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Blending of Imported Coal Blending of Imported Coal with Indian Coals & with Indian Coals & Its Associated Effects on Its Associated Effects on Boiler Boiler Operation Operation Dr V T Sathyanathan Technical Advisor Cethar Ltd (Retired General Manager - B H E L, Trichy) Trichy - 620014 Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T SATHYANATHAN, Dr V T SATHYANATHAN, M.E., Ph.D. M.E., Ph.D. Graduated in Mechanical Engineering from Coimbatore Institute of Technology, Coimbatore in 1971. Master Degree In Design And Production Of Thermal Power Equipment From Regional Engineering College, Tiruchi in 1984. Ph.D Degree in Mechanical Engineering from Regional Engineering College, Tiruchi, in 1998 Prediction of Unburnt Carbon in Tangentially Fired Boilers Using Indian Coals. Joined BHEL In 1973, worked in R & D, Field Engineering Services, Engineering in various capacity & as General Manager/Quality for two years Retired as General Manger in 2008 from BHEL Trichy Presently Working As Technical Advisor in Cethar Limited Trichy Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T SATHYANATHAN, Dr V T SATHYANATHAN, M.E., Ph.D. M.E., Ph.D. Specialised In Coal, Oil & Gas Combustion, Boiler Pressure Parts Failure Analysis Trouble Shooting Of Coal , Oil And Gas Fired Boilers, Chemical Recovery Boilers And Stoker Fired Boilers Plant Betterment Of Old Boilers Performance Testing & Performance Optimisation Of Boilers Has vast experience in the area of Residual Life Assessment of boiler pressure parts Petrographic Analysis Of Coal Member enquiry committee for investigation of a severe explosion in the Rotary Holding Furnace (RHF) in Copper Smelting Plant of M/s. Sterlite Industries (I) Ltd., Tuticorin Tamilnadu Has presented more than 40 papers in both National and International Seminars & 83 in http://www.brighthub.com/members/drvts.aspx My PhD work was referred by seven renowned universities abroad Leeds University, U K etc Teach Special Subjects In Horticulture - Art Of Bonsai & Cacti Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Introduction Coal Formation Coal Blending Why Blend Coals Methods of Blending Establishment of Procedure Issues of Imported coal firing Conclusions Coal blending - What all to look for Arrangement Arrangement Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Introduction Introduction Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Coal Formation Theories Coal Formation Theories Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this In-situ coal formation Drift theory of coal formation Coal formation theories Coal formation theories Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this In In--situ Theory situ Theory of of coal coal Formation Formation Coal formed froma particular place Coal generally appear to have been formed either in brackish or fresh water, from massive plant life growing in swamps, or in swamp interspersed with shallow lakes. Coal formed in this way have bands of coal and inorganic sedimentary rocks arranged in a sequence. Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Huge Tropical Ferns And Giant Tress In Huge Tropical Ferns And Giant Tress In Vast Swamp Areas Vast Swamp Areas ( ( Wilfrid Wilfrid Francis, 1961 ) Francis, 1961 ) Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Drift Theory of Coal formation Drift Theory of Coal formation Coal formed from plant material on dry land The original plant debris transported by water deposited under water in lakes or in the sea No true soil found below the seam of coal. Regular settling of inorganic and organic in succession or togather Deposition depend on water current Subsequently by mineral matters, sand etc. and result in coal seams. Coal property vary widely due to deposition pattern Difference in coal properties of Gondwana coals led to formation of drift theory Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Gondwana land Gondwana land ( Stacks E., et al ) ( Stacks E., et al ) Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Indian Coal Formation Indian Coal Formation The Gondwana coals of peninsular India were generally believed to be drift origin. The main reason for favouring such views include: pronounced regional variation in thickness and quality of seams. high ash content of most of the seams. lateral transition of coal to carbonaceous shales absence of seat-earth and upright stems in the under clays. scarcity of plant leaf impressions in the roof of coal seams and bifurcation and branching of coal seams. Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Blending of coal Blending of coal Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Blending of coal Blending of coal Burns giving heat Organics Behaviour friendly not friendly Inorganics Transport drying Moisture Coal Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Sudden or low change in furnace behavior leading to low boiler efficiency, load reduction and serious outage Time to turn around is normally high Can also lead to irrecoverable change in furnace behaviour Why Fear Blending of coal Why Fear Blending of coal Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Decision about coal blending must deal with uncertainty and variability in coal properties the effect of off-design coal characteristics on power plant performance and cost. Blending of coal Blending of coal Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Blending of coal Blending of coal Can pose peroblem High Moist High VM Low FC low rank Low Moist Low VM High FC High rank Organics Composition Trasformation Deposition Transport Aglomeration Trace Elements In-organics Blending Drift In-situ Type of Formation Lignite Bituminus Anthersite Rank of Coal Blending of Coals Time of residence High swirl Low Swirl PC FBC Combustion Temerature Size Reducing Oxidising Oxygen Effected by Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Blending of Coal Type of Formation Drift Insitu Blending Organic In-organic Rank of Coal Lignite Bituminous Anthersite Can pose problem Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Blending Organic Low Rank High Moisture High V M Low F C High Rank High Moisture High V M Low F C In-organic Composition Transformation Deposition Transport Agglomeration Trace Elements Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Effected by Time of Residence Temperature Combustion P C High Swirl Low Swirl F B C Size Furnace Particle Oxygen Oxidizing Reducing Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Why Blend Coals Why Blend Coals Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Why Blend Coals Why Blend Coals Cost saving Controlling the mineral content of coal Helping to solve existing problems Providing fuel that possess better combustion properties - flame stability Enhancing fuel flexibility Improve coal availability Meeting of SOx particulate & other emission requirements Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Methods of Blending Methods of Blending Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Methods of Blending Methods of Blending Blending can be done At coal mines At coal preparation plants At transshipment points At power stations In India mostly done at power stations Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Methods of Blending Methods of Blending (Cont (Cont.) .) Blending method chosen will depend on Site conditions Level of blending required Quantity to be stored & blended Accuracy required End use of blended coal Manual blending - for small quantity Stacking method fully mechanised Bin storage blending Belt blending Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Establishment of Procedure Establishment of Procedure For Blended Coal Firing Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Need For Blended Coal Firing Need For Blended Coal Firing Indian coals contain high ash Requirement of limiting the ash content of coals fired at TPS to 34% Price of low ash imported coal with higher HHV is equivalent to that of Indian coals Availability of new fuels like petcoke, refinery residue, orimulsion, etc at a comparatively lower price Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Prime Concern Prime Concern Boiler furnace Slagging Lead to outages in many cases Lead to load reduction Performance parameters change Arriving at the right proportion Maintaining the right mix Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Coal Boiler Furnace Design Boiler Operation Slagging Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Elivation Heat Loading Vol Heat Loading Size Slop Angle Avoid Ash Load Shape Furnace High Swirl Low Swirl Burner Water Steam Type Nos Soot Blower Mill Sizing Air / Coal Ratio Primary Windbox Control Secondary Air Distribution ID Fan Sizing Slagging Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this MAJOR SILICATES -[ CLAY MINERALS -[ KAOLINITE RALS KAOLINIT E Al 2 Si 2 O 5 (OH) 4 ILLITE - CLAY MINERAL QUARTZ Si O 2 MINOR CALCITE Ca CO 3 CARBONATE DOLOMITE (Ca, Mg) ( (CO 3 ) 2 ANKERITE CA (FE, Mg) CO 3 SIDERITE FECO 3 DISULFIDES PYRITE Fe S 2 CUBIC MARCASITE Fe S 2 ORTHORHOMBIC COFUIMBITE Fe 2 (SO 4 ) 3 9H 2 O SZOMOLONOKILE Fe SO 4 2H 2 O SULFATES GYPSUM Ca SO 4 2H 2 O BASSANITE Ca SO 4 1/2 H 2 O ANHYDRITE Ca SO 4 JAROSITE K Fe 3 (SO 4 ) 2 (OH) 6 FELDSPARE PLAGIOCLASE (NaCa) Al (Alsi) Si 2 O 8 ORTHOCLASE KALSi 3 O 8 Common Coal Minerals Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Calcite Pyrites Ouartz Oxidizing Reducing 700 . C S 1 H 2 S FeS.Fe 2 (SO 4 ) 3 FeO Fe Temperature Feo (Partial Melt) invesions (Partial melt) 950 . C 970 . C S 1 H 2 S 1000 . TO 1100 . C CO 2 Fe Cao liquid 2570 Fe 2 O 3 SiO 2 2570 . C liquid liquid 1600 . C 1723 . C Phase Transforamation Of Some Mineral Matter Commonly Found In Coal Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Kaolinite Illite Metakaolinite (A1 2 O 3 2sio 2 950 . C 925 . C SI O 2 (Clay lattica destroyed) Spinal amorphous quartz A1 2 O 3 Mgo glass Si O 2 Silion Spinel 1050 . C (2A1 2 O 3. 