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Combustion Optimization Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy.

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Presentation on theme: "Combustion Optimization Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy."— Presentation transcript:

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2 Combustion Optimization

3 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Emerging Market Requirements 1. Higher Availability & Reliability 2. Highest Plant efficiency 3. Lower Heat Rate 4. Minimum Auxiliary Power Consumption 5. Ability to operate under adverse grid conditions/fluctuation in demand 6. Minimum emission of Pollutants

4 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Measures to improve Plant Efficiency Boiler side: 1. Minimum flue gas temperature at AH outlet 2. Minimum excess air at AH outlet 3. Minimum un-burnt Carbon loss 4. Minimum RH spray 5. Minimum SH spray 6. Reduced Auxiliary Power Consumption

5 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Measures to improve Plant Efficiency … Measures to improve Plant Efficiency … Turbine side measures 1.Higher steam parameters ( MS Pressure & SHO/RHO Steam Temp). 1. Adoption of double reheat cycle 2.Increasing feed water temperature with Enhanced Regenerative feed heating 3.Increase in condenser vacuum

6 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) 2a. Boiler - Various Losses By GasDry Gas Loss Loss due to Moisture in Gas Due to Fuel Moisture Due to moisture formed by H 2 in fuel Due to air moisture By AshUnburnt carbon Loss Sensible heat loss in Fly ash Sensible heat loss in Bottom ash Other LossCarbon monoxide Loss Radiation Loss Heat loss through Mill rejects

7 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) NoLossFactor 1Dry Gas LossFlue Gas Temperature, Excess Air & Fuel 2Unburnt Carbon Loss In AshAsh in Fuel & Unburnt Carbon In Fly / Bottom Ash 3Mill Reject LossReject Rate & CV Of Reject 4Due to Moisture formed from Hydrogen Hydrogen Content In Fuel & Flue Gas Temperature 5Due to Fuel MoistureMoisture Content In Fuel & Flue Gas Temperature 6Due to Air MoistureHumidity Of Combustion Air, Excess Air Level & Flue Gas Temperature 7Radiation & Convection LossInsulation Of Boiler 8Sensible Heat Loss In AshAsh Temperature Factors Influencing Various Losses

8 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Ensure consistent mill fineness - +50, - 200 Good burner maintenance Proper secondary air adjustment - SADC Reduce PA air to the minimum possible – min PA velocity variation Cut out oil support at higher loads where coal flame is stable as oil preferentially deplete o 2 in the area and reduces o 2 for coal particles to burn Check coal property and tune combustion Keep boiler heat transfer surface clean so that losses can be reduced thus reducing the coal input Methods to reduce unburnt carbon loss Methods to reduce unburnt carbon loss

9 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Methods to reduce dry gas loss Methods to reduce dry gas loss Correct excess air High mill outlet temp. Better combustion – combustion tuning Arrest air ingress Air heater performance – leakage, proper elements Cleanliness of the heat transfer surfaces

10 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Optimization of Boiler Efficiency 1 HHV All Losses 2 FG APH out Temp Dry gas, Sensible heat in Ash, H 2, Fuel and Air Moisture Loss 3 Excess air Dry gas, Unburnt & Air Moisture Loss 4 Fuel Moisture Fuel Moisture Loss 5 Air Moisture Air Moisture Loss 6 2 H 2 in Fuel H 2 Loss 7 Mill reject rate or GCV Mill reject Loss The Major parameters to be looked into for Better Efficiency: 1.FG Temp 2.Excess air Level 3.Mill reject rate and 4.Unburnt carbon in ash Control / Optimization of other parameters (i.e GCV, H2, Fuel moisture and Air Moisture) are not possible.

11 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Major reasons for increase in APC Major reasons for increase in APC Operation of unit with higher excess air Air heater leakage Higher PA fan outlet pressure High mill fineness, more no. of mills Air ingress into boiler Pluggage in line / ducting Partialy blocked APH

12 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Sources of air ingress Sources of air ingress Furnace roof Expansion joints Air heaters Ducts Esp hoppers Peep holes Manholes Furnace bottom

13 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Factors affecting APC - a summary FACTORS AFFECTING AUXILIARY POWER ID FANS AH LEAK GAS TEMPERATURE DUCT LEAKAGES EXCESS AIR LOAD/ PLANT HEAT RATE DRAUGHT LOSS AH CHOKING FD FANS AH LEAK WIND BOX PR. EXCESS AIR LOAD/ PLANT HEAT RATE PRESSURE LOSS AH CHOKING SCAPH CHOKING PA FANS AH LEAKAGE PA HEADER PR. MILL AIR FLOW PRESSURE LOSS AH CHOKING MILL COAL QTY. GCV LOAD/ PLANT HEAT RATE COAL MOISTURE HGI COAL FINENESS MILL CONDITION

14 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB) Capacity Reduction in a Boiler Fuel input Low cv coal Milling capacity Grinding capacity Drying capacity Carrying capacity Drive capacity Draught system ID fan limitations Pressure drops high AH choking Chimney back pressure high High volume AH leakages Duct leakages High gas temperatures Worn out impellers Metal temperatures high High spray requirements Fouling of surfaces

15 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB)

16 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Problem: Heavy clinkering build up upto S-panel /Bottom of burner reported from many boilers Investigations: Poor mill fineness (50% through 200 mesh) Non-working of SADC as per control Poor coal quality – usage of ground stock Non- working of wall blowers Improper evacuation of bottom ash Solution :After taking above corrective actions no further problems faced.

17 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Problem: Frequent choking of coal pipe Investigations: Clean air flow test Checking of orifice Calibration of coal flow/air flow -check Foreign material entrapped in classifier ( cloth) Solution: Problem resolved after removal of foreign material from classifier.

18 Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to make a better world FIELD ENGINEERING SERVICES (FB) Bharat Heavy Electricals Limited TIRUCHIRAPALLI Committed to making a better world FIELD ENGINEERING SERVICES (FB)


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