Dr V T Sathyanathan

Combustion &
Combustion Tuning
- Part 3

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

COMBUSTION

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

COMBUSTION
Any Relatively Fast Exothermic
Chemical Reaction

FLAME
Combustion Reaction Which
Can Propagate Subsonically
Through Space
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Principles of Combustion
Combustion is Rapid Chemical Combination of
Oxygen With the Combustible Elements of A Fuel
Three Combustible Elements of Significance in
Most Fossil Fuels
Carbon
Hydrogen
Sulfur - Minor Significance
Concept of Mole is Generally Used
Fundamental Laws for Combustion Calculation
Conservation of Matter
Conservation of Energy
Ideal Gas Law - V ∝ T/P
Avogadro Law - Led to Mole Concept
Dalton Law - Total Pressure Sum of Partial Pressures
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Air requirement of fuels

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Oil & Gas Burners

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Oil Burners

Evaporation type Atomised

Atmospheric Steam
Recirculation Rotating Mechnical
pressure Atomiser
type cup type type
atomiser type

Spring
Swirl pressure Spil control Internal External
loaded
type type mix mix
piston type

Vapourising type of oil burners are onlyfor very small heat output and can not be used for industrial
applications of higher capacity. The rotating cup type is one of the medium capacity burners. But, these
burners require higher grade oil and can not burn the commercial quality oil of recent origins.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Spray Combustion
Spray Combustion first Used in 1880
Atomization of 1 cm Diameter Droplet of
Liquid into Droplets of 100 µm Diameter
Produces 106 Droplets & Increase Surface
Area by 10,000 Times
Droplet diffusion Flames Are Characterized by
Their Yellow Flames
Individual Droplets Burning -- Heterogeneous
Flame
Homogeneous Flames -- Blue in Color

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Atomization
Can be Accomplished by
By Forcing the Liquid at High Pressure
Through an Orifice as in Jet Atomizers
By Passing a Stream of Gas at High Velocity
Over the Liquid Surface so That Waves are
Generated Which become Extended into Thin
Films as in Twin-Fluid Atomizer
By Impinging One Liquid Jet upon Another
Liquid Jet
By Use of Centrifugal Forces as in the Rotating
Cup Atomizer
By Use of Ultrasonic Waves
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Pressure Jet Atomizers

(a) Simple Pressure Jet

Atomizer

(b) A Back-Spill Atomizer

(c) A Front Spill Atomizer

(d) A Duplex Atomizer

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Spraying Parts of Inside Mix Tip for Steam or Air

Atomization

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Twin Fluid Atomizers

(a) Air Blast Atomizer, (b) Simple Low Pressure Atomizer, (c)
Medium Pressure Air Atomizer,
(d) ‘Y’ Type Atomizer

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Spraying Parts of Straight Mechanical Oil Gun

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Spraying Parts of Wide-

Wide-Range Mechanical
Oil Gun

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Spraying Parts of Steam Atomizing Oil Gun

External Mix Tip

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Steam Atomizer
(a) Conventional ‘Y’ Type Atomizer, (b) ‘F’ Type Atomiser

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Assisted Pressure Jet Atomizer

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Rotary Atomiser Types

(a) Sharp Edged Discs - Used in Recharge Application
(b) Air Blast Type

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Resonator Type Sonic Atomizer

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Internal Recirculation & Its Influence

on the Flame Front

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Distributed Mixing Burners Concept

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Type of Oil & Gas Burners

Front Wall Fired Burners
R Burners
S V Burner
Opposed Wall Fired Burners
Tangential Burners
Down Shot Fired Burners
Multi Fuel Fired Burners
High Swirl Burners
Premixed Burners
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

R-Type Burner
Wall Burner for Multiple Installation
Throat Size - 20 to 39 Inches
SteamCapacity - 8,000 to 40,000 Kg/Hr
Suitable for Natural Gas, COG, Oil
Design Turn Down - 5 : 2
Steam or Air Atomisation, Wide Range
Mechanical, Straight Mechanical
Ring Damper for proportioning Air
Between Burners from Common
Windbox
Adjustable Secondary AirSpinner Damper
Adjustable Primary Air Control Drum,
With Either Adjustable Primary
Centrifugal of Fixed Axial Spinner Vanes
Minimum Excess Air
15 % on Oil
10% on N.Gas

