WELCOME

BOILER BEST PRACTICES

o o

Typical composition (Proximate analysis) 1. Fixed carbon 2. Fuel ash 3. Volatile material 4. Total Moisture 5. Sulfur High calorific value/ Lower calorific value (Kcal/kg) Hardgrove Index (HGI)

o o

Typical composition (Ultimate analysis) 1. Carbon 2. Hydrogen 3. Sulfur 4. Oxygen 5. Nitrogen 6. Fuel Ash Initial Deformation temperature (IDT) High calorific value/ Lower calorific value (Kcal/kg)

Carbon, hydrogen, sulfur are sources of heat on combustion

Surface moisture removed on heating during pulverization. Inherent moisture and volatiles are released at higher temperature, making coal porous and leading to char/ coke formation. (Thermal preparation stage)

 Three

1. Heavy Fuel Oil (HFO) 2. LSHS (Low Sulfur Heavy stock) 3. High speed Diesel (HSD)

liquid fuels used in power plants

Oil firing is preceded by Lowering viscosity and increasing flowability on heating for better combustion in given turn down ratio.(125oC) Droplet formation on atomization (by steam/ compressed air/ mechanical pressurization) Combustion initiation by High energy spark ignition

Reaction rate depends on concentration of one of the reactants

Concentration varies on partial pressure of the reactants. Partial pressure is a function of gas temperature. Therefore, reaction rate depends on temperature and substance that enter the reaction.

Reaction rate [k] is expressed by Arrhenius law,

Where

k k0e

E / RT

k0 = pre-exponential factor E =Activation energy (i.e. sufficient energy to destroy the molecular bonds) R= Gas constant T= Absolute temperature of the process

Main reactions
2C C + O2 = 2CO + 3950 BTU/lb (Deficit air) + O2 = CO2 +14093 BTU/lb C

Secondary reactions

2CO + O2 = 2CO2 + 4347BTU/lb + CO2 = 2CO -7.25MJ/kg

Carbon reaction
2C + O2 C + O2 reaction at 1200oC 4C + 3O2 Reaction at 1700oC 3C + 2O2 =2CO [Eco =60kJ/mol] =CO2 [Eco2 =140kJ/mol] =2CO + 2CO2 (Ratio 1:1) = 2CO +CO2 (Ratio 2:1)

It is desirable to supply combustion air at lower temperature regime in furnace

Hydrogen reaction 2H2 + O2 Sulfur reaction S + O2 (undesirable)

= 2H2O +61095 BTU/lb

= SO2 + 3980 BTU/lb

Nitrogen reaction
e(-K2/T) [N2][O2]1/2 t = constants = mole fraction = time = Temperature

[NO] = K1 Where K1, K2 [] t T

Theoretical air for complete combustion is known as stoichiometric air. Excess air for completion of combustion (20% at NCR i.e. 3.6% O2)
Total combustion is divided as

O2 % ExcessAir 21 O2 %

Primary air For drying & pulverised coal transportation Secondary air Additional air for combustion Ratio of SA/ PA = 2:1 (Approx)

 Anthracite
Semi-anthracite Bituminous Lignite Peat

Semi-Bituminous

High CV, low VM High CV, low VM Medium CV, medium VM Medium CV, medium VM Low CV, high VM, high TM Very low CV, high VM & TM

Heat input in the furnace

QFurnace

MWElect

Efficiency of thermal power plants is 37%45% for different types of cycle For typical conventional P.F. boilers, coal flow rate is
290-350 T/hr 120-145 T/hr For 500 MW units For 200 MW units

Cycle

Coal is pulverized in mills at a fineness of 70% thru 200 mesh. Dried powdered coal is conveyed to furnace (at a temperature < 95100oC)
Total coal flow is distributed among running mills and fed thru coal burners at 20-25 m/sec. Coal flow is arranged in tiers. Maximum heat release rate must not exceed plain area heat loading. It generates excessive NOx and making ash fused.