3 Si O 2 1100 . C Si O 2 1100 . C Mullite 1:1Mullite type phase 1300 . C (3A1 2 O 3 (A1 2 O 3 .Si OO 2 ) 2Si O 2 1400 C Sio2 (Coristobailite) 1400 . C Mullite 3A1 2 O 3 . 2Si O 2 liquid glass May not be completely liquid untill 1800C 1800 . C Phase Transforamation Of Some Mineral Matter Commonly Found In Coal Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Total Iron in Coal Ash Vs IDT Total Iron in Coal Ash Vs IDT Total Iron in Coal Ash I D T D e g F (C) Oxidizing Basis Reducing Basis Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Total Iron in Coal Ash Vs HT Total Iron in Coal Ash Vs HT I D T D e g F (C) Total Iron in Coal Ash Oxidizing Basis Reducing Basis Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this % Basic Components Vs AFT % Basic Components Vs AFT Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this % Na % Na 22 O in Coal Ash Vs Deposition Rate O in Coal Ash Vs Deposition Rate For For Lignitic Lignitic Ash Ash Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this 1 LB COAL 1.7 SLON 1.7F 1.75 1.7 FLOAT 1.7 SINK 1.5 SOLN 1.9 SLON 1.55 1.9F 1.95 1.55x1.7F 1.75 x 1.9F PRACTION PRACTION 1.5F 1.5 FLOAT 1.9 SINK 1.3 SLON 2.1 SLON 2.1F 1.35 .95 x 2.7F 2.15 FRACTION 1.35 x 1.5F 2.1 SINK FRACTION 2.5 SOLN 1.3F 2.5F 2.55 1.3 F 2.15x2.9F FRACTION FRACTION 2.5 SINK 2.95 2.55x2.9F FRACTION 2.95 2.95 FRACTION Gravity Separation Procedure Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this EXPERIENCE SEVERE SEVERE MODERATE NONE NONE CYCLONE INDEX MED - HIGH LOW-MED. LOW LOW LOW SULFUR SLAGGING INDEX HIGH MEDIUM LOW LOW LOW FUSION SLAGGING INDEX SEVERE SEVERE MEDIUM LOW LOW VISCOSITY SLAGGING INDEX MED - HIGH LOW - MED LOW LOW LOW Slagging Index Matrix Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Procedure Developed Procedure Developed Laboratory analyses of fuel samples Trials at Fuel Evaluation Test Facility at various blend proportions and optimising the blend proportion Implementation of the recommended blend proportion at TPS for long duration observation Furnace inspection during shut down after long duration operation Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Basis for recommendation Basis for recommendation Flame stability Carbon loss Heat flux reduction due to slagging and fouling Heat flux regain ability on wall blowing SH and RH spray levels Emission Acid dew point Ash resitivity Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Issues of Issues of Imported coal firing Imported coal firing Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Issues of Imported coal firing Issues of Imported coal firing The imported coals are mostly from Indonesia, Australia, south Africa, China and Russia Indonesian coal is used in many power stations in India today in varying proportion Major properties High volatile matter content >40% High moisture content >25% Very low ash content 1 to 10 % Surface moisture 8 to 10% Gross calorific value 5000 to 6000 Kcal/Kg Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Issues of Imported coal firing.. Issues of Imported coal firing.. contd contd Blending of import coal with the Indian coal is not tried more than 30% Ash fusion temperature T1, T2 1190 C, 1200C Gap of T1 and T2 is less resulting in slagging /Fouling High volatile content risk for mill fire and explosion Mill out let temperature is to be restricted to < 60C to avoid mill fire Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Issues of Imported coal firing.. Issues of Imported coal firing.. Contd Contd To maintain lesser MOT more tempering air is used APH performance affected - increased boiler exit gas temperature High moisture content reduced milling capacity and heat loss in the boiler Slagging and fouling reduces heat absorption in the furnace and other heat transfer surfaces Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Issues of Imported coal firing.. Issues of Imported coal firing.. contd contd Overall efficiency of the boiler is reduced, when 100% import coal firing is resorted to. Increased fuel air quantity at the burner to maintain flame front. Increased wall blowing and soot blowing frequency Up set in the secondary air distribution across the wind box. Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Issues of Imported coal firing.. Issues of Imported coal firing.. contd contd Coals from South Africa and Australia found to have low ash fusion temperatures and high sulphur content. Coals from china Russia have very high calorific value 6000 7000 Kcal/ Kg. for which elevation heat loading is to be verified and restricted before usage. Super heater/ re heater performance and achieving boiler out let parameters to be studied. Blending /firing in boiler is to be preceded by laboratory study/ pilot model study Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Conclusions Conclusions Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Conclusions Conclusions Blending of coals expected to grow over the next decade as electric utilities attempt to Reduce cost Meet SO 2 emission limits Improve combustion performance