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

R (Ring Damper) Burners

Suitable for Front Horizontal Firing
Duel Fuel Firing and Gas
Low Velocities
Stand by Service in Case of Non
Availability of One Fuel
Change From One Fuel to the Other
Without Interrupting Operation
Wall Cooled Throat for Low
Maintenance of Throat Refractory
Adjustable Primary and Secondary
Air Vanes
Full With Wind Box Assuring Uniform
Air to All Burners
Varity of Throat Sizes
Tailored Flame Shapes Possible

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

SV (Spinner Vane) -Type Burner

Wall Burner for Shop Assembled Boilers
Throat Size - 141/2 to 51 Inches
Steam Capacity - 5,000 to 130,000 Kg/Hr
Suitable for Liquid & Gaseous Fuels
Design Turn Down Ratios 10 : 1
Depending Upon Fuel Conditions
Steam or Air Atomisation
Adjustable Primary Air Damper
Adjustable Modulating Secondary Air
Damper
Adjustable Centrifugal Primary Spinner
Vanes
Adjustable Centrifugal Secondary
Spinner Vanes
Minimum Excess Air
15 % on Oil
10% on N.Gas

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Gas Burners
Ring Burners
Circumferential Pipes
Inner Diameter is in flush with refractory
throat
Gas flow towards the burner axis

Spud Burners
Pipe or pipes arranged on or surrounding
the axis

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Typical Oil Gun

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

High Energy Arc Ignitor

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Ionic Flame Monitoring Side Ignitor

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Coal Combustion

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Pulverised Combustion

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Fundamentals Of Pulverised
Coal Combustion
Investigation of coal particle combustion in industrial
conditions is not an easy task
Most of the present knowledge has been gained
through experiments with single coal particles (Jery
Tomeczech 1994)
The number of parameters influencing the process is
limited to the following:
• type of coal
• size of coal particle
• rate of heating
• gaseous atmosphere surrounding the particle.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Combustion Behaviour of a solid fuel

Particle ( Jaakko J. Saastamoinen, et al. 1993)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Brief about Development Of Wall Burners

Prior to 1971 it was high swirl, high capacity
burners in use
These burners could be designed for very
high capacity thus reducing size of high
capacity boilers more so furnace
But had a very high NOx production
Could be used only for low slagging coals
One of the very popular & very efficient wall
burner was B&W S-type burners.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

B&W S-
S-type Burner

•The total secondary air goes through one spinner vane row
•The flame is short & intense

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Low NOx Burners

Most of the low NOx burners are duel
register burners
B&W’s DRB-XCL burners reduce 50 to
70 % NOx from the normal high swirl
burners
The upper and the lower spinner vanes
together is tuned to reduce the NOx
levels

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

B&W DRB-
DRB-XCL Burners

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

B&W DRB-
DRB-XCL Burners

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Low NOx Burner

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Low NOx Burner Flame

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Riley CCV (Controlled Combustion Venturi)

Venturi)
Burner Tuning
First look at the burner & burner disposition drawings in
the O & M manual of the boiler you are tuning and
understand fully
Burner setting for start-up – Make sure inter burner air
distribution is set equally
The TA swirl position for all burners and all vanes set at
30 degree open to moderate swirl
The SA swirl position are all factory set at 30 degree open
for moderate swirl
The SA flow control damper positions are all set at fully
open position
Spreader position: All set at Zero inch retraction or flush
with end of coal nozzle

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Riley CCV (Controlled Combustion Venturi)

Venturi)
Burner Tuning
Primary burner head vanes: See O & M for setting
this as this depends on number of burners and
layout.
Shrouds: All set uniformly at the same position to
produce approximately 3.5 inches windbox to
furnace differential pressure (delta p). Only plus
minus 15 % deviation
Igniter to be set as per manufacturer guide lines.
As the boiler load increases the windbox to furnace
drop increases from 1.5 inches to 3.5 from a load of
50% to 100%

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Burner at Adani Udupi Boiler

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Flame In Tangential Firing

(Joseph. G. Singer, 1981 )

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

The Pattern of
Recirculation In
Tangentially Fired Boiler.
(Joseph. G. Singer, 1981 )

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Trajectory Plot of Gas From Each Burner of

500 MW Coal Fired Boiler
( Hiroya Shida, 1984 )

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Cumulative Heat Release Rate of

Four Indian Coals
( Nandakumar. K, 1992 )

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Concentric Firing

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Adjustable OFA injection

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

SOFA Assembly

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Effect of tilting on furnace absorption

