Loesche Experiences

Optimization & Efficiency improvement in Coal

Pulverisers
IOCL 2nd All India Servo Power Meet 2016,
Ghaziabad (INDIA)
Presented by:
Brishank Srivastava
(Loesche Energy Systems India Pvt. Ltd.)
Vishal Agarwal
(Loesche India Pvt. Ltd.)
Agenda

1. Introduction to the Loesche Group

2. Coal Fineness Control & Impact on Boiler Performance
3. Loesche 4th Generation Dynamic Classifier and Lubrication
Requirements.
4. References
5. Dynamic Classifier Retrofit Case Studies

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Section 1

Section 1

Introduction to the Loesche Group & Offerings

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1.1 Introduction Loesche Group

LOESCHE GmbH is a privately owned

company founded 1906 in Berlin, Germany
Head office based in Dusseldorf, Germany
Main shareholder: Dr Thomas Loesche
Management: Dr Thomas Loesche,
Mr Rdiger Zerbe
Employees in Dusseldorf: 300+
Employees worldwide: approx. 600+
Certified according to DIN EN ISO 9001

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1.2 Loesche Worldwide

America Europe Africa Asia

LOESCHE America, LOESCHE Energy LOESCHE South LOESCHE Middle East
Inc. Systems Africa (Pty.) Ltd., Tehran Branch Office
Pembroke Pinkes, Horsham, UK Johannesburg Tehran, Iran
Florida, USA South Africa
LOESCHE Latino- LOESCHE Energy Systems
LOESCHE Energy americana S. A. LOESCHE Nigeria India (Pvt.) Ltd, New Delhi,
Systems, America. Madrid, Spain Ltd., India
Branch Office Lagos, Nigeria LOESCHE India (Pvt.) Ltd.
LOESCHE GmbH
Pittsburgh, New Delhi, India
(Head Office) /
Pennsylvania,USA LOESCHE Mills Ltd.
LOESCHE Automation
Dsseldorf, Germany Shanghai & Beijing, PRC
LOESCHE OOO LOESCHE GmbH Vietnam
Moscow, Russia Branch
Ho Chi Minh City, Viet Nam
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1.3 Purpose of Loesche Energy Systems (LES)

LES is the Centre of

Excellence for coal mill
application in the power
utilities industry.
In early 2004 Loesche GmbH identified an
opportunity to diversify into the Power Market

Consequently a special purpose vehicle name

LES was formed (2006).

This approach allowed the recruited boiler

specialists to focus the Loesche products more
directly into the Power industry
In addition develop novel solutions to some of the
current industry bottlenecks

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 1.4 Overview of Loesche Energy Systems (LES)

Loesche Energy Systems Ltd (LES) is a 100%

owned subsidiary of Loesche GmbH
Founded in February 2006 in Horsham, West
Sussex, United Kingdom

LES is the coal mill technology holder for the

Loesche Group.
United Kingdom (Power Head Office)
LES have introduced two new daughter
companies in 2014 to expand geographical
presence in the Pittsburgh(USA) and New Delhi
(India)
LES has its manufacturing base in Chennai, as
Loesche Energy Systems India (P) Ltd.

Chennai, India (Manufacturing Unit)

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1.4.1 Loesche Energy Systems - Products
i. Coal Mill Upgrade (Classifiers)
Referenced retrofit on BTMs, HP, RP, MPS & E mills
Increases mill throughput by upto 20%
Increases fineness by 5-10% on 75 Micron
Eliminates retention on 300 Micron
Reduces LOI by approx 50%
Reduces Nox by 12-15%
Over 400+ retrofits completed globally

ii. Advanced Modelling & Scanning

Combustion optimisation through two phase modelling
and simulation of furnace combustion to determine
optimised burner and after air port design to minimise
the formation of NOx.
SCR & SNCR flue gas flow modelling leading to
optimisation of sorbent injection points to substantially
reduce running OPEX (payback less than 12-18
months)
FGD flue gas flow modelling leading to optimisation of
limestone injection points to substantially reduce
running OPEX (payback less than 12-18 months)

