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Presentation Title ( Arial, Font size 28 )
Date, Venue, etc..( Arial, Font size 18 )
Presented by :
Kalyan Panda
Punarbasu Bhattacharya
13/2/2013
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Background
2
Coal Sourcing/ Market dynamics are undergoing disruptive changes. Future
positioning of Utilities should be based on the ability to design large steam
generator capable of tolerating a wide band of Fuel Quality variation from
Multiple Source(s) , Multiple Mine(s) and Multiple Countries as compared to
the existing practice of design FUEL specific/Mine Specific/Country Specific
The success of Power Project in Future will largely depend upon how
quickly and effectively it adapts to the changed scenario.
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Coal Classification-ASTM
3
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Fuel Property Variation
4
0
10
20
30
40
50
60
70
a b c d e f g h i j k l m n o p q r s t u v w x y
Fixed Carbon
Volatile Matter
Ash
Total Moisture
Indian Coal a
Indian Coal b
Indian Coal c
Indonesian Coal d
Indonesian Coal e
Indonesian Coal f
Indonesian Coal g
USA Coal h
USA Coal i
Afghan Coal j
Hungary Coal k
Hungary Coal l
Czech Coal m
Mongolia Coal n
South African Coal o
China Coal p
German Coal q
Polish Coal r
Brazil Coal s
Colombian Coal t
Australian Coal u
Chile Coal v
Korean Coal w
South African Coal x
Australian Coal y
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Fuel Property Variation
5
0
1000
2000
3000
4000
5000
6000
7000
8000
a b c d e f g h i j k l m n o p q r s t u v w x y
GCV [Kcal/Kg] Indian Coal a
Indian Coal b
Indian Coal c
Indonesian Coal d
Indonesian Coal e
Indonesian Coal f
Indonesian Coal g
USA Coal h
USA Coal i
Afghan Coal j
Hungary Coal k
Hungary Coal l
Czech Coal m
Mongolia Coal n
South African Coal o
China Coal p
German Coal q
Polish Coal r
Brazil Coal s
Colombian Coal t
Australian Coal u
Chile Coal v
Korean Coal w
South African Coal x
Australian Coal y
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Fuel Property Variation
6
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Moisture-Variation
7
0
5
10
15
20
25
30
35
40
45
50
a b c d e f g h i j k l m n o p q r s t u v w x y
Total Moisture Indian Coal a
Indian Coal b
Indian Coal c
Indonesian Coal d
Indonesian Coal e
Indonesian Coal f
Indonesian Coal g
USA Coal h
USA Coal i
Afghan Coal j
Hungary Coal k
Hungary Coal l
Czech Coal m
Mongolia Coal n
South African Coal o
China Coal p
German Coal q
Polish Coal r
Brazil Coal s
Colombian Coal t
Australian Coal u
Chile Coal v
Korean Coal w
South African Coal x
Australian Coal y
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Sulphur, Nitrogen - Variation
8
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
a b c d e f g h i j k l m n o p q r s t u v w x y
Sulpher
Nitrogen
Indian Coal a
Indian Coal b
Indian Coal c
Indonesian Coal d
Indonesian Coal e
Indonesian Coal f
Indonesian Coal g
USA Coal h
USA Coal i
Afghan Coal j
Hungary Coal k
Hungary Coal l
Czech Coal m
Mongolia Coal n
South African Coal o
China Coal p
German Coal q
Polish Coal r
Brazil Coal s
Colombian Coal t
Australian Coal u
Chile Coal v
Korean Coal w
South African Coal x
Australian Coal y
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Ash Property - Variation
9
0
10
20
30
40
50
60
70
80
a b c d e f g h i j k l m n o p q r s t u v w x y
% o
f in
co
al
SiO2
Al2O3
Fe2O3
CaO
MgO
Indian Coal a
Indian Coal b
Indian Coal c
Indonesian Coal d
Indonesian Coal e
Indonesian Coal f