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Fluidised Bed Combustion

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Fluidised Bed

Bubbling Circulating
(BFBC) (CFBC)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Principles of FBC
Inert Bed Of Solid Particles Suspended
on Upward Stream of Air or Flue Gas
Bed Exhibits Properties Associated
With a Fluid
Light Objects Float; Heavier Ones Sink
Pressure Drop ∝ Bed
Height Horizontality of Bed
Top Surface Maintained

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Principles of Fluidisation - I

Fixed / Static Bed Light Object Floats Heavy Object Sinks

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Principles of Fluidisation - II

Fixed
Bed Fluidised Bed

∆P

Air Flow

Fixed Bed Fluidised Bed

Pressure Drop ∝ Bed Height

Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Principles of Fluidisation - III

Fixed Bed Of Solids Fluidised Bed

Horizontality Maintained

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

FBC Boilers
Commercial Operation Started In Late 70s
No. & Unit Size Increased During 80s And
90s
Relatively Large Scale Plants for
Cogeneration and Power in Reliable
Operation
Inherent Emission Control and Fuel
Flexibility are the Special Advantages

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

SO2 Control in FBC

Straight forward method (Limestone

injection into the combustor)
Reliable in operation
Reactions
CaCO3 CaO + CO2 (Calcination)
CaO + SO2 + 1/2 O2 CaSO4 (Sulphation)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

NOx Emission in FBC

Mainly fuel Nox

Low due to low combustion temperature
Air staging (in CFBC)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Bubbling FBC

Offered for a variety of fuels

Coal, lignite, washery rejects
Biomass (Rice husk, Rice straw )
Maximum capacity 100 tph

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

CFBC Advantages

Better combustion efficiency

Better limestone utilization
Fewer fuel feed points
Lower NOx (Air staging)
Reduced erosion problem
Simplified load following

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

FBC & PF Furnace Comparison

Lower combustion temperature of
around 850 to 900 deg C
Heat transfer in furnace is by
conduction & convection in FBC and by
radiation in PF
Fuel size is around 6 mm in FBC
Larger quantity of bottom ash & lesser
fly ash in FBC

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Combustion Tuning in
Coal Fired Boiler
-Tangential Firing

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Scenario

Coal quality deterioration

Imported coals coming to use
Efficient operation of the unit

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Adani Udupi 2x600 MW

Boiler
The burner system is a mix of
tangential system concept & wall
firing in the case of NOx control
The OFA concept is used for
NOx control
The burner tuning to be done
with OFA fully closed
Under boiler shutdown
condition (Generally before
commissioning) the static
pressure equalization between all
burners with all vanes full open
to be done
This ensures equal air flow in
all burners
On full load with OFA closed
find maximum NOx generated by
the burner or base NOx level
Then open the OFA damper to
get the desired NOx level.
A minor adjustment of the
burner vanes may be required in
some burners after this

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Combustion optimization
Optimization of combustion is of special interest
Organic and inorganic interaction
Large amount of variation in organic & inorganic.
Coal combustion in boiler furnaces needs understanding of
the complex organic and inorganic mix up.
High percentage of ash
Low reactive in the organic of coal
Encapsulation of organic in inorganic
Oxidised coal in some cases
Blending of many type of coals

The reasons for varying behavior of

coals during combustion.
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Combustion optimisation (Cont)

Ash coals can result in high primary air

requirements
Primary Combustion Dilution
Sec. Air distribution at required
elevation is very important
Avoid / reduce all unwanted sec. Air at any
location
Divert them to other needy elevation.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Combustion optimisation (Cont)

Keep mill air flow just above settling velocity.
Keep total air flow - 20% excess air @ eco out
Close OFA dampers and get Base NOx value. Do comb tuning.
Close all fuel air dampers if VM less than 20 - 22% Look flame
front - decide for higher VM coal
Keep wind box pr. 100 - 150 mm - better distribution Across
elevation.
Wind Box Damper Setting for Combustion
Make sure % indication in control room is actual position of damper
Increase LRSB operation for fouling type ash
Change in SH spray pattern indicates furnace behaviour &
change combustion completion elevation.
Check PC analysis on Rieve distribution / Roslin-Rammler chart
Change in SH spray without change in other parameters
indicates furnace deposit increase

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Recommended Primary Air Velocity

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Where Do We Start
We Start from Control Room & Move on

Look at the scanner intensity to Look at the windbox damper

know about flame condition position & cross check in local

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Study Flame from Topmost Peep-

Peep-hole up to the
bottom most Peep-
Peep-hole

8 Peepholes at 59.8 meter level

Four at elevations of 22.15 meters.

