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P M V Subbarao
Associate Professor
Mechanical Engineering Department
IIT Delhi
Correct Size, shape and quantity of Diet For Complete Digestion..
Combustion Limits on Furnace Design
The lower limit of the furnace volume is dominated by the space
required for burning the fuel completely, or
to an extent less than the allowable unburned fuel loss.
To complete the fuel combustion within the furnace space, the fuel
injected into the furnace has to reside there for a time longer than
critical time t
*
r
.
The fuel residence time can also be estimated by the residence time of
the combustion gas produced in the furnace.
An average residence time t
r
can be proposed.
e unit volum per generation heat of rate Allowable Max. furnace the of Volume
furnace the entering energy Fuel
=
r
t
v
c
r
Vq
LHV m
t >
gas. of density
generated gas of mass
= V
v
g
g
c
r
q
m
LHV m
t
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v
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g
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q
m
m
LHV
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F
A
LHV
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Validation of Design
For best desingn: X = 0.
Acceptable designs: X = +/- 0.05.
If X is not in the limits above, the design and performance
calculations should be repeated.
At any time during Operation above conditions should be
maintained for most efficient and reliable operation of mill.
Derate Analysis and Operating Concerns
Pulverizer capacity limitation : A derate is due to the fuel
burn rate exceeding predicted pulverizer capacity with all
pulverizers in service.
Feeder capacity limitation : A derate is due to the fuel burn
rate is greater than the total actual feeder capacity with all
pulverizers in service.
An exhauster mill limitation: A derate is due to the
calculated airflow required with all pulverizers in service is
greater than the actual exhauster fan flow.
Improper pulverizer outlet temperature: A derate is due to
the heat available in the primary air for drying coal in the
pulverizers is less than that required.
Auxiliary Power Requirements
The pulverizer system annual auxiliary power requirements are
calculated in a multistep process.
The first step is to calculate the fractional load per pulverizer in
service (Milllod) at load point i.
where
FBR
i
= fuel burn rate, t/h, at load i,
N
mill,i
= calculated number of pulverizers in service at load i, and
C
mill
= calculated capacity, t/h, per pulverizer.
The second step is to calculate the power required per pulverizer.
mill i mill
i
i
C N
FBR
Milllod
=
,
( )
|
|
.
|
\
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.
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=
j mill i mill
Milllod
dld
dP
RP P 1 1
,
where
RP
mill
= Rated Power Consumption of mill, and
dP/dld = slope of pulverizer power Vs fractional pulverizer
load curve based on manufacturer data.
The third step is to calculate the power required (MWh/yr) for the
pulverizer system at load point i.
where
q
motor
= motor efficiency.
Finally, the auxiliary power requirements for each load point are
summed to obtain the total auxiliary power requirements for the
pulverizer system.
motor
i i mill mill
i y sys
Hours P N
P
q
=
,
, ,
=
=
K
i
i y sys tot sys
P P
1
, , ,
The Control of Coal Mills
Mill PA /Differential Pressure Control
Closed Loop Control of PA Flow
Parallel Control of Feeder Speed & PA Flow
Control of Suction Mills
Mill Temperature Control
A comprehensive Mill Control System
Steam Temperature control with 2 stage
Attemperation
OPERATIONS AND MAINTENANCE CONTROLLABLE FACTORS
Four controllable heat rate factors are directly related with
furnace performance and furnace flue gas uniformity.
These are: superheater temperature, reheater temperature,
desuperheating spray water flow to the superheater, and
desuperheating spray water flow to the reheater
Balancing of the fuel and air to each burner has much to do with
furnace combustion efficiency, and the completeness of
combustion at the furnace exit.
The residence time of the products of combustion from the
burners to the superheater flue gas inlet is about one or two
seconds.
Not very long for furnace mixing of fuel rich and air rich lanes of
combustion products.
Optimized combustion at the superheater inlet can be quantified
by use of a water-cooled high velocity thermocouple probe.
Slagging at the superheater flue gas inlet has been a problem in a
number of boilers due to stratified flue gas.
Slagging at the lower furnace results in large boulder sized
clinkers blocking the lower ash hopper.
Tube spacing becomes ever closer as the heat transfer changes
from radiant in the furnace, to convective in the back pass.
Recall the typical tube spacing of pendant superheater and
reheater tubes.
If lanes in the furnace outlet flue gas approach the ash softening
or even the ash fluid temperature, upper furnace slagging and
blockage can result in a very short time.
Several cases studies should be reviewed to show how the
application of the Thirteen Essentials will improved slagging,
heat-rate, capacity factor, reliability, NOx and/or flyash carbon
content.
AIRFLOW AND FUEL FLOW OPTIMIZATIONS : A Case Study
Design Data Used
On Going Problems
Erratic performance and severe slagging problems in
both the upper furnace and the lower ash hopper.
It was concluded that the furnace exit gas temperature
was varying due to non-uniform products of combustion
entering the superheater gas side.
Ash fusion temperatures are often lower in a reducing
atmosphere than in an oxidizing atmosphere.
Since many of the opportunities for improvement that
were experienced on this boiler were slagging related,
this was a significant factor.
For example, the peak furnace exit gas temperatures
were above 2472F. (the maximum point indicated on
the digital thermometer, the true temperature was even
higher.)
Also, the reducing ash fluid temperature from is
2400F.
The combination of the fuel richness and ash chemistry
together is the root cause of severe slagging.
A highly localized temperature is also usually due
to fuel rich and creates a reducing atmosphere.
Therefore, this peak temperature corresponds to a
reducing atmosphere.
It is this combined effect of lower ash fusion
temperature in a reducing atmosphere (chemistry
effect) and the poor fuel and air balance
(mechanical effect) that greatly accelerates
slagging.
The furnace exit, excess oxygen and temperature
stratifications were found to be the result of a non-
homogeneous mixing of the combustion air and fuel in the
burner belt zone.
Zero oxygen points at the furnace exit could be due to either
an abundance of fuel, or a shortage of combustion air.
The Comprehensive Diagnostic Test technique was utilized
to quantify the opportunities for each.
Upon completion of the Comprehensive Diagnostic Tests,
the following changes were implemented:
Fuel lines were balanced
Flow nozzles were installed for primary airflow measurement
and control
Pulverizer classifier changes
Secondary air duct changes to balance combustion airflows
to each of the four corners.