Beruflich Dokumente
Kultur Dokumente
By
Rajneesh Vachaspati
NPTI
1. Introduction
Solid fuel embraces a wide variety of
combustibles, ranging from wood, peat and
lignite, through refuse and other low
calorific value substances, to coal and other
solid fuels derived from it.
Coal represents by far the largest
component of the world’s fossil fuel
reserves.
2
In thermal terms 90% of the known
hydrocarbon fuel deposits are formed by
coal.
The carbon: hydrogen ratio of coal is the
highest of the fossil fuels, hence the
calorific values of coals are principally
determined by the carbon in the fuel.
3
It is usual to consider coals in terms of their
rank: in general, a high ranking coal will have a
high carbon content.
5
Coal was the fuel which fired the Industrial
Revolution, but it is no longer the cheapest
option among the fossil fuels.
The cost of working the deposits and the
investment in technology needed to meet
increasingly stringent emissions standards
have increased the cost of burning coal.
6
Recent developments in gasification
processes have shown that it is possible to
produce gas from coal at a viable thermal
efficiency and to remove the sulfur from the
fuel at the same time.
7
ADVANTAGES OF COAL:
-CHEAP
-TRANSPORTABLE
PULVERISED COAL
-MAX. C %USE
-EFFICIENT USE OF LOW GRADE
COALS
-PROVIDES COAL/AIR FUEL CONTROL
-GIVES FLAME STABILITY
2. Coal Classification
As the rank of a coal increases, its carbon
content increases from 75% to about 93%
(by weight), the hydrogen content decreases
from 6% to 3%, and the oxygen content
decreases from 20% to 3%.
A useful method for analyzing a coal is the
proximate process.
Proximate analyses of some common fuels
are given in Table 9.1 (next slide).
9
Table 9.1 Composition of some typical solid fuels (% by mass)
10
The moisture in coal is made up of two
components: surface moisture and inherent
moisture.
The former is affected by the way in which
the coal is stored, and is thus variable.
11
Coals are also analyzed in terms of their
elemental constituents, giving the ultimate
analysis which was used earlier in
stoichiometric calculations.
Typical ultimate analyses of two types of
solid fuels are given in Table 9.2 (next
slide).
12
Table 9.2 Ultimate analyses (% by mass) of some coals
Coal Carbon Hydrogen Oxygen Nitrogen Sulfur
Anthracite 94.4 2.9 0.9 1.1 0.7
13
3. Coal Properties
There are a number of properties which are
important in identifying the suitability of a
coal for any given application:
Size
Some common size groups, together with
their rather picturesque names, are given in
Table 9.3 (next slide).
14
Calorific value
The ranking of a coal is not necessarily
related to its calorific value.
Coal fuels generally have a range of values
from 21 to 33 MJ/kg (gross).
The design rating of a coal-fired burner is
usually based on an estimated calorific
value of 26 MJ/kg (6,200 kcal/kg).
15
Ash Fusion Temperature
The melting point of the ash left after combustion of
the coal is of particular importance in terms of the
combustion and ash disposal equipment.
If the ash fuses it produces a glassy, porous substance
known as clinker (slag).
The combustion equipment will be designed to handle
either clinker or unfused ash, and use of the wrong
type of coal can have dire consequences.
16
Sulfur Content
Many deep-mined coals have a fairly high sulfur
content, typically around 1.5% by weight.
The same consideration apply to coal-fired
installations as to oil-fired combustion equipment
namely that condensation inside the plant must be
avoided and that the design of the flue must ensure
that ground concentration of sulfur oxides are
controlled within acceptable limits.
17
4. Coal Combustion
Coal combustion is a two-phase process and
the objective of the burner is, as always, to
achieve complete combustion of the fuel
with maximum energy efficiency.
Three common ways of burning solid fuels
are currently in use and are briefly reviewed
below.
18
Pulverized Fuel
The coal is ground to a very fine size (about 0.08mm
or more than 70% pass through #200 mesh) when it
can be made to behave rather like a liquid if air is
blown upwards through the powder.
The preparation and handling equipment is very
expensive and pulverized fuel installations are
generally only economically viable in very large scale
applications, such as thermal power stations.
19
Calorific Value
It is defined as the heat liberated in kJ by complete combustion of I kg of fuel
solid or liquid. For gaseous fuel ,the normal practice is to express calorific
value in kJ /m3 of gas at S.T.P
1. H.C.V:- It is the total heat liberated in kJ/kg or m3. All fuels
containing hydrogen when combines with oxygen will form steam
during the process of combustion. If product of combustion are
cooled at initial temperature,the steam formed as a result of
combustion will condense.Thus maximum heat is abstracted. This is
called HCV
2. L.C.V:- It is difference between the H.C.V and heat absorbed by
water due to combustion and surface moisture.Unit is kj/kg
R.O.M. 23 to 0 cm.