Two each at elevations of 50.6,

47.6, 44.5, 41.5, 38.0, 34.9, 31.7
and 28.6 meters.

Peephole
Locations Peephole Locations Front
at 10 water wall
elevations
Peephole
Locations
at 11
Peephole Locations Side
water walls elevations

Dr V T Sathyanathan Page 43 of 100

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

1 – The peep-hole after FSH gives an

idea about the tail of the flame
2 - The peep-hole before FRH & after
PSH gives an idea about the tail of
flame incase the view in 1 is dark
3 – The 6 to 8 peep-holes in FWW
below the PSH gives a good idea of
the stability of fire ball & flame
condition. Less than 10 to 15 flickers
per min indicates a very stable flame
4 – The peep-holes just above the WB
2nos at each corner indicates the
intensity of the flame & fire ball. Fire
ball can even be visualized.
5 – There are peep-holes in between
elevations as AB, BC, CD, etc. Here we
can see the flame front. The FA
damper adjustment can be done
based on this.
6 – The bottom most peep-holes of the
boiler near the man hole in bottom
hopper gives a clear idea of clinker fall
and deposition dislodge.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Adani Udupi
Boiler Peepholes
Peephole (OD) in this boiler are at
elevations in furnace
51.4 mts
48.0 mts
38.8 mts
30.1 mts
25.7 mts
21.7 mts &
9.1 mts
51.4 mts peepholes can give an
idea about the flame length
38.8 mts peephole gives an idea
about combustion quality – As this
peephole is above OFA
30.1, 25.7, & 21.7 mts peepholes
enable to check individual flame of
burners
9.1 mts peephole gives an idea of
clinkers falling
Additional peepholes are required
at on upper levels and 16.0 mts
level on both sides

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Flame
from
Various
peep--
peep
holes

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Heated coal particles

as the move from the
coal burner tip

Flame front highlighted

The flame as it progress

Start of secondary region of flame

Flame Structure & regions
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Wall Burner Flame - UPCL Boiler 1

• Show flame video of 9th Dec 15 E Mill Left

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

SH & RH Spray Control is Very Important

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Load Vs SH L & R and RH spray L & R –

1st Nov to 20th Nov 2014 - Ukai Unit 6 Boiler

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Slagging & fouling

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

SLAGGING
Slagging is caused by softening or partial
melting of the ash with pasty or molten
deposits settling on the furnace walls or
other heating surfaces which are exposed
radiant heat.

FOULING
Foulling results from ash sintering on
convection sections where heat transfer
by convection prevails

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Coal

Boiler
Slagging Furnace
Design

Boiler
Operation
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Elevation
Heat loading
Size
Volumetric
Furnace Heat Loading

Slop Angle
Shape
Avoid Ash load
High Swirl
Burner
Low Swirl

Slagging Water
Type
Soot Blower Steam
Numbers
Mill Sizing
Air / Coal
Primary
Ratio
Air Distribution
Registrar
Secondary
ID Fan Sizing Control

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Ash Properties & Behaviour

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Inorganic Compounds - Four Groups

Inorganic matter from original plants
Inorganic - organic complex minerals
Formed due to inorganic and organic interaction
during the first stage of coal formation process.
Minerals introduced by water or wind into the
coal deposits as they were forming.
Minerals deposited, during the second phase
of coal formation process

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Ash Properties & Behaviour

Combustion & ash deposition in a boiler is an
complex process
Coal devolatilisation
Char combustion
Mineral matter transformation
Fly ash formation, transport & deposition
Each of the above is influenced by
Heating rate
Temperature regime
Localised gaseous environment
Bulk & local fluid dynamic condition

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Ash Properties & Behaviour (cont.)

Operational experience on slagging
fouling and corrosion in large dry bottom
boilers have proven that the tendency
towards a conservative’ design is the right
way to minimise problems and damages.
But
It has to be stated that because of
insufficient knowledge of the coal
constituents - macerals & minerals - it is
not yet possible to propose an optimal
design.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Common Coal Minerals

MAJOR
SILICATES -[ CLAY MINERALS
RALS -[ KAOLINITE
KAOLINIT E Al 2 Si 2 O5 (OH) 4
ILLITE - CLAY MINERAL
QUARTZ Si O2

MINOR
CALCITE Ca CO3
CARBONATE DOLOMITE (Ca, Mg) ( (CO3) 2
ANKERITE CA (FE, Mg) CO3
SIDERITE FECO3

DISULFIDES PYRITE Fe S2 CUBIC

MARCASITE Fe S2 ORTHORHOMBIC

COFUIMBITE Fe 2 (SO4)3 9H2 O

SZOMOLONOKILE Fe SO4 2H2 O
SULFATES GYPSUM Ca SO4 2H2 O
BASSANITE Ca SO4 1/2 H2O
ANHYDRITE Ca SO4
JAROSITE K Fe 3 (SO4) 2 (OH)6

