1

Trial Report of PENTOMAG 2550-I (Coal Additive)

ALOK INDUSTRIES LIMITED C 16 / 2, Village: Pawane

TTC Industrial Area, Navi Mumbai

Dist: Thane, MaharashtraDist: Thane, MaharashtraDist: Thane, MaharashtraDist: Thane, Maharashtra

2

Ref: TCPL / AIL / BRG – TS / 1110 / 2012 - 13 Date: 11.10.2012

Tellabs Trial Report for PENTOMAG 2550 I - Coal Additive

ALOK INDUSTRIES LIMITED C 16 / 2, Village: Pawane TTC Industrial Area, Navi Mumbai Dist: Thane, Maharashtra

Prepared For: Mr. S. K. Biswas Chief Engineer Prepared By: Bibek Ranjan Guha Sales Manager Mob: 9831191032 Coordinated By Tanvi Shigwan Commercial Manager Ramesh Tripathi Area Manager Hemant Lokhande Service Engineer TELLABS Chemicals Private Limited Kamanwala Chambers, Sir Phirozeshah Mehta Road, Mumbai 400 001, INDIA. Tel: +91 (22) 67477900 Fax: +91 (22) 67477901 TELLINE: +91 9322737722 (24 hr) Email: bibekguha@telgroup.com Web Site: www.telgroup.com

3

1.0 Preface & Objectives of the Trial We are thankful to the management of Alok Industries, Mumbai for giving us an opportunity to establish the performance of our additive PENTOMAG 2550-I in their 5 TPH Smoke Tube Anjani (Make: Heat Ex) Coal fired Boiler. Our sincere thanks go to Mr. Umang Garg – Vice President, Mr. Raju Kapadia- General Manager – Commercial, Mr. S. K. Biswas – Chief Engineer and the entire team of Boiler Engineers and Operators for timely guidance during the entire period of trial. We are also grateful to one and all, those who have helped us directly or indirectly in making this trial a success. The direct benefits are evident from the increase in Steam to Fuel ratio (Total Steam produced in Kgs divided by total Coal consumed in Kgs) after dosing our additive. It can be observed from the enclosed report that by using our additive, over all fuel savings of 5.64% is achieved, which amounts to an estimated net savings of Rs. 32.46 Lacs per annum, Objectives of the Trial:

1) Reduction of clinker / slag formation on grate and walls of combustion chamber of boiler. Acute clinkering / slagging hinder boiler operation, reduce boiler availability, increase maintenance cost etc.

2) Reduction of dark black smoke emission

Alok Industries was facing acute clinker formation problem along with acute dark black smoke emission problem.

4

2.0 Necessity of Coal Additive

As you are aware, there is substantial amount of un–burnt combustibles in the fly ash and bottom ash generated by any coal fired boiler. These un–burnt combustibles consist mainly of Carbon particles. These Carbon molecules remain un burnt because of incomplete combustion in the fire box for lack of sufficient oxygen. To increase this oxygen availability in the firebox, a higher level of turbulence is required. But, with the increase in turbulence there will be an increase in dry flue gas quantity and corresponding heat losses. Even if the best of firing conditions are provided, there is still going to be enough avoidable combustibles to be concerned with because of cooling off of fly ash particles below ignition temperature due to extremely short time available for them in the fire box. The second problem is slagging, formation of hard (melted) deposits sticks to heating surfaces (evaporator, super heater, re heater) brick works or other elements inside the boiler. Loose ash deposits are not considered as slagging. When coal enters the furnace, most of the minerals in coal melt. The furnace is designed so that by the time the molten fly ash particles leave the furnace, they become solid. However only about 80% of the fly ash leaves furnace and rest falls down as bottom ash or in molten state deposits on the furnace wall tubes. These deposits are known as slag. Formation of slag leads to

� Loss of heat exchange balance (Resulting in steam and flue gas temperature pattern inside the boiler. In most cases there is increase of flue gas exit temperature and reduction in boiler efficiency.)

� Decrease in steam temperature after super heater and re heater creates problem for the turbine.

To overcome the above mentioned problems, research has shown that a combustion optimising and anti slagging additive is the most economical and effective solution.

