualities.
• Use the spare mill into service for peak periods to ensure full
output.
22/11/2012 Manohar Tatwawadi
• Size reduction is energy intensive and generally very inefficient with
regard to energy consumption.
• In many processes the actual energy used in breakage of particles is
around 5% of the overall energy consumption.
• Pulverizing coal is no exception to this.
• There are basically four different types of pulverizing mills which are
designed to reduce coal with a top particle size of about 50 mm to the
particle size range necessary for fairly complete combustion in a modern
pulverized coal fired boiler.
• Each type has a different grinding mechanism and different operating
characteristics.
• There are four unit operations going concurrently within the mill body,
coal drying, transport, classification and grinding.
• For coal pulverizers the capacity of a mill is normally specified as tonnes
output when grinding coal with a HGI of 50, with a particle size of 70% less
than 75 micron and 1 % greater than 300 micron and with a moisture in
coal of less than 10%.
• A few manufacturers specify 55 instead of 50 with respect to HGI.
• This standardization enables selection of an appropriate mill for a specific
duty.
Grindability
Moisture content, %
22/11/2012 Manohar Tatwawadi
Sizing of Pulverizers
• Feeder capacity is selected to be1.25 times the
pulverizer capacity.
• Required fineness, is selected to be
• 60% through a 200 mesh screen for lignite(75 mm),
• 65% for sub-bituminous coal, 70-75% for bituminous
coal, and 80-85% for anthracite.
• Heat input per burner is assumed to be to 75 MW for a
low slagging coal and 40 MW for a severely slagging
coal, With intermediate values for intermediate slagging
potentials.
• General Capacity of A Coal Mill : 15 – 25 tons/hour.
• Power Consumption: 200 – 350 kW.
22/11/2012 Manohar Tatwawadi
Performance Calculations
• Several performance parameters are calculated
for the pulverizer train.
• These include the following:
• Effectiveness of Coal drying requirements.
• Pulverizer heat balance.
• Primary air flow requirements.
• Number of pulverizers required as a function of
load.
• Auxiliary power requirements.
Hot air
Heat loss
Puliverizer frictional
dissipation
Dry pulverized coal +
Coal Air + Moisture
Coal-air mixture o
C 85 78 76 81 72 71 70 75 75
temp
Coal fineness
% 70 65 68 70 60 61 62 61 62
below 75 micron
DP mmWC 437.9 494.00 496.83 485.50 467.83 440.33 430.50 496.50 431.90
PA pressure I/L mmWC 991.5 900.50 927.50 999.83 909.67 922.33 933.50 929.17 958.80
PA flow t/h 104 120.31 123.01 110.52 102.18 104.80 108.66 113.13 120.17
Power kW 406 393.72 404.22 458.29 379.51 382.57 365.17 445.18 428.11
Energy kWh/h - 383.52 395.76 451.92 370.62 374.22 350.94 441.48 433.12
Load factor % 84.58 82.03 84.21 95.48 79.06 79.70 76.08 92.75 89.19