Fuel air is supplied around coal nozzles (at velocity of 30-35 m/sec).
Secondary air is supplied in adjacent tiers of sec. air dampers from wind box (Hot air from Secondary APH) Overfire/ Tempering air is supplied at the top of the burnaer zone for NOx control. Gas recirculation is adopted for steam temperature control in oil/ gas fired units. Furnace draft is maintained at -5 mmwcl with Forced and Induced draft fans (balanced draft)

Lignite, peat, garbage (For low CV, high ash, high Sulfur) Corner and Front fired furnaces are suitable for power plants In India for Bituminous coals

Down shot firing Front fired Single wall Opposed wall Corner fired Tangential tilted -30o to +30o Fluidized bed combustion

For Anthracite (Low VM) Bituminous (Medium VM) Bituminous (Medium VM)

Suitable for sub bituminous and bituminous coal More uniform heat absorption in furnace wallls Inherent feature of low NOx formation due air deficit region at centre Air plenum near walls reduce slagging and prevent fireside corrosion. Arrangement of steam temperature control by tilting the coal burners (-30o to +30o)

Heat generated in furnace is managed in such a way that it fulfills 1. No dry out of waterwall tubes
2. Enough residence time for combustion 3. Gas temperature before convection super heater < Ash fusion temperature 4. Selection of metallurgy (Carbon steel Grade-C)

For criteria of keeping flue gas temperature below Ash fusion temperature, following parameter are designed. 1. Furnace Height, Width, Depth 2. Furnace Volume 3. Furnace residence time (2.5 to 3.0 seconds) 4. Rate of steam generation in furnace, going to drum 5. Additional heat transfer surface as Platen SH, Wall Reheater, Divisinal Panel SH 6. Furnace exit gas temperature (FEGT) is the criteria for design of furnace.

Made of carbon steel (Grade-C) hollow circular tubes and DM water flows inside Above burner zone, tubes are internally spiraled for better drying thru spinning action Furnace walls are made as tangent wall whereas 2nd pass walls are made as membrane walls. Waterwalls are stiffened by the vertical stays and buck stays to safeguard from furnace pressure pulsation & explosion/ implosion The boiler as a whole is hanging type, supported at the top in large structural columns. Vertical expansion is allowed downwards and provision is made at bottom trough seal near ring header.

Ash is characterized by 1. Initial deformation temperature 2. Ash fusion temperature (IDT-50oC Approx) 3. Hemispherical temperature 4. Flow temperature

Indian coals are suitable for dry bottom furnace design only, because of a. High fuel ash (35-50%) b. High silica in ash (55-65% & vitrification temp. is 2000oK) c. High flow temperature (1600oC approx)

Configuration of Dead chamber

Steam drum HORIZONTAL PASS w/w hanger Screen tubes tubes

ARCH TUBES
GOOSENECK
Downcomer BCW p/p

DOGHOUSE BACKPASS

FURNACE

To APH

Drum

DPNL SHTR
Downcomer waterwall

Reheater S C R E E n Gooseneck

Fireball

Platen SHTR

LTSH
Economiser

Chimney

ID fan

APH Bottom Ash

ESP

Steam power plants operate on Rankine Cycle, DM water as working fluid. Sensible heat is added in economiser +furnace Steam generation takes place in waterwall. Typical furnace efficiency is 45% approx. Heat transfer in furnace and enclosed superheater takes place thru radiation.

HPH+Eco

w/w

SH RH HPT IPT LPT

BFP
LPH CEP condenser

Heat associated with the flue gas is used in superheaters & Reheater, LTSH, economiser. Maximum steam temperature is decided by the operating drum pressure and metallurgical constraints of the turbine blade material. Reheating is recommened at pressure above 100 ksc operating pressure. Reheating is done at 20-25% of the operating pressure. Carbon steel, alloy steel & SS used for tubing of SH & RH.