5

3.0 PENTOMAG 2550 I - Additive for Coal Fired Plant

Coal additives have been used for several years, initially in powder form. Practical experience was however not satisfactory, first of all because of relatively high particle size of powder components. The smaller the particle the greater is the active surface. Pentol is the first manufacturer who developed production of fuel additives in form of stable slurry containing micronized active substances in oil suspension. Slurry is also resistant to water (powder will agglomerate in contact with moisture and its efficiency will be strongly limited). Also storage of additive in slurry form is easier and dosing is more precise.

PentoMag 2550 is an additive to optimize coal combustion and to prevent coal slagging (fouling). The term "slagging" is understood as formation of hard, sticky deposits covering evaporator and super-heater heat exchange tubes inside the furnace. Usually the slagging starts on the firebox tubes or around the burners, then, once a first layer has formed, fouling occurs rapidly as the outside of the tubes is not "cooled" sufficiently anymore. As the temperatures begin to increase, ashes with higher melting points also start to melt. Thus more deposits are formed and higher temperatures obtained. In addition, a shifting of temperatures towards the super-heaters can be noticed. During operation of the boiler, the ash is sticky and in molten form. It cannot be removed by soot-blowing. The actual time of built-up of such deposits varies from boiler to boiler and depends largely from the firebox design and temperatures.

Starting PentoMag 2550 dosing on a clean boiler prevents slag formation. In the most unfavourable conditions (burning coal with strongly slagging properties in a firebox with very high heat transfer rate), the slagging process will proceed much more slowly and mildly

Advantages of uAdvantages of uAdvantages of uAdvantages of using Pentosing Pentosing Pentosing PentoMMMMag 2550 ag 2550 ag 2550 ag 2550 I I I I areareareare given below given below given below given below

� Optimisation of combustion in coal fired plants � Reduction of deposits in burning chamber thus longer cleaning intervals and

reduce adverse effects on heat exchanger � Deposits are brittle, so that cleaning is easier and piping remains undamaged � Higher efficiency due to better heat transfer � Higher boiler availability � Reduces black smoke and particulate emission through flue gas � Efficiency improvement

(Reduces exit gas temperature)

6

4.0 System Details and Recommended Dosage

System Details:

Equipment Smoke Tube Boiler (Package Type)

Fuel Coal Make Heat Ex

Steam Generation Capacity, in TPH 5 Working Pressure, in Kg/ cm2 10.5

Running Hours 24

Coal Consumption per month, in MT 900 Coal Size, in mm 6-30 (90-95%), 25-50 (5-10%) GCV of Coal, in Kcal/ Kg 5500-5800 Landed Price of Coal, in Rs. per MT 6500.00 Cost of Coal per month, in Rs. 5850000.00

Recommended Dosage: 100 ppm i.e, 1 Kg of PentoMag 2550 I in 10 MT of Coal. Dosage may vary depending upon nature of fuel and severity of problems.

7

5.0 TRIAL METHODOLOGY

The performance of Boiler in terms of Steam produced and Coal consumed per day from 1st Sep’ 2012 to 29th Sep’ 2012 before dosing the additive and from 30th Sep’ 2012 to 9th Sep’ 2012 after dosing the additive were noted. Other operating parameters were noted for understanding the overall Boiler performance during with out and with additive period. Dosing of additive has been started from 30th Sep’ 2012 morning (around 7.30A.M.) on wards @ 100 ppm i.e, 1Kg of in 10 MT of Coal. The Steam to Fuel Ratio (Total Steam produced in Kgs divided by total Coal consumed in Kgs) for with out additive and with additive period are calculated. The percentage improvement in SFR during post additive period over that of pre additive period is taken as the fuel savings.

8

6.0 CONCLUSIONS

1. By using PENTOMAG 2550 @ 100 ppm dosage, fuel savings of 5.64% (Please refer Annexure 1& 2) is realized in your Coal consumption.

2. As a result of this fuel savings, a net minimum monetary benefit of over Rs.

32.46 Lacs per annum can be obtained, after accounting for the cost of additive, through regular usage of additive.

3. Intensity of dark black smoke emission has been reduced drastically and sometimes smoke becomes invisible. Maximum time smoke color is brown indicating occurrence of proper combustion. Please refer annexure 3.

4. From the first day of with additive analysis, clinker formation is totally stopped. Please refer annexure 4.

5. Reduction in exit gas temperature indicating efficiency improvement

6. Quantity of both bottom ash and fly ash get reduced and also there is a change in colour of ash indicating improvement in combustion.