(Run of mine)
Large coal 15 to 5 cm
(Steam Coal)
Small Coal 5 to 0 cm
(Slak Coal)
UGM OCM
Name of Area Name of Colliery
BAIKUNTHPUR --Churcha
-- Katora
-- Katkona
-- Jhilimili
CIRIMIRI --Duman Hill
-- Korea
-- Kurasia
-- Chirimiri
-- N.C.P.H.
HASDEO West JKD.
--Rajnagar R.O.
-- Bijuri
-- New Rajnagar O.C.M.
MOISTURE 5 - 30 %
ASH 1 - 60 %
VOLATILE MATTER 2 - 70 %
ABRASION INDEX 5 - 100 %
Mg/Kg
HGI 30 - 85 %
EFFECT OF COAL ON MILL CAPACITY-
HIGH CAPACITY
HGI
INDIAN HIGH ASH
COAL HIGH SILICA
GRINDED
RE CIRCULATED
RE GRINDED
HIGH WEAR
COAL CHARACTERISTICS.
NTPC - RECENT TENDERS.
HEAVY
PARTICLES CLASSIFIER
P.F.+AIR
HOT AIR GRINDING ZONE
DRYING & GRINDING
REJECTS
EFFECTS OF COAL CHARACTERISTICS ON MILL
DESIGN
MILL OUTLET
DETERMINE
VOLATILE TEMP
MILL INLET
HGI GRINDABILITY
HAMMER MILL
MEDIUM SPEED 40-70 RPM
TUBE MILL
HAMMER MILLS:
HINGED OR FIXED HAMMER IN
ENCLOSED CHAMBER
IMPACT
GRINDING
ATTRITION
FAN ON MAIN SHAFT
APPLICATION LIGNITE
DEMERITS HIGH MAINTENANCE DUE TO HIGH
SPEED
HIGH POWER CONSUMPTION
REDUCTION IN CAPACITY WITH WEAR
REDUCTION IN FINENESS WITH WEAR
MEDIUM SPEED MILLS
1. BOWL MILLS
-COLLABORATION WITH COMBUSTON ENGG. USA,
CALLED RAYMOND MILLS, TYPE RP,XRPNGG. USA
-QUIET OPERATION
-HIGH REJECTS
8.5 E9 TO 13 E 10
GRINDING ELEMENTS
NI-HARD
HI-CHROME
DESIGNATION
8 E 9
80 “(TRACK DIA NO ON BALLS
IN INCHES ( 9 NOS)
MERITS:
•HIGHER CAPACITY MILLS AVAILABLE.
•HIGHER WEAR LIFE OF BALLS.
•CAN HANDLE ABRASIVE COALS -YGP 90-100.
•HYDRAULIC LOADING SYSTEM CAPABLE ON
ADJUSTMENT OF GRINDING FORCES.
•NEGLIGIBLE REJECTS.
•FINENESS WITH STATIC CLASSIFIER 80% TO
90%.
•CONSISTENT OUT PUT.
DEMERITS
-HIGHER INITIAL COST
-HIGHER GRINDING ELEMENT COST
-HIGHER REPLACEMENT TIME
-METAL TO METAL CONTACT
-HIGHER NOISE LEVEL
-HIGH VIBRATIONS
-NEEDS VIBRATION ISOLATION
-PRONE TO BREAKING OF BALLS
-HIGHER PRESSURE DROP
-HIGHER POWER CONSUMPTION
-LARGER STATIC CLASSIFIER TO IMPROVE FINENESS
3. MPS MILLS
(MULHE PENDEL SCHUSSEL= MILL PANDULAM BOWL)
•CUSTOMER APPREHENSION
-DIFFICULT TO MAINTAIN HYDRAULICS
•TALLER IN SIZE
GRINDING
IMPACT
ATTRITION
CRUSHING DUE BALL ROLLING
CRUSHING BALL ROLLING OVER
LINERS
GRINDING MEDIA
Mn STEEL LINER & FORGED BALLS
HI-CHROME LINERS & HIGH CHROME
BALLS
MERRITS
•MAINTENANCE FREE
•CONSISTENT FINENESS
•CONSISTENT OUTPUT
•ZERO REJECTS
DEMERITS
• MILL EXPLOSIONS
S G IRON
INSERTS
MADE OF
FMU 18
660 MW SIPAT TENDER
REQUIREMENTS:
1) 9 MILLS
E MILLS 9 x 12 E 10
9 x B& W 118 K
CONCLUSION
1) METALLURGY
2) AERODYNAMICS
M.S.L.ASSLY A 514 GR B
C Si Ni Cr Mo Mn
WANAKBORI
LIFE 5000 HRS
PROBLEM
C Si Ni Cr Mo Mn
LIFE
XRP 623 TO XRP 883 2500 HRS. TO 3500
HRS
GR 5000 HRS
VALVE BODY CERAMIC LINING
ELECTRODE COMBUST
ALLOY
MML - USA
LIFE 18,000 HRS