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1.4.2 Loesche Energy Systems - Products
iii. Coal & Biomass Mills
Capable of grinding all types of coal from anthracite,
bitumous, sub bitumous and lignite
Capable of grinding all types of pelletised biomass
(wood or straw)
2, 3 and 4 grinding roller mills
Capacity up to 250 t/h @ fineness exceeding 85% on
200 mesh
Drive motors up to 1,200 kW
Supply of coal mills for NEW BUILD and RETROFIT
Notable active markets, China, India, South East Asia
and Poland
Clients include DH, Doosan Babcock, Ansaldo, Rafako
etc

iv. Novel Power Plant Solutions

Loesche has supplied grinding terminals for IGCC and
Oxyfuel
Current developments include high coal moisture
enhancement process at minesite or front end of power
plants
Notable active markets, South Korea, Australia,
Indonessia & Nigeria

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Section 2

Section 2

Coal Fineness Control & Impact on Boiler Performance

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2.1 Power Industry Fuel Based Challenges

Observations from the trends are

1. New emissions legislation

To reduce NOx, SOx, SPM etc. (Owing to MOEF Norms
issued in December 2015 Compliance by December 2017)

2. Change in Coal Flows

Due to cost reduction drives (cheaper coals)
Due to Use of Alternative fuels having different
grindabilities

3. Upgrade of Old Power stations

Efficiency improvement
Reduction in unburnt carbon

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 2.2 Classification Historical
Traditional Static Classifier Design
Power plant coal mills were historically supplied
with 1st generation static classifiers
These were fit for purpose when considering the
station drivers of the day, namely
Stable/reliable combustion
Efficient combustion
Emission regulations were negligible
Drive was to minimise LOI and CO
Static classifiers were cone type with external,
manually adjustable fineness control static
blades
Target fineness was 70% passing 75 micron with
a PSD slope of 45, which gave 99% on 300
micron
Classification is achieved by changes in air
velocity and direction.
The product size can be altered to some extent
by changing the angle of the vanes, but the
efficiency is low and static classifiers can be
regarded more as grit separators than efficient
classifiers. Typical XRP Mill Design

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 2.3.1 Classification Impact on Combustion
Pulverised Coal Particle Size Distribution Variance

45m 75m 220m

325 mesh 200 mesh 65 mesh

No. of particles

75m

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 2.3.2 Classification Impact on Combustion
Pulverised Coal Particle Size
i. The particle size distribution of the PF will affect the combustion taking place in the boiler
ii. The larger a particle, the lower its surface area: volume ratio
iii. Low NOx coal burners designed for 200 mesh (75 micron) particle size
iv. The further from the 200 mesh ideal particle size the worst the impact on the combustion
v. The surface area to volume ratio affects how the particle will combust primarily, how
fast it will burn
vi. Particles that are too large/coarse have an insufficient surface area to combust fully, as
well as being physically excessively heavy, and will drop into the ash at the bottom of the
furnace
vii. Particles that are too small/fine have an excessive surface area and will combust too
rapidly, increasing the flame temperature and catalysing the formation of increased
levels of NOx

NOx unburnt
Ideal carbon
formation

45m 75m 220m

325 mesh 200 mesh 65 mesh

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 2.4.1 LOESCHE 4th Generation Dynamic Classifier
Solution 4th Generation Dynamic Classifier

Secondary classification:
It is achieved by horizontally active forces
between static flaps and rotating rotor
blades. Material is thrown against the static
flaps and falls back onto the table via the
grit cone. This is coupled with centripetal
and horizontal forces imparted by the rotor
blades.

Primary classification in the mill by vertical

forces - upstream gas flow versus gravitation
(weight and density) . oversized particles are
recirculated to table for regrinding and getting
into liftable product range.

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 2.4.2 Classification Impact on Combustion
Pulverised Coal Particle Size Distribution Variance
i. The slope of the graph is broadly analogous to the variance of the distribution
ii. To put it simply, the RRSB slope gets steeper as the distribution of particle size gets
narrower
iii. Thus the goal of any classifier design is to:
Minimise/eliminate all particles greater than 250 micron
Minimise all particles less than 45 micron
Without increasing mill pressure drop
iv. This is only achieved by increasing the RRSB slope

No. of
particles

75m 75m
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 2.5 LSKS Classifier Benefits

Fineness: Throughput:
1. Steep grain size distribution curve 1. Reduction in system pressure drop,
typ. 54 to 57 which allows.
2. Reduced coarse end fineness typ. 2. Increase of mill throughput by typ.
trace on 50 mesh 15-20%
3. Retrofit applications HAVE 3. Allows for return to n+1 operation in
achieved > 55% reduction in LOI USA, India and RSA
4. Retrofit applications HAVE
achieved > 15% reduction in NOx