Indonesian Coal g
USA Coal h
USA Coal i
Afghan Coal j
Hungary Coal k
Hungary Coal l
Czech Coal m
Mongolia Coal n
South African Coal o
China Coal p
German Coal q
Polish Coal r
Brazil Coal s
Colombian Coal t
Australian Coal u
Chile Coal v
Korean Coal w
South African Coal x
Australian Coal y
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Ash Property - Variation
10
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
a b c d e f g h i j k l m n o p q r s t u v w x y
K2O
Na2O
Indian Coal a
Indian Coal b
Indian Coal c
Indonesian Coal d
Indonesian Coal e
Indonesian Coal f
Indonesian Coal g
USA Coal h
USA Coal i
Afghan Coal j
Hungary Coal k
Hungary Coal l
Czech Coal m
Mongolia Coal n
South African Coal o
China Coal p
German Coal q
Polish Coal r
Brazil Coal s
Colombian Coal t
Australian Coal u
Chile Coal v
Korean Coal w
South African Coal x
Australian Coal y
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Ash Property - Variation
11
800.00
900.00
1000.00
1100.00
1200.00
1300.00
1400.00
1500.00
a b c d e f g h i j k l m n o p q r s t u v w x y
IDT [Deg.C] Indian Coal a
Indian Coal b
Indian Coal c
Indonesian Coal d
Indonesian Coal e
Indonesian Coal f
Indonesian Coal g
USA Coal h
USA Coal i
Afghan Coal j
Hungary Coal k
Hungary Coal l
Czech Coal m
Mongolia Coal n
South African Coal o
China Coal p
German Coal q
Polish Coal r
Brazil Coal s
Colombian Coal t
Australian Coal u
Chile Coal v
Korean Coal w
South African Coal x
Australian Coal y
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Paradigm Shift
12
EXISTING
Fuel/ Mine specific
design - Linked mine/ Single
rank/Single location
Fuel security perception - Single Contract (CIL)
- Acquire Mines
domestic/overseas
Contracts- Guarantee
centric - Efficiency/APC/BMCR
Cost Centric Design
SHIFT
Unlimited fuel flexibility
- Multiple mines/ Multiple
ranks/ Multiple countries
Fuel security perception - Strategic tie-up for multi
location sourcing
Contracts – Function
Centric - Reliable/Safe/Optimal
operation
Optimal Design
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Shift in Boiler Design
13
Parameters Current Future
Fuel Specific Design Narrow Range Wide Range
Tolerance to GCV
variation Low High
Slagging / Fouling
Index
Low / Medium
(Fuel -Specific) High
Acceptable Moisture
Limit 25 to 30 % Up to 50 %
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FUEL SWITCH
Innovation @ Power Sector 14
Future Requirement
LARGER
FLEXIBILITY
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Future Requirement
WIDE FUEL
FLEXIBILITY &
HIGH
RELIABILITY
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Fuel switch impact
Equipment Impact Possible
options
Steam Drum No -
Mud Drum No -
Separator (For
Once Through
Boiler Alloy
steel)
No -
Equipment
(Furnace) Impact
Possible
options
Width Yes Design furnace
dimension with
high slagging
coal
Height Yes
Depth Yes
Tube
Metallurgy No
Water wall
cleaning
system
Yes
-Design on high
slagging coal.
-Install water
canon etc.
Firing
System
Design
Yes
(Firing
System
design
differs for
low and
high VM
coal
Design boiler
with available
coal considering
low VM
Equipment (Piping) Impact Possible
options
Down-comer, riser etc and
other miscellaneous integral
piping
No
Equipment Impact Possible
options
Economizer
arrangement
Yes
Depends on fuel
fouling index and
erosion index.
Design based
on worst fuel
Equipment Impact Possible options
Rotary air
pre heater
(Basket
profile)
Yes
Selection on
-Worst ash
characteristics
-Space of additional
elements
-Hot end and cold end
soot blower.
