Impact of coal quality variation on power plants Pratosh Saxena, Head, Proposal Engineering, Tata Projects Limited al will continue to be the main. stay of power generation in the country for years to come, How ever, itis fossil fuel and, therefore, itis important to address concerns related to its consumption and quality at a time when power plants are facing acute fuel shortages and supply uncer- tainties, In the absence of or due to delayed policy measures, dependence on imported or domestic coal of any grade can be acceptable only after assessing its impact on plant perfor mance and the environment Fuel selection for pow plays a key role in establishing adv- anced steam parameters; achieving the generation required gross heat rate and combustion efficiency of the plant; and identifying the best-suited equipment and pollu: tion control systems. Thus, the success of'a power plant depends on the source and type of fuel supplied as well as the equipment design The following is a look at the impact of coal quality variations (a mix based on various sources including imported coal) on the selection of new boilers as well as the performance of existing plants and equipment. Effect on new boiler design and selec- tion: This requires an increase in the furnace size and volume, a large pull veriser size and high power availability It also results in low boiler efficiency and higher fuel requirement per MW of power generation, Effect on existing boilers: It makes it difficult to maintain steam and reheat temperatures. Therefore, high de: POWER LINE yuly 2013 superheating flow would be required, High moisture content also results in low boiler efficiency, pulveriser cap: acity and outlet temperature, Effect on new boi selectior the furnace size and volume based on ash characteristics as well as a large pulveriser and high power requirement. In addition, there is a er design and : This requires an increase in higher fuel requirement per MW of power generation. Effect on existing boilers: This leads to an increase in the erosion of pres- sure parts, slagging and fouling of ‘trostatic pre and pressure parts, poor el cipitator (ESP) pe overloading of draft fans. Effect on ESP: ESP design parameters are dependent on fuel characteristics;therefore, the ESP size, performance and cost vary with a change in fuel composition and ash characteristics. Volt matter * Effect on new boiler design and selec- tion: Ifthe volt matter (VM) in the fuel, used is low, special type down-shot burners are required. It also impacts the boiler turndown ratio and fuel res- idence time in the furnace. + Bffect on existing boilers: VM in fuel helps in its combustion. Hence, a sud- den reduction in VM results in issues in ‘maintaining flame stability in the boil- er and requires secondary fuel oil sup- port to manage partial load operations. Caloritic value of fuel + Bffect on new boiler design and selec- n: Low calorific value of fuel has a cascading effect on the size and design of boiler, mills, ESP, draft fans, the air and flue gas ducting size, fuel handling and storage systems, ash handling and storage systems and auxiliary power consumption. + Effect on existing boilers: If the calorific value of coal is reduced, there will be a need to fire additional coal into the boiler and for higher heat transfer in the convective surfaces Also, the requirement for de-super- heating spray to maintain main steam temperatures would increase. It will also lead to low efficiency of boilers, mills and ESP; and erosion of pressure parts and draft fans. Hard grove index + Bffect on new boiler design and selec- tion: The Hard Grove Index (HGD is one of the important factors govern- ing the selection and size of the pul- veriser. A high HGI value indicates the ease with which coal can be ground in a mill. However, the mills are conserv- atively designed for worst/low HGI value, thereby resulting in high equip- ment costs. Effect on existing boilers: Coal fineness is severely affected if the HGI of the fired fuel is less than the design value, This results in frequent mill mainten- ance and downtime and impacts boiler FORUM Ce OLE SSC UAC SL Le Wi a Bermo Moisture 19 40 Ash 266 421 Volatile matter aid 128 Fixed carbon 50.4 ata GCV (kCal perka) 6,058.0 4,096.0 GOV: Gross caloric value efficiency and performance. Fuel constituents - carbon, hydrogen, ‘sulphur and nitrogen * Effect on new boiler design and selec- tion: The ultimate analysis of fuel is required to determine its carbon, hy- drogen, sulphur and nitrogen content. ‘This helps in calculating the stoichio- mettic air and excess air requirement for efficient combustion. * Effect on existing boiler: A change in the fuel composition affects the com- bustion process. Emission control + SPM: Coal combustion leads to the generation of suspended particulate matter (SPM) (ash and unbumed car- bon). The selection of equipment used for SPM removal depends on fuel char- acteristics, boiler type, ash analysis, particle loading and particle size. + NOx control: Controlling nitrogen ‘oxide (NO,) emissions has now be- come a statutory requirement for up- coming and operating power plants. About 25 per cent of NO, produced ‘while burning coal is thermal NO, and the remaining is fuel NO,. Thermal NO, control is possible by reducing the combustion zone temperature. Fuel with low nitrogen content pro- Securing the right coal type is key to achieving the desired efficiency, emission levels and plant life. POWER LINE « July 2013 Damodar Valley Trombay Umaria field alana 72 68 at 273 198 56 208 2A m2 447 78 BB 5953.6 61480 3,774.4 duces less overall NO, than that with higher nitrogen content. + SO, control: Sulphur oxide (SO, is an acid gas formed by the combustion of sulphur in the fuel with oxygen. Tech- niques commonly used to control SO emissions include switching to low- sulphur fuel and using post-combus- tion flue gas desulphurisation, Challenges Supercritical and ultra-supercritical power plants can achieve efficiencies of 40 per cent and 45 per cent respective- ly, Fuel characteristics can have a sig- nificant impact on the overall of a power plant performance and econom- ics and, therefore, understanding their effect and taking mitigation measures are of importance. In a rush to acquire multiple fuel sources, secure coal at a competitive price and minimise the overall cost of plant design and operations, entities often ignore the impact of coal on a plant’s operations and the environ ment. Therefore, the challenge is to strike a balance between alternative so- urces of fuel supply and their impact on the operational plant. Conclusion Coal is an important requirement for plugging the country’s huge power deficit. Securing the right coal type is key to achieving the desired efficiency, emis- sion levels and plant life, Power cannot be generated without coal, but even with coal, it may be difficult to achieve the generation targets in the absence of the desired design fuel. =