Flexibility
1. Ability to change classifier speed
online allows.
2. Optimization for fineness when coal
is good (increase speed)
3. Optimization for throughput when
coal is bad or wet (reduce speed)
4. Optimization when co-firing
BIOMASS

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Section 3

Section 3:

Loesche 4th Generation Dynamic Classifier

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 3.1 LSKS Dynamic Classifier - Overview

I. LSKS Dynamic Classifier is the 4th

generation of Loesche rotary classifier.

II. Original development and trials in

power undertaken in early 1990s.

III. Over 400+ retrofitted to existing

stations in the last 5 years.

IV. All type of mills have been retrofitted

(MPS, HP, E-Mills, XRP, RP and Ball
Tube Mills)

V. NFPA 85 and Atex compliant

VI. ZERO performance liquidated damages

to date

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 3.2 LSKS Classifier Components
i. Coal feed chute.

ii. PF Outlet duct. v. Drive motor.

iii. Classifier rotor cpl. vi. Classifier housing.

iv. Static guide vane.

vii. Grit cone.

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 3.3 LSKS Classifier Lubrication
LOESCHE DYNAMIC CLASSIFIER - LSKS
Grease lubrication of bearing
cartridge:
Grease reservoir with level sensor
Continuous low level alarm will trip the
system after X hours (usually 8 hours)
Single outlet grease pump
Grease splitter (50:50)
2 lines into (upper / lower bearing)
Pump runs for 10 minutes, shuts down for 50
minutes and restarts as long as classifier is
running
The bearing temperature is monitored
continually by temperature sensors
Grease type
KPF 2G20 or comparable

Illustration

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 3.3 LOESCHE Mill Lubrication Scheme

Classifier Assembly
Bearing Cartridge Grease KPF 2G20
Gearbox (if applicable) Mineral Oil
VG320

Roller Assembly
Bearing Lubrication Mineral Oil VG320

Rocker Arm Assembly

Bearing Lubrication Grease 2K10

Gearbox
Gearbox Lubrication Mineral Oil VG320
Hydraulic System
Hydraulic Oil VG68

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Section 4

Section 4:

Power Plant Coal Mill - Retrofit References

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 5.1 LSKS Reference List

450
Mil Type/Design No. of Retrofits
400 XRP 200

B&W 63
350

Babcock (E-Mills) 62
300
BBD Mills 24

250 Loesche 38

Others (MPS/IHI/ZGM 33
200
etc.)

150

100

50

0
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Classifier Sales 4 14 24 43 66 94 117 169 190 210 224 232 307 392 420

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Section 4

Section 4:

Dyn. Classifier Retrofit - Case Studies

SherCo 2 x 750MW (Built in 1970s)
Big Sandy 1 x 800MW (Built in 1969)
Ratcliffe 4 x 500MW (Built in 1968)

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4.1.1 SherCo Power Plant Case Study 1
i. Plant:
Xcel, Sherborne County Power Station, Minnesota,
USA
2 x 750 MWe Units, Built 1970s
14 x Alstom HP 1003 Pulverisers with Static
Classifiers
ii. Problem/Requirement:
10% NOx reduction by increasing fineness
Existing mills (<68% on 75 micron & <98.5% on 300
micron)
iii. Target:
Increase fineness to +75% on 75 micron & +99.9%
on 300 micron
No increase in mill dp, mill kW & No reduction in wear
life.
iv. Solution:
Retrofit 14 x LSKS 36 - Dynamic Classifiers

v. Project execution data:

Order placed February 2014
Delivered between July November 2014
Average install duration 10 days
Commissioning & Testing 9 out of 14 complete

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4.1.2 Sher Co Power Plant Case Study 1
Results

Target
Increase fineness to +75% on 75 micron & +99.9% on 300 micron
No increase in mill dp, mill kW & No reduction in wear life.
PGT (9/14)
Increase fineness to +89% on 75 micron & +99.9% on 300 micron
No increase in mill dp, mill kW & No reduction in wear life.