FELDSPARE PLAGIOCLASE (NaCa) Al (Alsi) Si 2O8

ORTHOCLASE KALSi 3 O8

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Ash Fusion Temperatures

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Slagging & Fouling Behavior in PC Fired Boiler

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Phase Transforamation Of Some Mineral

Matter Commonly Found In Coal

Calcite Pyrites Ouartz

Oxidizing Reducing

700 . C S 1H2S
FeS.Fe2 (SO4)3 FeO Fe Temperature
Feo (Partial Melt) invesions
(Partial melt) 950 . C
970. C S1H2S
1000. TO 1100. C
CO2
Fe

Cao liquid 2570

Fe2 O3 SiO2
2570. C liquid liquid
1600 . C 1723 . C

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Phase Transforamation Of Some Mineral

Matter Commonly Found In Coal
Kaolinite Illite

Metakaolinite (A12 O3 2sio2

950 . C
.
925 C SI O2
(Clay lattica destroyed) Spinal amorphous quartz
A12 O3 Mgo glass Si O2

Silion Spinel 1050. C

(2A12 O3. 3 Si O2
1100 . C Si O2
1100. C

Mullite
1:1Mullite type phase 1300. C (3A12 O3
(A12 O3.Si O2) 2Si O2
1400 C Sio2
(Coristobailite) 1400. C

Mullite
3A12 O3 . 2Si O2 liquid glass

May not be completely

1800C. C
liquid untill 1800

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Gravity Separation Procedure

1 LB COAL
1.7 SLON
1.7F 1.75

1.7 FLOAT 1.7 SINK

1.5 SOLN 1.9 SLON

1.55 1.9F 1.95

1.55x1.7F 1.75 x 1.9F
PRACTION PRACTION
1.5F

1.5 FLOAT 1.9 SINK

1.3 SLON 2.1 SLON
2.1F

1.35 .95 x 2.7F 2.15

FRACTION
1.35 x 1.5F 2.1 SINK
FRACTION 2.5 SOLN
1.3F
2.5F
2.55
1.3 F 2.15x2.9F
FRACTION FRACTION

2.5 SINK
2.95

2.55x2.9F
FRACTION 2.95

2.95
FRACTION

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Segregated Iron og 2.9 Sp Gr

Sink Fraction

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Slagging Index Matrix

EXPERIENCE SEVERE SEVERE MODERATE NONE NONE

CYCLONE INDEX MED - HIGH LOW-MED. LOW LOW LOW

SULFUR SLAGGING INDEX HIGH MEDIUM LOW LOW LOW

FUSION SLAGGING INDEX SEVERE SEVERE MEDIUM LOW LOW

VISCOSITY SLAGGING INDEX MED - HIGH LOW - MED LOW LOW LOW

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Inferences from Slagging & Fouling

Analysis
Inferences are for design & ash data analyzed
Sanvi, MBA Future, Grand Sky, & Double Miracle have tendency to
slag based on % base in coal ash
No steam explosion expected in any of the analyzed coal ash
Grand Sky Coal ash will result in very high strength deposits based on
Fe2O3+P2O5 %
Sanvi & Sks Tagus have tendency to result high strength deposits
based on Fe2O3+P2O5 %
Sks Tagus, Sanvi, Bulk Malasia, & Grand Sky have slagging tendency
based on Fe2O3, CaO molar ratio
Design, Sanvi, & Grand Sky have high fouling tendency based on
fouling index
Mba Future &Double Miracle have sever fouling tendency
So all coal ash analysis some tendency to slag or/& fouling

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Slagging - Summary
Slagging Cannot Be
Predicted Accurately Using
Available Correlations

There Is A Need For An

Improved Analysis
Approach
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Deposit Development

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

How of Deposition

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Deposits in various locations

Burner Eyebrow Deposits Form
Ash, Slag, and Sludge Buildup on the Edge of Burners and on
on Slope Walls or in Hoppers Adjacent Walls

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Deposits in various locations

