Coal Mill Gyanendra Sharma NPTI Delhi

Fuel System
Saturday, March 27, 2021 Gyanendra Sharma, NPTI Delhi 1

Presentation Plan
• Fuel oil System
• Oil burners
• Coal mills and feeder
• Types of feeders
• Classification of Mills
• Features of different Mills
• Burner arrangement

Fuel oil System
• Purpose: (a) to establish initial boiler light up.
(b) to support the furnace flame during low
load operation.
• Fuel oil system Consists of
• Fuel oil Pumps
• Oil heaters
• Filters
• Steam tracing lines
Objective is to get filtered oil at correct pressure
and temperature
Atomization
• Atomization breaks the fuel into fine particles that readily

mixes with the air for combustion. Oil should be divided up
into small particles for effective atomization. The
advantages of atomization are:
a) Atomizing burners can be used with heavier grades of oil.
b) Can be adopted to large applications because of large
capacity range.
c) Complete combustion is assured by the ability of the small
particles to penetrate turbulent combustion.

Classification: Oil burners
Oil burners are classified according to the method
used for atomization, as follows:
a) Air-atomized burners
b) Steam-atomized burners
c) Mechanically atomized burners
Air atomizing system are not recommended for
heavy oil system as they tend to chill the oil and
decrease atomization quality
Steam Atomization
This System uses auxiliary steam to assist in the atomization of the
oil. The steam used in this method should be slightly superheated
and free cf moisture. As in the air atomizing system, the steam used
for atomizing as well as heating the fuel as it pass through the tip
and into the furnace. The main advantages of steam atomizing
burners over other are:
a) Simplicity of its design
b) Initial cost of installation is low
c) low pumping pressure
d) low preheating temperature.
Disadvantage is steam used in atomizing process

Oil Burners
The types of oil used in the oil burners are:
a) Light Diesel Oil
b) Heavyfuel oil
c) Low sulpher heavy stock (LSHS).
Heavy oil guns are used for stabilizing flame at
low load carrying. Warm up oil guns are used
for cold boiler warm up during cold start up
and ignitor are used for start up and oil flame
stabilizing.
Oil Guns
The guns used in this

system have two main
components for
atomization. They are:
a) Mixing plate
b) Spray Plate.

Oil Gun Compartment

Coal Mill & Feeder
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Gyanendra Sharma, NPTI Delhi
Components
The Major components are :
• Coal Preparation Equipments
• Feeders
• Mills
• Coal Firing Equipments
• Burners

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

Gravimetric Feeder

C L A S S IF IC A T IO N O F M IL L S
V E R T IC A L S P IN D L E TUBE
BO W L/ P R E S S U R IZ E D
BALL & RACE
XRP E M IL L S M PS
(B H E L ) (B A B C O C K )

Classification-As per Speed
Types of Mills
Low Speed Medium Speed High Speed
17 to 20 Rev/min 30 to 100 Rev/min 500 to 1000 Rev/min
Tube and ball mill Bowl Mill, Ball and Beater Mill, Impact
Race mill Mill

BOWL MILL
Model no. Base
capacity(T/Hr)
623XRP 18.4
703XRP 26.4
763XRP 33.8
803XRP 36.5
883XRP 51.1
903XRP 54.1
1003XRP 68.1
1043XRP 72.0
BASE CAPACITY(T/HR)
AT
HGI -55
Total Moisture-10%
Fineness-70% THRU 200
MESH

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.

Pictures of Bowl Mill
Coal Entry
Classifiers
To burners
Hot Air
Flow from
Rollers
PA Fan

Typical Mill (Pulveriser)

Internal Details
of a Mill

BALL& RACE MILL(E MILL)
Model no. Base

capacity(T/Hr)
7E9 25
8.5E10 35
8.5E9 40
10E10 55
10.9E11 61
10.9E10 70
10.9E8 80
TUBE MILL
Model no. Base

capacity(T/Hr)
BBD4760 83
BBD4772 90

Tube Mill Internals

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

RC Feeder
Classifiers 4 No.
Drum Feeder
Classifiers Distributors
2 No.
Hot Air Ball and Tube Mill

Entry
Coal entry to Drum

Pictures of Tube Mill
Steel Balls

Role of Mills
• Produces Pulverized coal 80% 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

Why Pulverized Fuel?
The economic motives for the introduction and development of

pulverized fuel firing are:
i) Efficient utilization of cheaper low grade coals.
ii) Flexibility in firing with ability to meet fluctuating loads.
iii) Elimination of breaking losses.
iv) Better response to automatic control.
v) Ability to use high combustion air temperature; increasing the
overall efficiency of boiler.
vi) High availability.

Mill Dampers and air system
• PF temperature to be maintained 900C

•All Shut off valves are required to be
kept wide open during operation
•Mill bearing is to be kept clean and no
dust should enter
•Low Primary air flow will cause unstable
flame and high flow result in high mill
reject

Burner Arrangement
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Gyanendra Sharma, NPTI Delhi
Firing System
• Direct Firing System: Coal is fed to the mill at controlled
quantity. Hot air (temperature controlled) is permitted to flow
through the mill. The air dries the coal and picks up the milled
product and flows through the classifier rejecting higher size
particle. The fine coal is carried through the coal burner to the
combustion chamber.
• Indirect Firing System: Mills are operated independent of
boiler loading and pulverised coal is stored in the intermediate
bunker. From the bunker it is taken to combustion chamber with
the help of primary air fan. Boiler loading is controlled by the
amount of pulverised fuel fed to boiler.

Direct Firing

Indirect Firing

Coal Burners
• Coal burners comprise of coal nozzle, steel tip, seal plate and
tilting link mechanism.
• Housed in coal compartment in all four corners of the furnace
and connected with coal pipes.
•One end (outlet) is rectangular and another end is cylindrical.
•The burner can be tilted on a pivot pin
•. The nozzle tip has separate coal and air passages.
• Coal and air passages is divided into sevaral parts

Methods of Fuel Firing
Vertical Firing : A number of rectangular fan shaped nozzles are set across the
width of the furnace in an arch. Pulverised fuel mixture ignites under the arch
and is directed vertically downwards to the bottom of the furnace where the
gases are made to turn upwards to pass through the combustion chamber this
gives a long path to the flame and is particularly suitable for coals of low
volatile content.
Horizontal Firing: Horizontal firing with the turbulent type of burner are set up
usually in the front (front wall fired) or rear walls of the furnace. Burner
consists of an inner cone for primary air and fuel which is given a rotary motion
as it passes through the burner.
Impact Firing : This is the arrangement with the type of burner used with slag
tap furnaces where the ash is kept in a molten state on the furnace floor and
tapped off as and when necessary.
Corner or tangential Firing: Burners are set at each corner of the
furnace and are directed to strike the outside of an imaginary
circle in the centre of the furnace.

Tangential Firing System

Arrangement

Typical Flame

Various Losses in A Boiler
• Heat loss from furnace surface.

• Unburned carbon losses.
• Incomplete combustion losses.
• Loss due to hot ash.
• Loss due to moisture in air.
• Loss due to moisture in fuel.
• Loss due to combustion generated moisture.
• Dry Exhaust Gas Losses.

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Fuel System

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• Atomization breaks the fuel into fine particles that readily

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Disadvantage is steam used in atomizing process

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The guns used in this

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Low Speed Medium Speed High Speed

17 to 20 Rev/min 30 to 100 Rev/min 500 to 1000 Rev/min

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Model no. Base

Model no. Base

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Hot Air Ball and Tube Mill

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The economic motives for the introduction and development of

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• PF temperature to be maintained 900C

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• Heat loss from furnace surface.

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