07/09/2018

Better Fuel Distribution To Improve

Combustion During Flexible Load
Operation
Osy Oaikhiena, Craig Lawson, Guisu Liu, Vivek Savarianadam, Charles Conroy

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2018, Hyderabad, India

• INTRODUCTION TO COMPANY
• DEFINING THE PROBLEM
• CFD AS A TOOL
• CASE STUDIES
• CONCLUSION
• Q&A SESSIONS

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 07/09/2018

GREENBANK IN THE UK - HEAD OFFICE

HARTSHORNE ROAD DERBYSHIRE

Over 64 years of engineering excellence.

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Hyderabad, India

GREENBANK GROUP
Incorporating:
Ammegen Ltd
GAIM Ltd Nitec Energy
Services.
Greenbank Engineering Services Ltd 7138 Waterloo Drive
Niagara Falls

Greenbank India Pvt Ltd Ontario

ON L2J 1E2
Canada

Greenbank Terotech Ltd Tel: +1 (905) 351 9703

Greenbank
India Pvt Ltd. Reaction
c/o ABSR ENGINEERS Analytic
& SERVICES PVT. LTD.
KOLKATTA Unit No.
Solutions Inc.
208, 2nd Floor, The 1212 S. Naper Boulevard
Terminus, BG 12, AA- Suite 119-108
1B, New Town, Naperville
Kolkata - 700156, Illinois 60540
West Bengal, India Unites States of America

Tel: +1 (630) 708 8810

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FUEL FLOW MANAGEMENT AND

EFFICIENCY MEASUREMENT
TECHNOLOGY
Manage and detect Monitor
boiler tube leaks combustion
Improve particle fineness directly using GA200® efficiency directly
and milling throughput using series boiler steam leak using G-CAM®
CoalValve and GravMaster detection system carbon-in-ash
gravimetric feeders monitor

Measure PF
Improve air to fuel ratio distribution and
and PF distribution on velocity using
multi-outlet mills using PfMaster PFMS
CoalFlo® PF balancing PF flow monitoring
dampers system

Improve air to
Monitor particle fineness fuel ratio and PF
and milling Performance distribution at
using MillMaster® particle pipe splitters
size analyser using VARB® PF
diffusers
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COMBUSTION AND EMISSIONS CONTROL

SOLUTIONS

LOI and SNCR

Particulate Secondary NOx
Measurement Control

Pulverised Fuel & AOFA

Air Distribution Primary NOx
Systems Control

Pulverised Fuel LNB

Measurement Primary NOx
and Control Control

Sorbent Injection Fuel Switching

SO2/SO3/HCl/Hg Coal to Gas or
Control Biomass

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WHAT PROBLEMS DO WE FACE?

Pulverised fuel pipe system are

complex with varying lengths.
Mill outlet splits to feed set of burners.
Pipe work configuration can cause
varying pressure drop resulting in
imbalance in the fuel distribution.
Fuel imbalances affect velocities and
air fuel ratio entering the burner.
Fuel imbalance increases LOI, CO, NOX
and slagging.
Reach saltation conditions, material
plug.

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2018, Hyderabad, India

MODELLING AND EXPERIMENTATION

Greenbank uses physics Modelling for

design
CFD gives an insight into flow
patterns that are difficult, expensive
or impossible to study using
traditional (experimental)
techniques.
CFD strategically important in
everyday engineering applications
involving fluid and material
transport.
Greenbank uses inhouse
experimental facilities to validate
CFD models

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METHOD AND TOOLS

Scientific CFD readiness

Problem
Knowledge CFD model Validation CFD method
definition
Test matrix Model Model and tools for
Characterising
and studies. development validation commercial
the problem
Test data applications

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2018, Hyderabad, India

MILL OUTLET: FUEL DISTRIBUTION

• 750MW supercritical boiler

• 5 separate mill outlet feeding each burner
• Fuel imbalance at full and part load

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FUEL DISTRIBUTION: SOLUTION

PF Distribution within ±20.2%

PF distribution system: CoalFlo®

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2018, Hyderabad, India

PF PIPE LAYOUT

500MWe Front wall fired boiler

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PF PIPE LAYOUT

• 2 primary outlet from each mill

• Each primary outlet splits into 3 feeder

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FUEL DISTRIBUTION

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PLANT PERFORMANCE DATA

A side higher CO than B side due to fuel rich condition

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FUEL BALANCE SOLUTION

• Mill F has the worst fuel imbalance

• After fitted with PF distribution system fuel flow is balanced

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COMBUSTION PERFORMANCE AFTER

BALANCED FLOW

After installing PF distribution system

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CASE STUDY 1: LIGNITE BOILER

Lignite ducting in Czech between the mill and burner.

The need:

Deliver fuel to upper 2 burners 60%

Deliver fuel to lower 2 burners 60%
Deliver fuel to all burners 25%

Take into account Variable inlet

New bespoke burners from local Czech

supplier.

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CASE STUDY 1: LIGNITE BOILER

Before After

• Burner rope breaker was not as

effective as originally designed.

• Optimising fuel position into

burners to ensure effective mixing
within the burner.

• Using smaller VARB products on

the burner legs to break the rope.

Contours of DPM concentration (Kg/m3) and Burner inlet

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CASE STUDY 2: FERRYBRIDGE POWER

STATION PF Distribution improved
Improve distribution at the burner. to within +/-5% across 6
burner pipelines on 8
Ferrybridge C Power Station UK separate mill sets.

Reduced unburned carbon-in-ash

from 16% to 8% in average.
Equated to a £2400 savings per
week in C-I-A & efficiency gains.

16 x 3-way splits

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CASE STUDY 3: LONGANNET POWER

PLANT
Improve distribution at the burner
Longannet PS UK

• Unit 1 carbon in ash reduced

from 9.5% (+/-26%) to 6.5% (+/-
13%), due to VARB installation.
• According to the station this
equates to £225k per annum on
efficiency savings.
• In addition there is a saving of
45- 48 tonnes of coal per day for
the unit, circa £2325 per day
(£814k PA).

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CASE STUDY 4: AMER 8 POWER STATION

Reduced pressure drop by 22%.

Increased maximum stable load by 40% on the Biomass co-firing unit.

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SUMMARY

• Fuel balance in PF pipe system is a problem at all loads due to complexity of

the system.
• Fuel imbalance results in increased CO, LOI and slagging due to higher
temperature.
• Greenbank’s PF distribution system: CoalFlo®, VARB®, Control Gate® can be
retrofitted to decrease fuel imbalance
• Greenbank’s Intelligent Flow Control System helps to meet demand of flexible
load operation.
• Greenbank’s PF distribution system has been retrofitted worldwide.

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Thank You!

Welcome to Greenbank Ammegen Booth for Discussions!

Greenbank Ammegen Limited

Regional offices:

Hartshorne Road 1212 S. Naper Boulevard 7138 Waterloo Drive Unit No. 208,
Woodville Suite 119-108 Niagara Falls 2nd Floor, The Terminus, BG 12, AA-1B,
Derbyshire Naperville Ontario New Town
DE11 7GT Illinois 60540 ON L2J 1E2 Kolkata - 700156,
United Kingdom Unites States of America Canada India
Tel: +44(0)845 0707 097 Tel: +1 (630) 708 8810 Tel: +1 (905) 351 9703 Tel: +91 89 0202 5579

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