Understanding Boiler & Auxiliaries

L B SAH PMI-NTPC
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Contents
Coal fired boilers Feeders Mills Fans Air Preheaters ESP
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Typical Plant Layout

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Typical Boiler Layout

Boiler Drum Platen Super Heater Secondary Air Duct Furnace APH Reheater Final Super Heater LTSH Economizer Wind Box Coal Bunker Chimney

PA duct

Flue Gas Duct

Coal Feeder

Coal Mill
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F D Fan

P A Fan

Specification of Reference Plant

Description Capacity Steam flow Boiler efficiency Furnace width Furnace depth Furnace height(Ring header to furnace roof) Furnace volume Maximum feed water pressure Super heater pressure Super heater temperature Reheater pressure Reheater temperature Number of ID fans Number of FD fans
24 May Number of APH (Trisector type) 2012

Value 210 700 87.28 13.868 10.592 43.168 5570 167.2 154 540 38.8 540 2 2

Unit MW TPH % m m m m3 Kg/cm2 Kg/cm2

0C

Kg/cm2
0C

No. No.

No.

TWO PASS BOILER ARRANGEMENT

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TYPE OF BOILER
Based on steam parameter- Sub critical/ Supercritical Based on steam/ water circuit-Once through/ drum type
Based on air/ flue gas path- Tower/Two path Type of fuel- Coal fired/ oil fired

Type of draft system

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TYPE OF BOILER
Type of burner arrangement- Tangential/Front

Selection of Firing system- Type of mills

Single reheat/ double reheat Type of water wall tube- Plain, rifled Type of tubing arrangement- Spiral/ straight
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Once Through Boiler (Spiral design)

Conventional

design More BFP power due to spiral tubes

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Heat Generation in furnace

Heat input in the furnace
QFurnace MWElect

Cycle

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
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For 500 MW units For 200 MW units

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Tangential Firing System

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Configuration

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Relative sizes of Tangential Fired furnace wall for different fuels

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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
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A Few words on Super Critical Boiler

Supercritical Cycle

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SUPERCRITICAL THERMAL CYCLE ADVANTAGES

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.
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SUPERCRITICAL BOILER ADVANTAGES

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.
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SUPERCRITICAL BOILER DISADVANTAGES

Higher power consumption of BFP Higher feed water quality Requires more complex supporting
and framing in Boiler due to Spiral Wall tubes. Slight higher capital cost.
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COMPARISION OF 660 MW Vs 500 MW BOILER

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

338.5
540 46.1

RH STEAM TEMP OUTLET RH STEAM PRESS INLET

KG/CM2
0C

FEED WATER TEMP

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291.4

255.2
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COST COMPARISON
FOR 660 MW vs. 500 MW

DESCRIPTION

3x660 MW 1970.73 Cr

2x500 MW 1020.54 Cr Included above 1020.54 Cr 1.02 Cr

1.Cost of Boiler alone 1

2 Cost of ESP 153.00 Cr Total cost of Boiler + 3 ESP 2124.00 Cr 4 Boiler cost Per MW Cost of TG for entire 5 stage 1.07 Cr

1204.72 Cr 0.6Cr

634.31 Cr 0.63 Cr
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6 Cost of TG Per MW 24 May 2012

Combustion generated Pollution

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Combustion generated Pollution

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Effect of emissions from combustion on human and environment.

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Coal Mill & Feeder

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Components
The Major components are :

Coal Preparation Equipments

Feeders Mills Burners

Coal Firing Equipments

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Feeders
Volumetric Type feeder Gravimetric Feeder
Chain Feeder Belt Feeder Table type belt Feeder

Chain Feeder

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Gravimetric Coal feeder

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Internals of coal feeder

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Role of Mills
Produces Pulverized coal 70-75 % of which
passes through 200 mesh Air mixed with Pulverized coal (PF) is carried to the coal nozzle in the wind box assembly PF from coal nozzle is directed towards the centre of boiler burning zone Pre-heated secondary air enters boiler and surrounds the PF and help in combustion
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CLASSIFICATION OF MILLS VERTICAL SPINDLE BOWL/ BALL & RACE

XRP (BHEL) E MILLS (BABCOCK)

TUBE PRESSURIZED

MPS

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Classification-As per Speed

Types of Mills

Low Speed 17 to 20 Rev/min Tube and ball mill

Medium Speed 30 to 100 Rev/min Bowl Mill, Ball and Race mill

High Speed 500 to 1000 Rev/min Beater Mill, Impact Mill

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BOWL MILL
Model no. Base capacity(T/Hr) 18.4 26.4 33.8 36.5 51.1 54.1 68.1 72.0

623XRP 703XRP 763XRP 803XRP 883XRP 903XRP 1003XRP 1043XRP

BASE CAPACITY(T/HR) AT HGI -55 Total Moisture-10% Fineness-70% THRU 200 MESH

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Features of Bowl Mills

Grinding chamber Classifier mounted above it Pulverization takes place in rotating bowl Rolls rotating free on journal do the crushing Heavy springs provide the pressure between the coal and the rolls Rolls do not touch the grinding rings Tramp iron and foreign material discharged.
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Pictures of Bowl Mill

Coal Entry

Hot Air Flow from PA Fan

Rollers

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BALL& RACE MILL(E MILL)

Model no.

Base capacity(T/Hr) 25 35 40 55 61 70 80
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7E9 8.5E10 8.5E9 10E10 10.9E11 10.9E10 10.9E8

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Internals of ball & race mill

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Ball & TUBE MILL

Model no.

Base capacity(T/Hr) 83 90

BBD4760 BBD4772

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Ball & Tube Mill Internals

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Pictures of Tube Mill

Steel Balls

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Feature of Tube Mill

Operate at 17 to 20 RPM Coal Feed from both end of the Tube Small Ball of 30,40, 50 mm Sizes are used Hot air blown to move coal to classifiers at two elevations in boiler furnace No Maintenance for long periods Better availability so no spare mill required Always a reserve of coal so there is no spark produced between Steel balls Consumption of power is more High Foundation and Initial cost of Equipment
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Burner Arrangement

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Tangential Firing System

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Arrangement

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AIR PRE HEATERS

OBJECTIVES
TO RAISE THE TEMPERATURES OF PRIMARY AND SECONDARY AIR BY UTILISING HEAT FROM FLUE GAS AT LOW TEMPERATURE

ADVANTAGES OF AIR PREHEATERS

INCREASE THE BOILER EFFICIENCY STABILITY OF COMBUSTION IMPROVED BY USE OF HOT AIR PERMITTING TO BURN POOR QUALITY COAL
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Tubular Air Pre-Heater

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Regenerative air pre heater

BYPASS SEAL RADIAL SEAL

HOT END

AXIAL SEAL

COLD END

HOT INTERMEDIATE

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Ljungstrom type Bisector

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APH (Trisector type)

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Regenerative Pre-Heater
Rotates with a low speed : 0.75 rpm. Weight : 500 tons. This consists of : rotor, sealing apparatus,

shell etc. Rotor is divided into 12 or 24 sections Each sector is divided into several trapezoidal sections with transverse division plates. Heat storage pales are placed in these sections.
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Heating Element Profile

Cold End

Hot End & Intermediate

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Heating Elements

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PERFORMANCE DEGRADATION OF APH

Seal Leakage Erosion Corrosion High Pressure Drop Across APH

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