Densely Sintered Enamel-Like Densely Sintered Enamel-Like
Sulfate-Rich Deposits Between Sulfate-Rich Deposits Thick
Tubes and Very Hard Deposits
Created over Longer Period of
Time

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Deposits in various locations

Light Grey–Light Brown
Densely Sintered Enamel- Deposits Covering a Major
Like Sulfate-Rich Deposits Portion of Convective Surface

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Deposits in various locations

Massive and Very Dense Massive Ash Deposition on
Deposits on Leading Edge and Overhang Superheat Pendents
Bridging Between Tubes

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Experience on Pressure Parts

Erosion & Corrosion in
Fossil Fuel Fired Boilers
An Overview

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

General
Indian coals have very high ash
Indian coal formation by drift theory
Leads to large variations in organic &
in-organic properties
Feed back from users and data
collected indicate more than 30 % of
tube failures are due to ash erosion
Corrosion is not predominat in Indian
coal fired boilers

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Various Types of Erosion

Fly ash erosion
Steam erosion
Soot blower erosion
Falling slag erosion
Mechanical rubbing
Coal particle erosion or PF erosion

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Parameters That Influence Erosion

Flow and Environmental conditions

Particle Property
Surface property

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Flow and Environmental conditions

Angle of impingement
Particle velocity
Particle rotation
Temperature
Particle impingement rate
Corrosion environment

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Particle Property

Size
Shape
Density
Hardness
Strength of friability

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Surface property

Shape
Stress level
Hardness
Other mechanical and material
properties

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Major Factors Influencing Fly Ash

Erosion in Coal Fired Boilers
The velocity of flue gas
The mineral content in coal
The change in direction of flue gas
The arrangement of pressure parts
The temperature of flue gas and
The operation above the maximum
conditions design rating or with excess
airflow above design rate.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Minerals in the Indian High Ash

Coals - Major
Kaolinite1 Al2Si2O5 (OH)4
Illite a
Major Silicates Clay Minerals Mixed Layer b
Chlorite (MgFeAl)6(SiAl)4O10(OH)8
Quartz SiO2

a. Illite has a composition similar to muscovite –

KAl2(Si3Al)O10(OH)2, except for less K+ and more SiO2 and
H2O.
b. Mixed layered clays are usually randomly interstratified
mixtures of illite lattices with montmorillonitic and / or
chloritic lattices.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Minerals in the Indian High Ash

Coals - Minor
Calcite CaCO3
Dolomite (Ca, Mg) (CO3)2
Carbonates Ankerite Ca(Fe,Mg)CO3
Siderite FeCO3

Disulfides Pyrite FeS2 (cubic)

Marcasite FeS2 (orthorhombic)

Minor Coquimbite Fe2(SO4)3.9H2O

Szomolnokite FeSO4.H2O
Gypsum CaSO4.2H2O
Sulfates Bassanite CaSO4.1/2 H2O
Anhydrite CaSO4
Jarosite KFe3(SO4)2(OH)6

Feldspars Plagioclase (NaCa)Al(AlSi)Si2O8

Orthoclase KAISi3O8

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Effect of Quartz & Pyrites on wear

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Ash Content & Abrasion Index

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Sand in Coal & Abrasion Index

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Areas Where Coal Ash Erosion Is

Normally Experienced
Economizer bends and tubes
LTSH bends and tubes
Screen tubes
Goose neck portion at furnace top
Soot blower openings in the water
walls
Wind box opening in the furnace
Bottom hopper tubes

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Study Carried Out to

Understand Erosion
Effect of baffle in containing
erosion
Effect of coal ash on erosion
Shrouding pressure parts and design
changes
Cold air flow tests and flow model
studies

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Effect of Baffle in Containing Erosion

Photos of Water table testing with various baffles (Dr K S L Prasad 1987)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Effect of Baffle in Containing Erosion (Cont)

Photos of Water table testing with various baffles (Dr K S L Prasad 1987)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Effect of Baffle in Containing Erosion (Cont)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Effect of Baffle in Containing Erosion (Cont)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Effect of Baffle in Containing

Erosion (Cont)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Understanding Erosion Further

Cold air flow test
and flow model
study
Study using
Computational Fluid
Dynamics
High temperature
erosion test rig

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Understanding Erosion Further

High Temperature
Erosion Test Rig

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Measures to reduce the erosion

Reduced gas velocity in second pass
Inline arrangement for all second pass
heat transfer surface
Shielding of places prone for higher
erosion
Cassette baffles for LTSH and economizer
bends
Refractory lining in areas of high erosion
where shields cannot be provided
Pressure parts layout improvement in 2nd
pass.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Change in direction of flue gas