7. Ash disposal becomes easy that leads to higher boiler availability

Note:

a. It is to be noted that without additive readings has been considered from 1st Sep’ 2012 onwards and if we consider the readings from 20th Sep’ 2012 onwards for keeping same time period for both with out and with additive then coal savings % will be more.

b. As steam is the output of a boiler and boiler thermal efficiency is determined by

steam production, steam production readings are taken into account for calculating the coal savings.

In view of the excellent results achieved by using our additive, we request management of Alok Industries for continuous usage of our additive in your Coal fired Boiler; realize the cost benefits and other indirect benefits. We also request your good selves to arrange to release our payment towards the supply we have made in Sep’ 2012. Please feel free to get in touch with us for cost effective solutions related to Fuel Management. Thanking you and assuring the best of our attention and services at all times. Yours truly, For TELLABS Chemicals Pvt. Ltd. Bibek Guha Sales Manager

9

ANNEXURE 1

Without Additive Readings

Date Steam Production Coal Consumption SFR

Bottom Ash -

1&3

Fly Ash-

1&3

Kg Kg (Kg / Kg)

No. of

Trolleys

No. of

Trolleys

1-Sep-12 74830 26994 6 6 7 12

2-Sep-12 87870 26928 18 10 19 14

3-Sep-12 97160 25212 11 11 8 12

4-Sep-12 101530 26994 9 7 6 11

5-Sep-12 107510 24222 7 8 8 7

6-Sep-12 83490 21120 7 6 6 10

7-Sep-12 0 0 0 0 0 0

8-Sep-12 79590 24288 7 8 6 11

9-Sep-12 96129 24882 7 8 6 13

10-Sep-12 106397 25278 8 10 7 12

11-Sep-12 100224 25410 6 13 6 12

12-Sep-12 106260 26730 11 12 6 8

13-Sep-12 95510 21648 9 7 6 9

14-Sep-12 0 0 0 0 0 0

15-Sep-12 102750 27390 7 14 13 12

16-Sep-12 107030 28380 7 11 13 13

17-Sep-12 97770 28314 9 9 14 12

18-Sep-12 96540 23100 6 10 12 12

19-Sep-12 0 0 0 0 0 0

20-Sep-12 78940 23760 6 11 18 14

21-Sep-12 0 0 0 0 0 0

22-Sep-12 93750 26730 11 11 7 12

23-Sep-12 99180 26730 16 16 16 17

24-Sep-12 104090 26928 15 14 16 16

25-Sep-12 103750 25674 12 14 16 17

26-Sep-12 95910 26730 12 14 15 18

27-Sep-12 94550 22572 15 12 10 11

28-Sep-12 606 5148 0 1 2 0

29-Sep-12 85584 25674 12 5 5 8

TOTAL 2296950 616836 3.72 234 248 248 293

10

ANNEXURE 2

With Additive Readings

Date

Steam

Production Coal Consumption SFR

Bottom ash-

1&3 Fly Ash-1&3

Kg Kg (Kg / Kg) No. of Trolleys

No. of

Trolleys

30-Sep-12 96030 25542 13 12 4 8

1-Oct-12 65860 25542 5 3 7 4

2-Oct-12 94700 24430 5 8 7 9

3-Oct-12 104420 25080 5 12 10 10

4-Oct-12 97620 21120 5 7 9 10

5-Oct-12 0 0 0 0 0 0

6-Oct-12 90293 24600 6 8 4 10

7-Oct-12 94110 23150 9 13 7 11

8-Oct-12 97400 23100 10 14 12 13

9-Oct-12 94000 19530 9 11 11 12

TOTAL 834433 212094 3.93 67 88 71 87

% Fuel Savings = (SFR With Additive - SFR With Out Additive )* 100

SFR With Out Additive

(3.93 - 3.72)*100

3.72

= 5.64%

11

ANNEXURE 3

STACK EMISSION BEFORE USING PENTOMAG 2550 I

STACK EMISSION AFTER USING PENTOMAG 2550 I

12

ANNEXURE 4

SLAG GENERATED BEFORE USING PENTOMAG 2550 I

NO SLAGGING AFTER USING PENTOMAG 2550 I