HPH+Eco

w/w

SH RH HPT IPT LPT

BFP
LPH CEP condenser

Density water and steam changes with pressure as shown. At higher pressure, density difference reduces. Flow establishment in down comer, waterwall and drum is due to density difference and height of water column (i.e. waterwall) at lower pressure.

185 ksc Sp. gravity

225 ksc

165 ksc
Pressure (KSC)

 Natural

circulation (upto 165 ksc)

Forced/

assisted circulation (185-190 ksc) Once thru boiler 1. Sub critical 2. Supercritical

Density difference & height of water column Assisted by external circulating pump (CC/ BCW pump) Below 221.5 bar 240-360 bar

It may be defined as ratio of feed water flow thru down comers to the steam generated in water wall. Ratio of the weight of 2-phase mixture to the weight of dry steam in waterwall. Ratio of the total fluid contained to the weight of the dry steam in waterwall.

CR = 30-35 Industrial boilers CR = 6-8 Natrual cir. Boilers CR = 2-3 Forced cri. Boilers CR = 1 Once thru boilers (Sub critical) CR = 1 Supercritical boilers

Temperature 374.16oC 2

3 1

1. Sub critical parameter 2. Critical parameter, (225.65 ksc/ 374.16oC) 3. Supercritical parameter

Entropy

Controlled point in circuitry C/R flow

Mix locations

External downcomers

Sulzer design

C/R pump Valved control of furnace ckt Combined C/R design Feed Benson Design

External downcomers

{0 from 60% to Full Load}

Definition CRITICAL is a thermodynamic expression describing the state of a substance beyond which there is no clear distinction between the liquid and gaseous phase. The critical pressure & temperature for water are Pressure = 225.56 Kg / cm2 Temperature = 374.15 C

Improvements in plant efficiency by more than 2 % Decrease in Coal Consumption Reduction in Green House gases. Overall reduction in Auxiliary Power consumption. Reduction in requirement of Ash dyke Land & Consumptive water.

Sliding pressure operation because of Once through system . Even distribution of heat due to spiral wall arrangement leading to less Boiler tube failure, thereby improving system continuity and availability of the station. Low thermal stress in Turbine . The startup time is less for boiler.

Higher power consumption of BFP Higher feed water quality required. More complex supporting and framing in Boiler due to Spiral Wall tubes. Slight higher capital cost.

Description

unit

660

500

S/H STEAM FLOW

T/HR

2225

1625

SH

STEAM PR

KG/CM2
0C

256
540 1742

179
540 1397.4

SH STEAM TEMP RH STEAM FLOW

T/HR
0C
0C

RH STEAM TEMP

INLET

303.7
568 51.17 291.4

338.5
540 46.1 255.2

RH STEAM TEMP OUTLET RH STEAM PRESS INLET FEED WATER TEMP

KG/CM2
0C

COST COMPARISON FOR

660 MW vs. 500 MW

DESCRIPTION
1.

660 MW 1970.73 Cr 153.00 Cr 2124.00 Cr 1.07 Cr 1204.72 Cr 0.6Cr

500 MW 1020.54 Cr Included above 1020.54 Cr 1.02 Cr 634.31 Cr 0.63 Cr

1 Cost of Boiler alone

2 Cost of ESP 3 Total cost of Boiler + ESP 4 Boiler cost Per MW 5 Cost of TG for entire stage 6 Cost of TG Per MW

% 46
double 300bar 600/600 250bar 540/560 120 40 1.15 1.25 130 170bar 535/535 single

0.03 bar

44

0.065bar

42

250bar 540/560

39 Excess exit gas steam conditions Air temp.

Reheat cond. Pressure

Pressure/ Temp 540oC/ 540oC

175 bar Ref.

245 bar 1.92

295 bar 2.44

540oC/ 566oC
565oC/ 565oC 600oC/ 600oC 600oC/620oC Advantage

0.72
1.35 3.10 3.62

2.74
3.45 5.30 5.91

3.33
4.12 6.09 6.61

1. Saving on coal consumption on higher efficiency 2. Reduction in fuel handling system & pollution control.

TEAM BFIL