-2 separate APH for
primary and
secondary to increase
operational flexibility
Equipment
Impact
Possible
options
SCAPH No except for very
high sulphur coal
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Fuel switch Impact
Equipment
(Super heater) Impact Possible options
Arrangement Yes
Design super heater
arrangement/
cleaning system on
worst coal
characteristics
Area
Yes
(Super
heater
normally
sized with
low
moisture
and high
GCV coal)
Following design
tools are used to
control:-
1. Super heater
spray
2. Divided back
pass design
3. SH Gas
tampering
4. SH Gas bypass.
Tubes/ Header
metallurgy Yes
Super heater
cleaning
condition
Yes
Select SH cleaning
system based on
worst fuel
Equipment
(Re-heater) Impact
Possible
options
Re-heater
arrangement Yes
Design on
worst fuel
RH Spray Yes
-Operation
flexibility tool
-Steam to
steam
attemperator
RH Tube
metallurgy Yes
Re-heater
arrangement Yes
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Boiler Non Pressure part-Effect
Equipment
(Firing
System)
Impact Possible options
Burner Yes Select on worst fuel
Oil System Yes Design on worst
fuel
Milling
system
Yes
Coal HGI
and
moisture
governs
mill
selection
-Milling system as
per coal band.
-Features like
furnace gas
recirculation,
-Additional heating
of PA
Bunker, Coal
pipe, mill
inlet pipe
design
Yes
Equipment
(Pollution
control
equipment)
Impact Possible
options
ESP
Yes
ESP design
depends on fuel
ash content and
ash resistivity
.
Equipment
(Ducting System)
Impact Possible
options
FD, ID, PA duct Yes
Additional flexibility
features gas
bypass/ Gas
recirculation
Yes
Equipment
(Miscellaneous
Components)
Impact Possible
options
Main structure No
Hot structure No
Hoppers No
Slings and support No
Low pressure piping No
Valves and instruments No
Equipment
(Ash Handling
and coal
handling)
Impact Possible
options
Ash handling
system design Yes
Coal handling
system design Yes
Designed
based on
maximum
coal
consumption
18
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Fuel Switch - Current Situation
19
o During the life time of Boilers - Utilities have experienced operational constraints due
to fuel switch/source changes
o Numerous examples of boiler modifications Post commissioning
o Study of the modifications clearly reflects
− Cause and Effect approach adopted for solution deployment
− Each of these modifications/solutions were selected from repository of few fixes.
If these fixes are proactively incorporated at Design Stage
the boiler fuel flexibility will increase to a great extent.
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Repository of Fixes/Design- Options
20
Type of fix Existing New unit
Improved SH Metallurgy
Larger Furnace Size
Flexibility Tool Divided Back pass
Flexibility Tool Gas Bypass / Gas Tempering
Furnace Gas Recirculation for PA Heating
Additional Mill
Additional Fan Margin
Additional Milling System
Coal Drying System
Water Cannon Vrs Soot blower
ESP Additional Margin
Application of Chemicals
Feasible
Not Feasible
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Design Options- Cost Impact
21
3 to 4%
1 to 2%
1 to 2%
1 to 2%
3 to 4%
7 to 8%
1 to 2%
28-35%
55 to 65%
3 to 4%
2 to 3%
Larger furnace size
Improved SH metallurgy
Flexibility tool divided backpass
Flexibility tool gas bypass / gas tempering
Furnace gas recirculation for PA heating
Additional mill
Additional fan margin
Additional milling system
Coal drying system
Water cannon vrs soot blower
ESP additional margin
Enhanced
Base
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FUTURE
NEED?
LARGER
FUEL
FLEXIBILITY
AT DESIGN
STAGE
STRATEGY
&
DESIGN
CHANGE
RELIABLE DESIGN
PRESENT TO FUTURE
22
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