Additional Comments

Installation, commissioning and optimization of the Dynamic Classifier retrofit on

both units is completed.. Sherco achieved their NOx objectives with only 9 of the
14 DC's installed.
Our team was complimented several times on their approach and technical input,
they achieved an excellent professional working relationship with station
employees.
LES met and exceeded tight deadline schedules required by the plant.

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4.2.1 Big Sandy Power Plant Case Study 2
i. Plant:
AEP, Big Sandy Power Station, Kentucky, USA
1 x 800 MWe Units, Built 1969
6 x B&W MPS 89 Pulverisers with Static Classifiers
ii. Problem/Requirement:
Trial to prove increased throughput
Ability to return boiler unit to n+1 mill operation and
avoid unit de-rate during planned & unplanned mill
outages
iii. Target:
Increase throughput by +10%
No increase in mill dp, mill kW & No reduction in wear
life or loss of fineness
iv. Solution:
Trial Retrofit 1 x LSKS 39 - Dynamic Classifier

v. Project execution data:

Order placed January 2012
Delivered between August 2012
Commissioning & Testing complete Dec 2012
Installation space extremely tight (1) but achieved
first time

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4.2.2 Big Sandy Power Plant Case Study 2
Existing v Retrofit

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4.2.3 Big Sandy Power Plant Case Study 2
Results

Target
Increase throughput by +10%
No increase in mill dp, mill kW & No reduction in wear life or loss of fineness
PGT (9/14)
Increase throughput to +19.3%
No increase in mill dp, mill kW & No reduction in wear life (ongoing) or loss of
fineness.
Eliminated the mill reject/dribbling issues
Reduced the specific power consumption of the mill by over 10%

Additional Comments

LES met and exceeded tight deadline schedules required by the plant.
Extremely tight area for install distance between mills were limited
Use of laser survey by LES enabled full installation plan to be determined
This led to zero clash issues during removal & installation.

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4.3.1 Ratcliffe Power Plant Case Study 3
i. Plant:
EOn, Ratcliffe Power Station, Nottingham, UK
4 x 500 MWe Units, Built 1968
8 x Babcock 10E10 Pulverisers with Static Classifiers
ii. Problem/Requirement:
UBC & NOx reduction by increasing fineness
Existing mills (<63% on 75 micron & <98.5% on 300
micron)
iii. Target:
Increase fineness to +70% on 75 micron & +99.9%
on 300 micron
No increase in mill dp, mill kW & No reduction in wear
life.
iv. Solution:
Retrofit 6 x LSKS 39 - Dynamic Classifier

v. Project execution data:

Order placed September 2004 2008 (all units)
Delivered by April of corresponding year
Commissioning & Testing complete Dec 2005
Success of 1st boiler unit led to subsequent 3 boiler
units

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4.3.2 Ratcliffe Power Plant Case Study 3

Results
Coal Flow:
Ratcliffe - LSKS Rosin Rammler Size Distribution
36.0 (Te/hr)
99.98
Contract Coal:
99.9
Bituminous

99

PF Fineness Results*:
% Passing Sieve

300 micron: 99.95%

passing
90
150 micron: 97.5%
passing
80
75 micron: 72.4% passing
70 *Clients test results
60

10 100 1000 50 Mesh - 99.95% Passing

Sieve Size - micron
100 Mesh - 97.5% Passing
Pre Conversion - 36t/h , Mean R-R Slope = 41.1
Post Conversion (2005) - 36t/h , Mean R-R Slope = 52.0 200 Mesh 72.4% Passing

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4.3.3 Ratcliffe Power Plant Case Study 3

Project Summary
Increased Boiler Combustion Efficiency
Independent testing found that the LSKS Dynamic Classifier gave a
substantial reduction in un-burnt carbon due to the greatly improved particle
size and distribution

At Ratcliffe an average reduction in UBC (at normal excess air levels) of

around 62% was achieved.

Subsequent results at other stations have led to LES often confirming a UBC
reduction of 40-50%

In addition it was found that LSKS Dynamic Classifier directly allowed a

reduction in NOx whilst increasing overall boiler efficiency. This was achieved
by reducing excess air levels at the burner (the unit operator was able to
achieve this due to the stabilised combustion). 12 15%

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 Thank you for your attention !
Questions or Comments?

Contact:
Brishank Kumar Srivastava
Phone: +91 9910018792
E-mail: brishank.srivastava@loesche.com

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