of their coals All aspects of a blends behaviour & its effect on all components of the power stations, from the stock pile to the stack, should be considered before the most appropriate blend composition is chosen IEA Publication Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Typical Coal Yard Typical Coal Yard Coal Stockpile Wetlands Rail Car Unloader Rail Line Material Handling System Crusher House Main Conveyor Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Conclusions Conclusions (cont.) (cont.) At present, the effect of coal blending on power station performance are not completely understood Even if the blended coal closely resembles the design coal for the boiler, the blend does not perform the same A limitation to blending coals is the compatibility of the coals themselves; problems are more likely when blending petrographically different coals or coals with different ash chemistry IEA Publication Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Conclusions Conclusions (cont.) (cont.) The impact of blending coals of different hardness on the finalize distribution & compositional distribution of the pulersied coal is sill not understood Non-additivity properties make blend evaluation for power generation inherently complex Traditional indices for ash deposition are unreliable when applied to blends IEA Publication Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Conclusions Conclusions (cont.) (cont.) More work is required on understanding how the inorganic components of coals in the blend interact & how it affects ash behaviour, including its emisivity, reflectivity & thermal conductivity SO 2 can be predicted with reasonable accuracy No adequate means of predicting Nox IEA Publication Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Conclusions Conclusions (cont.) (cont.) Because of the complexity of the combustion process and the number of variables involved (which are still not fully understood) It is difficult to extrapolate small - scale results to full - scale plant. Power station operational experience in a wide range of plant configurations with a variety of coal feedstock is essential for determining the practical significance of results from bench - and pilot - scale tests. More published data on how the behavior of the coals / blends utilize in these tests differ from their actual performance in power station boilers are required. IEA Publication Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Conclusions Conclusions (cont.) (cont.) Tests are widely utilised, providing a preliminary indication of the behaviour of the coal / blend. One of the most successful outcomes of blending is in providing a fuel of consistent quality. Coal is a heterogeneous material and its properties and composition vary even within a single seam or single shipment / train load. There is a need to minimise the variability. This can be achieved by blending. Indian power stations use mainly blended coals only. IEA Publication Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Coal blending Coal blending -- What all to look for What all to look for Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Coal blending Coal blending -- What all to look for What all to look for Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Coal blending Coal blending -- What all to look for What all to look for (Cont) (Cont) Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this How power stations to view Look at proximate and ash analysis Look for FC/VM ratio idea on reactivity Ash composition ratios slagging Trial with low mixture ratio 95% + 5% 95% of regular usage coal Watch parameters like SH spray, steam temp, exit gas temp, unburnt carbon,load on bottom ash collection after maintaining load, steam pressure, excess air& mixture ratio for about a week Blending of coal Blending of coal My conclusion Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this What to Insist while importing Coal What to Insist while importing Coal Specify the proximate analysis you look for Coal ash composition range which is compatible with the coal being fired Restrict moisture level to the minimum possible may be a max of 20% If high moisture coal the min size of coal must be 40 mm or above Never accept on fines must be zero This reduces problem in handling Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Preferred Solution for All these Preferred Solution for All these Decide high moisture coal to be used or not If yes, then go for 100% high moisture coal firing rather than blending Decide to buy only coal with Zero fines and sizes above 40 mm Prefer only CFBC boilers for high capacity boilers Today you can get even super-critical CFBC boilers CFBC boiler can handle high moisture coals without any problem If no, then think of blending in PC fired boilers Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this ANY QUESTIONS PLEASE ANY QUESTIONS PLEASE Dr V T Sathyanathan Mankind is in pursuit of truth, let us work towards this Thank You All Thank You All