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Arrangement of pressure parts

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Shrouding pressure parts

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Cassette Baffles for LTSH and

Economizer Bends

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Refractory to Protect Pressure

Parts From Ash Erosion

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Stud Welding Adopted to Protect

Pressure From Falling Slag

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Study Done by
CEGB – Screens for
a 500 MW Boiler
Reported by EPRI in Feb. 1987

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

CEGB – Screens for a 500 MW Boiler

Screens on WW Tubes -
Typical
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

CEGB–
CEGB – Screens (Cont)

Under Side of Upper LTSH

Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

CEGB – Screens (Cont)

Between Economiser Tube & Outer Wall

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

CEGB – Screens (Cont)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

CEGB – Screens (Cont)

Over the Gap Between Bundles in Center of Economiser

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

CEGB – Screens (Cont)

In Economiser area
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

CEGB – Screens (Cont)

In Passage Between Boiler and Back Pass

Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Conclusion – CEGB Study

The known experience with the use of
expanded metal screens to control
flyash erosion has been limited to
applications in Canada, Australia &
Germany. In these applications, the
flyash loading range from light to
moderate.
Hence for high ash coals this may need
more maintenance & replacement (Self)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Conclusion
Coal is the main fuel for power plants in
India for years to come. The coal
quality deterioration in the past has
thrown lot of challenge to boiler
designers in India to compact /
minimize erosion in pressure parts.
Erosion is one of the major
contributing factor for pressure parts
damage in Indian boilers and
minimizing erosion will extend life and
thereby the availability of the boiler.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Conclusion (Cont)
Some of the major design changes
adopted for reducing erosion are
Lower gas velocity in 2nd pass (around
10 m/sec),
Use of only inline arrangement in 2nd
pass heat transfer surfaces,
Cassette baffle to protect the bends in
the 2nd pass heat transfer coils, etc.

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Conclusion (Cont)

Corrosion in Indian coal fired boilers

is not a major threat as Indian coal
has low vanadium and sulphur.
In the case of new fuels from oil
refineries like petcoke, vacuum
residue, etc. are concerned;
boiler designers, operation and
maintenance group must take
adequate precautions to reduce
corrosion.
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Nox formation & Control

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

NOX Formation Mechanisim

Three different mechanism

• PROMPT NOX

• THERMAL NOX

• FUEL NOX

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

PROMPT NOX
Generated within the flame
Very short residence time
Temperature reduced prompt nox
Additional O2 increased NOx for fuel rich
flame fronts but reduced for fuel lean
flame fronts
Only of subordinate importance in
combustion of pulverized fuel

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

THERMAL NOX
N2 From atmospheric air
Zeldovich first described thermal NOX
N2 + O < === > NO + N
N + O2 < === > NO + O
N + OH < === > NO + H
Thermal NOX can be predicted by
[NO] = K1 e(-K2/ T ) [N2] [O2]1/2 t
where [ ] = mol fraction
T = Temperature
t = Time
K1 , K2 = Constants
Thermal NOX Varies with time, temperature,
concentration of N2 & O2
Exponential dependence on temperature

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

FUEL NOx

Produced from N2 in fuel

Conversion reduce with
increasing fuel N2
Varies with air at early stages
of combustion
Varies with mixing intensity

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Low NOX Burners And Systems

Classified broadly under two

groups

Combustion based technology

Post combustion based

technology

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Temperature Vs NOx

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

NOx Vs Fuel
ratio (FC/VM)

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

NOx Vs Air at
firing zone

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Analysis And Inference

From Field Data

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Analysis And Inference

From Field Data
Do a detailed Trend analysis of operating
data
This will really gives a clue how the
parameters vary over a period more so with
load
Do the trend plot with related parameters
Your impressions looking at data can be
different when you do a trend analysis
A detailed coal receipt analysis & property
analysis is important
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

% Combustibles in FA & BA

y = -3E-06x 4 + 0.0004x 3 - 0.0161x 2 + 0.2969x -

12 25
0.9438 y = 0.0233x 4 - 0.3925x 3 + 1.9277x 2 - 0.1593x
+ 0.2357
R2 = 0.8824 R2 = 0.9412
10
20

8
% FA Com b

15

% BA Com b
6

10
4

2 5

0
0
0 20 40 60 80 0 2 4 6 8 10
{(FC/VM)+(HHV/7842)*100+Log(A)}/RES^2 PLUS 50

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan
4 3 2
y = -3E-06x + 0.0004x - 0.0161x + 0.2969x - 0.9438
2
R = 0.8824

12

10

%
8

Combustibles
% FA Comb

6
in FA
4

0
0 10 20 30 40 50 60 70 80

Sai - Vel

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Sai--Vel – Factor on X
Sai X--axis

[{(FC/VM)+(HHV/7842)*100+
LOG(A)}/RES^2]

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Why Sai-
Sai-Vel Correlated
FC & VM are the main organic constituents
for combustion - hence FC/VM shows the
mix up of these organics
(HHV/7842)*100 indicates the degree of
carbonisation
Log (A) takes into account the mix up
organics with inorganics
Inverse of Square of residence time take in to
account the decreasing incremental benefit
of increase in time

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

25 4 3 2
y = 0.0233x - 0.3925x + 1.9277x -
0.1593x + 0.2357
2
R = 0.9412
20
%
15
Combustibles
% BA Comb

in BA
10

0
0 2 4 6 8 10

PLUS 50

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Conclusion

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Conclusion
Steam generator performance greatly
influenced by the coal/ash properties
Special design considerations required to
ensure satisfactory performance for the
range of coals
Trade offs required to accommodate wide
bands- increases the cost and at times
compromises the equipment performance.
The design of a modern day power plant is a
synthesis of thermal performance criteria with
economic considerations.
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Poor Combustion in Boiler

Importance of combustion in boilers
Increased FEGT (Furnace Exit Gas Temperature)
Local deposits &/or slagging
Increased spray in SH & RH
Oxygen unbalance in flue gas at economizer outlet
High metal temperature
Higher amount of nitrogen oxides
High carbon in ash (LOI)
Reduced throughput – Load
Reduced efficiency
Increased excess oxygen
Localized fouling
Localized hot spots
Localized corrosion
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Combustion Trials to be Done

Close OFA damper to understand base NOx
generated
Optimize primary air through each mill
Fuel air damper – very high opening –
Optimize
Optimize OFA
Handling deposition – Salgging & Fouling
Optimize WB & LRSB
Need for large volume data analysis

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Point to Remember – Air Distribution

Total air constant for a design of boiler
P A you have no control
Min dictated by settling velocity & coal characteristics
Sec Air used as Fuel Air, OFA & Sec Air
Hence Sec air distribution very important for boiler performance

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Boiler Efficiency (contd..)

Every 20degc increase in exit gas temp. reduces
the boiler efficiency by 1%
Increase in excess air by 1%reduces the boiler

efficiency by 0.04%

Higher moisture and higher H2 content and lower

calorific value of coal decreases the boiler

efficiency -1%H2 increase leads to approximately

1.3% loss and 1%M increase leads to 0.2%loss in

efficiency
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Summary of losses in a boiler

controllable
L1 Dry gas loss % 5.542
L3 Combustible loss % 1.453
L8 Carbon monoxide loss % 0.065
L7 Mill reject loss % 0.049
7.109
un -controllable
L2 Moisture loss % 6.523
L5 Radiation loss % 0.270
L4 Air moisture loss % 0.200
L6 Sensible heat of ash % 0.415
7.408

L Total % 14.517

E Efficiency % 85.483
100 - L

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Large Volume Data Analysis

Pick up log data for 3 to 6 moth operation – Full load
& 10 minutes interval
Do day tend on load, Steam flow, seam temps, DESH
flow, Exit gas temp, O2 & ambient temp
Pick out periods of constant load operation periods
Do detailed trend analysis of various independent
parameters affecting the dependent parameter
Understand the behavior of these parameter
Draw out explanations and pick out corrective action
/ further trials
Work out plans for correction of problems or
handling the problem

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Methodology to address concerns

Operational
feedback
Design
improvements

Design
Feedback
New
Design

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

One must understand Boiler

Performance Optimization may differ
from boiler to boiler, but the
fundamentals governing
optimization depends on
fundamentals of combustion,
property of fuel being burnt, the heat
transfer envisaged by designers, the
operating intelligence & analysis of
data to make course correction.
Dr V T Sathyanathan
Mankind is in pursuit of truth, let us work towards this
 Dr V T Sathyanathan

Any Questions Please

Mankind is in pursuit of truth, let us work towards this

 Dr V T Sathyanathan

Thank you all

Dr V T Sathyanathan
[email protected] ; [email protected]
+919443352170

Mankind is in pursuit of truth, let us work towards this